You are on page 1of 10

PETROLEUM DEVELOPMENT OMAN

AL HASSAN ENGINEERING SAOG

SWISS INTERNATIONAL LLC

PETROLEUM DEVELOPMENT OMAN


GATHERING STATION ON PLOT (NO. 47), GHABA NORTH
PDO CONTRACT NO..

APPLICATION PROCEDURE AND METHOD STATEMENT FOR EPOXY


INTUMESCENT FIREPROOFING OF EQUIPMENTS SADDLES .

Swiss International LLC


P.O. Box: 1840, PC:133, Al Khuwair
Sultanate of Oman

03

DD/MM/YY

Approved for
Construction

02

DD/MM/YY

Issued for Approval

01

17/11/15

Issued for Review

REV

DATE

REASON FOR
ISSUE

AHEC PROJECT No.:


PO. No.: AHEC/PROC/B211/2015/OSE20843

PREPARED

CHECKED

APPROVED

AUTHORISED

JA
DISCIPLINE
ENGINEER

JA
DISCIPLINE
CHECK

JA
LDE/DH/TA2

JA
PROJECT

REVIEWED

APPROVED

JV

PDO

SWISS PROJECT No: OMAN0058


SWISS DOC. No.: SI/MS/EP/002/15
This document is the property of Swiss
International LLC and Al Hassan Engineering
Co. SAOG. It is not to be copied or shown to a
third party without prior consent.

AREA
CODE

UNIT/PLANT
CODE

ORIGINATOR
CODE

DISCIPLINE
CODE

DOC.
TYPE

SEQUENCE
NO

SHEET
NO.

The approvals from Al Hassan Engineering Co.


SAOG do not absolve the responsibility of Swiss
International LLC in any manner to meet the
requirements of the purchase specification as
well the correctness and adequacy of the
content of the document.

Page 1 of 10

Revision: 01
17/11/15

Table of Contents

1.0.
2.0.
3.0.
4.0.
5.0.
6.0.
7.0.
8.0.
9.0.

10.0.
11.0.
12.0.
13.0.
14.0.
15.0.

Scope & Objectives


Standards and References
Materials
Definitions
Roles & Responsibilities
Materials Delivery, Storage & Handling
Site Preparations
Ambient Conditions
Application Method
9.1. Blasting
9.2. Primer (Intergard 251) Application
9.3. Chartek 7 Application Using Hand Trowel
9.4.Top Coat (Interthane 990) Application
Quality Assurance & Control
Repair Procedure
Safety Measures
Manpower Requirements
Tools and Equipment Requirements
PPE Requirements

Page
3
3
3
3
4
4
4
5
5
5
6
6
8
8
9
10
10
10
10

1.0. Scope & Objectives :This method statement details the application procedure for Epoxy Intumescent
Fireproofing System (Chartek 1709 System) to protect equipment saddles (V-4703 & V4704) from fire and corrosion at Gathering Station on Plot (No. 47) at Ghaba North, the
PDO site.

Page 2 of 10

Revision: 01
17/11/15

2.0. Standards and References: Chartek 1709 Application Manual (Ch1709wp_uk, rev. 1, date 17/04/2014).
Technical Data Sheets of Chartek 1709, Intergard 251 and Interthane 990.
SP 1246.
DEP 34.19.20.1.
DEP 80.47.10.20.
DEP30.48.00.3.

3.0. Materials :Application

Type of materials

Product Name

Primer Coat

Zinc Phosphate Epoxy

Interguard 251

First Layer Chartek 1709

Epoxy Intumescent

Chartek-1709

HK-1 Mesh

NA

HK-1 Mesh

Second Layer Chartek 1709

Epoxy Intumescent

Chartek-1709

Top Coat

Acrylic Polyurethane

Interthane 990

4.0. Definitions :MS Method Statement


ITP Inspection & Test Plan.
MAS Material Approval Sheet.
QCP Quality Control Procedure.
QCF Quality Control Format.
TDS Technical Data Sheet.
MSDS Material Safety Data Sheet.
WFT Wet Film Thickness.
DFT Dry Film Thickness.
PDO Petroleum Development Oman LLC.
PPE Personnel Protective Equipment.
FIFO First In First Out.
ISO International Organization for Standardization.
SSPC Society of Protective Coatings.

