METHOD OF STATEMENT

PAINTING SYSTEM
GENERAL REQUIREMENT
1.GENERAL

1.1 PURPOSE: This procedure is intended to describe the minimum requirements for

1.Surface preparation,

2.Paint application

3. Intermediate and final inspection of Painting/coating of steel penstock Pipe

1.2 SCOPE: This is applicable to surface preparation and coating of steel penstock pipe.

1.3 INTERNATIONAL CODES AND STANDARD

SSPC - PA1 - SHOP, FIELD and Maintenance Painting
SSPC - PA2 - Measurement of Dry Paint Thickness
SSPC - SP1 - Solvent Cleaning
SSPC - SP2 - Hand Tool Cleaning
NACE STANDARD RP0287

1.4 MATERIALS:

1.4.1 The coating materials in accordance with the coating system specifications shall be
used. Coating materials from client-approved manufactures shall only be used.
1.4.2 All coating materials like paint, thinner, etc. shall be retained in their sealed, labeled
containers until use. Containers shall be clearly marked with date of manufacture and batch
number, and any materials exceeding the recommended shelf life shall be discarded.
1.4.3 Coating materials shall be stored in shaded and well-ventilated area in accordance with
the Manufacturer's recommendations.

1.4.4 The type of abrasive to be used shall be determined by the degree of cleanliness and
roughness required for the coating system. Abrasives commonly used in this project is grit.
2. SURFACE PREPARATION PROCEDURE

2.1 PRE-BLAST CHECK

2.1.1 The substrate shall be cleaned with solvent to remove grease, oil etc. prior to Grit
blasting if required.

2.1.2 All the NDT requirement shall be passed prior to grit blasting
2.1.3 Prior to blasting, rough welds and cut-offs shall be ground to a small radius, and weld
spatters shall remove. No objection from NDT.

2.1.4 The compressed air supply shall be tested for presence of oil, moisture and
contamination. Test procedure: Attach a piece of blotter or absorbent paper to a clip board,
then hold it approximately 45-60 cm in front of the blast nozzle during air flow with nozzle
pressure 50 psig for approximately one minute. Satisfactory results shall be no water or oil
contamination on the blotter.
2.1.5 Blasting and coating personnel shall be experienced and sound knowledge about grit
blasting and Painting.

2.2 SURFACE PREPARATION

2.2.1 The surface cleanliness and roughness shall be inspected against coating system
requirements.
2.2.2 Spent abrasive shall be removed from cleaned external surface by dry brushing and
blowing down with clean, dry compressed air. Internal surface shall be dry-brushed and
vacuum cleaned.
2.2.3 Grit blasting shall be done in accordance to Sa2 ½ and shall achieve as surface profile
of 38 to 75 micron.
2.2.4 Grit blast-cleaned steel surfaces should be measured by using Elcometer surface profile
gauge.

2.2.5 All surface preparation shall be subject to no objection/approval of the employer

before any paint is applied.

2.2.6 Abrasive-cleaned surfaces shall be primed before the surface condition degrades
below the specified cleanliness level. Preferably within two-four hours of the
commencement of blasting whichever is the sooner

2.2.7 Blast cleaning shall not be carried out whilst the temperature of metal surfaces is less
than 3˚C above the dew point of the surrounding air or when the relative humidity of the air
is greater than 80%.
2.3 SURFACE PREPARATION-POWER TOOL

2.3.1 Prior to cleaning all grease and oil contamination shall be removed by wiping or
scrubbing the surface with rags or brushes wetted with solvent/Paint stripper chemical
followed by a wipe down with clean dry cloths. Solvent cleaning shall be carried out in
accordance with SSPC SP-1.

2.3.2 Surface shall be cleaned by Wire Brush & Power Tool to remove all lose paint films and
rust. Cleanliness to be achieved to Sa2 ½.

2.3.3 Cleaning shall not be carried out whilst the temperature of metal surfaces is less than
3˚C above the dew point of the surrounding air or when the relative humidity of the air is
greater than 80%.

2.3.4 All cleaned surfaces shall be primed before visible re-rusting occurs or preferably
within two-four hours of the commencement of cleaning whichever is the sooner.

2.3.5 Surface shall be cleaned by dry air blow after power tool cleaning.
2.3.6 Surface preparation with Power Tool or Hand Tools shall be pursued to achieve a
minimum level of Cleanliness equivalent to Sa2 ½.

2.4 SURFACE PREPARATION AT FIELD

2.4.1 FIELD surface preparation local to weld areas shall be carried out by Power tool grinding
method as required in the painting system as far as is practicable within the FIELD construction
conditions. Where surface cleaning by abrasion blasting is prohibited, weld and other small areas
shall be prepared by use of Power Tool Cleaning or Hand Tool Cleaning or a combination of these
methods depending on the contour and position of the surface to be painted.

2.4.2 Surface preparation with Power Tool or Hand Tools shall be pursued to achieve a minimum
level of Cleanliness equivalent to the Sa2 ½.

3.PAINT APPLICATION

3.1 Weather and Surface Conditions

No painting work shall be performed under the conditions of being extremely high (≥45˚C) or low
atmospheric temperature (≤10 ˚C) or high humidity of the air ((≥80%) or as per TDS of manufactures.