5.0. Roles & Responsibilities :5.1. The Projects Engineer has over-all responsibility to implement this method
statement, ensure that the QC Engineer, Supervisor and Safety Officer are aware of

Page 3 of 10

Revision: 01
17/11/15

this MS and also ensure that proper working resources (labours, materials and
equipments) are available to carry out the work as planned.
5.2. The Project Engineer, QC Engineer, and Supervisor are responsible to ensure that
work has been carried out as per the specification, drawings and approved MS and
all works are offered for inspection as per Inspection & Test plan.
5.3. The Project Engineer/Supervisor/Safety Officer shall be responsible to ensure that all
safety precautions are in place, and that all personnel are using the required
personal protective equipments. Must also ensure that all relevant permissions are
available for the works.
5.4. The Project Engineer/Supervisor/Safety Officer shall be responsible to ensure that
the requirements of Section 12.0 of this MS are met properly.
5.5. The Project Engineer/QC Engineer/Supervisor shall perform the activities as
specified in Section 10.0 of this MS.
5.6. The Project Engineer/Supervisor/Safety Officer shall conduct tool box talk prior to
starting any blasting and painting activity.

6.0. Materials Delivery, Storage & Handling :6.1. All the materials shall be delivered at site in original unopened packages. Only
approved materials shall be in the storage.
6.2. Expired or damaged materials shall not be stored in the materials storage.
6.3. The material shall be stored indoors and out of direct sunlight. Storage temperature
should not be more than 300C.
6.4. Packages of material shall be kept off the ground by means of wooden pallets or
others. Materials shall be grouped according to delivery at site.
6.5. While performing materials handling, extra care must be taken to avoid damages and
injuries.

7.0. Site Preparations :7.1. Ensure that adequate power, water, safe scaffolding, lighting, protection items, etc.
are available before the application process.
7.2. Ergonomically setup equipments/machineries at working area before starting
blasting/ painting activities.
7.3. Ensure that only trained and certified personnel to be used.
7.4. Prior to start the work, ensure that all the equipments are third party certified.
7.5. Identify modes of transportation of material to work areas etc.
7.6. Ensure protection of surrounding areas, machineries, tools, environment etc from
over spray of paint/blasting.

Page 4 of 10

Revision: 01
17/11/15

7.7. Ensure adequate ventilation at spraying or blasting area(s) prior to initiation of paint
spraying or blasting.
7.8. Prepare a list of items (Traceability List/Release Note) to be painted or blasted,
which shall be confirmed by AHEC.
7.9. Other trades shall be kept away during spraying of paint or blasting.

8.0. Ambient Conditions :Suitable application conditions are of critical importance for the successful
application of coating. Blasting and painting should only be carried out when the
ambient conditions are within the following parameters:
-

Air temperature: minimum 100C, maximum 500C.

Relative humidity: maximum 85%.

Surface temperature: at least 30C above dew point temperature, less than 500C

Blasting and painting activities shall not be carried out under the following conditions:
-

High wind speed.

Airborne dust/sand.

Rain, fog, mist.

Insufficient lighting.

Likelihood that weather will change within 2 hours

9.0. Application Method


9.1.

Blasting :9.1.1. Prior to blasting, steel surface shall be degreased and cleaned.
9.1.2. The coating which has been applied earlier shall be blasted and removed. The
surface shall be in accordance with standard ISO 8501-1 to Sa 2.5 with the profile of
50-75 microns.
9.1.3. The blasted surface shall be inspected and the approved surface shall be cleaned to
remove eventual traces of dust/garnet materials. No arc strikes, weld spatters, or
sharp edges, oil, grease etc shall be remain on the surface.
9.1.4. The blasted surface shall be tested with masking tape to confirm that the surface is
free of dust. The surface shall be protected from contamination until priming.
9.1.5. Time duration between blasting and priming must not be more than 4 hours. If there
is any unintentional delay, the surface shall be sweep blasted to remove flash rust.
9.1.6. The surface shall not be blasted, which can not be painted within the same working
day.

Page 5 of 10

Revision: 01
17/11/15

9.2.

Primer (Intergard 251) Application :9.2.1. Weather conditions shall be monitored and confirmed as per Section 8.0. of this MS
prior to start of painting.
9.2.2. Intergard 251 is a two pack primer: Part A and Part B. Mixing ratio of 4 volume(s)
Part A to 1 volume(s) Part B shall be well maintained. Paint shall be mixed using
power agitator.
9.2.3. All edges, corners, weld joints and the areas inaccessible to spray shall be stripe
coated by brush prior to spray application.
9.2.4. Spray Intergard 251 onto dry, clean & approved substrate using airless spray
machine. The machine should have output fluid pressure at spray tip not less than
141kg/cm2. Use 0.38 0.53 mm nozzle orifice.
9.2.5. After mixing the primer, it shall be used within its pot life. The pot life of Intergard 251
is 3 hours at 400C. In case pot life is exceeded, the spray unit shall be cleaned as per
clause 10.6.
9.2.6. If the spray unit becomes sluggish, it is recommended to flush the pump, hoses and
gun thoroughly using suitable cleaner.
9.2.7. Apply minimum WFT of 80microns to achieve required DFT of 50 microns. Care
should be taken so that maximum WFT should not be more than 119 microns.
9.2.8. Overcoat interval shall be maintained as per technical data sheet.

9.3.

Chartek 1709 Application Using Hand Trowel :9.3.1. Weather conditions shall be monitored and confirmed as per Section 8.0. of this MS
prior to start of application of Chartek 1709.
9.3.2. Before over-coating with Chartek 1709, ensure that primer has reached sufficient
levels of cure prior to over-coating. The minimum over-coating time of Chartek 1709
with Intergard 251 primer shall be 16 hours. If there is any chalking on primed
surface or the surface has exceeded its maximum over-coating period, the primed
surface shall be roughened prior to over-coating. Hand abrasion is only
recommended in small areas and care should be taken that the surface is not
polished when using abrasive paper. In case of hand abrasion, P80 P100 grade
aluminium oxide abrasive paper shall be used.
9.3.3. Before start of application of Chartek 1709, all visible oil, grease and other soluble
contaminants must be removed from primed surfaces. Water jetting may be used to
clean previously primed surfaces. Cleaning and degreasing shall be carried out as
per SSPC-SP1.
9.3.4. To ensure good bonding of Chartek 1709, dry film thickness of primer (Intergard 251)
should not be more than 75microns, up to 150 microns is acceptable in overlap
areas. If there is any excessive thickness, primer thickness shall be reduced to
Page 6 of 10

Revision: 01
17/11/15

maximum 75 microns using P80 P100 grade aluminium oxide abrasive paper.
Care should be taken to prevent polishing of the surface which would lead to
inadequate adhesion of the Chartek 1709. Frequent changes of abrasive paper
should be made. After primer reduction, surfaces should be cleaned of dust and
contaminants and thoroughly dry prior to the application of Chartek 1709.
9.3.5. To facilitate application by hand/trowel the Chartek 1709 Part A and Part B materials
should be maintained at a temperature of 21-27 0C for a minimum of 24 hours prior to
use.
9.3.6. Cut and ready mesh to required sizes before starting Chartek 1709 application.
9.3.7. A small amount (max. 1 litre for 20kg kit of Chartek 1709) of GTA123 thinner may be
added into Part A to reduce viscosity for mixing and trowel application. When Part A
has reached a smooth consistency, Part B is then poured into the Part A container,
scraping the sides of Part B container to empty it completely. The two parts are
thoroughly mixed using powered paint mixer. Always a full kit should be mixed.
For hand/trowel application, 20 kg kit should be used instead of 50kg kit. As a full kit
shall be mixed ratio checking is not recommended.
9.3.8. The well mixed Chartek 1709 shall be spread out onto the clean boards or steel
surfaces using hand trowel. This prevents the material from curing too quickly and
allows sufficient working time.
9.3.9. As the mesh shall be at mid of specified DFT (as attached Appendix B), using hand
trowel take the mixed and spreaded Chartek 1709 from board and apply onto the
saddles (V-4703 & V-4704) and build up first coat of approx. 5.6mm thickness and
trowel into the surface to ensure good wetting and even thickness.
9.3.10. Trowel marks and high points shall be reduced with a short nap roller dampened with
GTA 123. Rolling shall be carried out, if the sprayed Chartek 1709 has gelled
sufficiently. Also avoid use of excessive solvent while rolling of Chartek 1709.
9.3.11. Install HK-1 mesh onto wet Chartek 1709 and rolled the mesh thoroughly into the wet
Chartek 1709 with short nap rollers dampened with GTA123 solvent. Maintain mesh
overlap of minimum 150mm.
9.3.12. Apply final coat to reach final thickness of 10.57mm.
9.4.

Top Coat (Interthane 990) Application :9.4.1. Before initiation of top coating, color shade of top coat shall be confirmed.
9.4.2. Weather conditions shall be monitored and confirmed as per Section 8.0. of this MS
prior to start of painting.
9.4.3. Interthane 990 is a two pack acrylic polyurethane based finish coat: Part A and Part
B. Mixing ratio of 6 volume(s) Part A to 1 volume(s) Part B shall be well maintained.
Paint shall be mixed using power agitator.