Paint materials shall not be applied in rain, fog or mist, nor to wet or damp surfaces.
3.2 Paint Mixing

3.2.1 Paint material shall be thoroughly mixed immediately prior to application. Mixing shall be by
means of mechanical stirrers, paddle mixers, can vibrators or can shakers.

3.2.2 Constant mechanical agitation shall be maintained in the paint reservoir throughout paint
spraying operations.

3.2.3 Thinners shall only be added strictly in accordance with the paint TDS

3.2.4 The type of thinner shall comply with the paint TDS.

3.2.5 When thinners are permissible, they shall be added during the paint mixing process in
accordance with the MANUFACTURER’s datasheets.

3.2.6 Paint mixing should be done strictly as per the mixing ratio given in the data sheet. No deviation
in mixing ratio is accepted.

3.3 Film Thickness

3.3.1 The applied DFT of each coat and the total system shall not be less than the specified minimum
stated in the specification.

3.3.2 The DFT shall be measured in accordance with SSPC – PA2. The average of any five (5) spot
readings on each 10m2 area shall be equal to or greater than the specified minimum DFT and no
single point reading shall be less than 80% of the specified minimum DFT.

3.3.3 DFT measurement shall be made of each coat and of the total system.

3.3.4 The total minimum dry film thickness for a multi-coat system shall not be less than the added
total specified minimum dry film thickness.

3.3.5 The dry film thickness of individual coats or system shall not exceed the MANUFACTURERs
recommended maximum thickness, and shall not prove detrimental, i.e. wrinkling, mud cracking,
general softness, poor adhesion, etc., to both the coating and/or the total system.

3.3.6 Inadequate film thickness shall require the further application of an additional complete coat
over the whole area until the dry film thickness is sufficient to meet the specified minimum. Excessive
thick coats shall be removed completely by blast cleaning, and shall be re-coated according to this
specification.
3.4 Application

3.4.1 Paint materials shall only be applied by the MANUFACTURER’ recommended method in
accordance with the paint datasheet.

3.4.2 Spray guns shall be held perpendicular to the surface being coated at a maximum distance of
300 mm from the surface and no closer than 200 mm to the surface. Wet film thickness (comb) gauges
shall be used by paint spray gun operatives to ensure an even and adequate DFT will be achieved.

3.4.3 Material and air pressure on the spray guns shall be regulated to achieve optimum atomization
of the paint with the lowest possible pressures to avoid spray ricochet from the surface being painted.

3.4.4 Overlapping horizontal passes shall be made for each spray coat to obtain uniform application.
Particular care shall be exercised to ensure that a uniform, complete wet coat is applied.

3.4.5 Coats of paint shall be uniformly applied without sags, runs, spots, damage or contamination;
such irregularities shall be removed and the affected area recoated.

3.4.6 Each coat of paint shall be in a proper state of cure or dryness before the application of the
succeeding coat. Attention shall be paid to the MANUFACTURER’s datasheet for curing times between
coats.

3.4.7 When paints are applied by brushing, brushes shall be of a style and quality that will permit
proper application of the material. Brushing shall be done so that a smooth coat as nearly uniform in
thickness as possible is obtained.

There shall be no deep brush marks.

3.5 Repairs:

3.5.1 Over areas considered to be inaccessible after erection SHOP applied primer repairs, FIELD
applied primers, undercoats and finishing coats shall be applied, dried and cured before construction
takes place. Care shall be taken to allow sufficient drying and curing time before moving, lifting or
erecting newly painted surfaces.

3.5.2 Damage to each coat of paint, whether SHOP or FIELD applied, shall be repaired by abrasive
paper cleaning and spot priming before succeeding coats of paint are applied. No succeeding coat of
paint shall be applied before preceding coat of paint is thoroughly dry
4. Intermediate and final inspection of Painting/coating of steel penstock Pipe
-All the inspection is done as per approved ITP

-The Grit blasted surface of penstock pipe will be inspected by contractor supervisor and Client
representative. (By using surface profile gauge)

-The grit blasted penstock pipe will be primed within 1-4 hrs. after blasted.

-DFT will be inspected by Contractor supervisor and Client representative in every coats of paint.
(Primer/finish coats)

-The Intermediate and final inspection of painting is done as per the coating inspection record.
5. Safety:

-All the blasters and painters should be equipped with proper PPE required for Grit blasting and
Painting.

FORMAT OF SAFETY CHECKLIST

SAFETY PARAMETERS REMARKS/STATUS/ACTION

Front released for Painting
Potential for trip,slips
Availability of air-fed helmet
Availability of coverall.,cape
Availability of Safety shoes
Availability of ear protectors
Availability of antistatic hose
Availability of deadman handle
All parts in good working order
Blasters and painters are trained
Availability of eye protector
Availability of Mask,gloves
Calibrated Equipments
Ventilation for work in confinement zone
Dry air blow for internal
Monitor of air and temperature inside confined
space
Confined space entry procedure explained

6.0 ASSOCIATED DOCUMENTS:

6.1 COATING INSPECTION RECORD.