Page 7 of 10

Revision: 01
17/11/15

9.4.4. All edges, corners, weld joints and the areas inaccessible to spray shall be stripe
coated by brush prior to spray application.
9.4.5. Spray Interthane 990 onto sufficiently dry, clean & approved Chartek 7 surface using
airless spray machine. The machine should have output fluid pressure at spray tip
not less than 155kg/cm2. Use 0.33 0.45 mm nozzle orifice.
9.4.6. After mixing Interthane 990, it shall be used within its pot life. The pot life of
Interthane 990 is 3 hours at 400C. In case pot life is exceeded, the spray unit shall be
cleaned following clause 9.2.6.
9.4.7. If the spray unit becomes sluggish, it is recommended to flush the pump, hoses and
gun thoroughly using suitable cleaner.
9.4.8. Apply minimum WFT of 90microns to achieve required DFT of 50 microns.
9.4.9. Overcoat interval shall be maintained as per technical data sheet.

10.0. Quality Assurance & Control :10.1. Ensure that all the incoming materials are as per approved material sheet (MAS) and
has been offered for inspection.
10.2. Ensure that all materials shall be grouped according to delivery date and stored
properly in storage facility.
10.3. Materials shall be used on FIFO basis and all the materials shall be used before its
date of expiry. Expired paint must be removed from storage facility.
10.4. It shall be ensured that approved MS, MAS, drawings, QCP, Technical Data Sheets
etc to be followed and must always be available at the working area.
10.5. Blasted surfaces and coatings shall be offered for inspection as per Inspection &
Testing Plan (ITP).
10.6. DFT and WFT shall be measured using International Protective Coatings
recommended gauges and keep records of it. Individual DFT shall not be less than
85% of recommended DFT (as per Appendix A).
10.7. Ensure that all the quality control instruments are calibrated from approved third
party and calibration certificates shall be available at site.
10.8. Ensure that all activities are carried our in controlled manner.
10.9. After application of Chartek 1709, coating shall be inspected visually. The coating
may be even and rolled finish.
10.10.It shall be ensured that the coating shall be free from cracks, runs, discontinuity,
sags, voids or isolated deposit of excess thickness. Caulking or sealing of free edges
and terminations is not required.
Note: This project specific quality assurance and control plan has been developed based on
the standard Quality control manual of International Paints.

11.0. Repair Procedure :Page 8 of 10

Revision: 01
17/11/15

11.1. Check the border area of surrounding Chartek 1709 for soundness and adhesion in
joint area.
11.2. Mark out the area to be repaired. Masking should be done around the area to be
repaired in a square or rectangular shape. This will give the patch a clean
appearance once completed.
11.3. Using a disc grinder, cut through the Chartek 1709. Care should be taken not to
damage the substrate.
11.4. Using chosen tools (hammer and chisel etc), cut into patch to remove damaged
Chartek 1709. Make sure all uncured material is removed.
11.5. Small areas, for example, welds and local repair areas, may be prepared by power
tools to achieve a clean, roughened surface in accordance with SSPC SP11 and
maintain a minimum profile of 50microns. Power tool cleaning should not be used as
a primary surface preparation method for large areas.
11.6. Abrade adjacent surfaces for a distance of 150mm from edge of repair area. After
roughening GTA123 thinner should be used to ensure the area is clean.
11.7. Reinstate primer to specification, if required. For repairs, Chartek 1709 may also be
applied to blast cleaned steel.
11.8. Reinstate Chartek 1709 to specification, taking care to smooth over the repair area
edges. Trowel application of Chartek 1709 is acceptable for repair areas.
11.9. Topcoat (Interthane 990) replacement and repair should follow its TDS.

12.0. Safety Measures :12.1. Project Engineer, QC Engineer, Site Supervisor and workers shall be well aware of
typical worksite hazards (mechanical equipment, lifting equipment, scaffolding,
painting, blasting etc).
12.2. Tool box talk shall be conducted by Site Supervisor/Safety Officer prior to
commencing of work every day and made all aware of the possible hazards in the
blasting and painting activities.
12.3. Eye, face, hearing and respiratory protection shall be supplied to all personnel
working at site.
12.4. A blasting/paiting zone shall be established and marked off with signs around the
perimeter of the area.
12.5. All blasting and painting equipments shall be properly earthed.
12.6. Hazard related information such as MSDSs shall be labeling near the material
storage area.
Page 9 of 10

Revision: 01
17/11/15

12.7. Paint and thinner shall be placed in designated storage area away from smoking
zone to prevent fire and explosion.

13.0. Manpower Requirements :a)

Project Engineer

b)

QA/QC Engineer

c)

Safety officer

d)

Supervisor

e)

Spray Painter.

f) Painter.
g)

Mason.

h)

Helper.

14.0. Tools and Equipment Requirements :a)

Blasting Equipments.

b)

Compressor.

c)

Airless Spray Machine.

15.0. PPE Requirements :Helmet, Goggles, Visor, Face Shield, Dust mask, Disposable Painting Coverall, Ear
Protectors, Safety foot wear, Apron, Chemical Protecting Gloves.

Page 10 of 10

Revision: 01
17/11/15

You might also like