P1064-00-M05-119-R0 Painting Work

Knexir Consultants Pvt. Ltd.
Consulting Engineers
Tel.: 91-22 61547800. Fax.: 91-2225111092
Website : www.knexir.in Email : Knexir@knexir.in
Doc. No.
Revision No.
TENDER DOCUMENT FOR PAINTING WORK

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 1 of 29
TENDER DOCUMENT
FOR
PAINTING WORK
Revision
Date
R0
14-05-2013
Prepared By
Faisal Farooqui
Checked By
K C Sanjay Kumar
Approved By
Jagdish Pathak
Status
Comments / Approval
R1
R2
R3

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 2 of 29
INDEX
1.0
GENERAL INFORMATION: ..................................................................................................................... 3
2.0
TECHNICAL SPECIFICATION FOR PAINTING ............................................................................................ 4
2.1
GENERAL ............................................................................................................................................................. 4
2.2
SCOPE ................................................................................................................................................................. 4
2.3
CODES & STANDARDS .............................................................................................................................................. 5
2.4
EQUIPMENT .......................................................................................................................................................... 7
2.5
RECEIPT AND STORAGE............................................................................................................................................. 7
2.6
SURFACE PREPARATION, COATING APPLICATION .............................................................................................................. 7
2.7
PROTECTIVE COATING & PAINTING MATERIAL .............................................................................................................. 14
2.8
PAINTING SYSTEM ................................................................................................................................................ 14
2.9
PAINTING COLOUR CODES ....................................................................................................................................... 14
2.10
IDENTIFICATION OF EQUIPMENT, PIPING ETC. ............................................................................................................... 14
2.11
INSPECTION & TESTING .......................................................................................................................................... 16
2.12
FIELD SAFETY AND HYGIENE ..................................................................................................................................... 17
2.13
GUARANTEE........................................................................................................................................................ 18
2.14
QUALIFICATION CRITERIA OF PAINTING CONTRACTOR ...................................................................................................... 18
2.15
DOCUMENTATION: ............................................................................................................................................... 18
ANNEXURE I - PAINTING MATERIAL INDEX ............................................................................................................................ 21

ANNEXURE II PAINTING SYSTEM SCHEDULE .......................................................................................................................... 21
ANNEXURE III COLOUR CODE ......................................................................................................................................... 22
SKETCH 1 - WITH PRIMARY COLOUR BAND ........................................................................................................................... 25
SKETCH 2 -WITH PRIMARY & SECONDARY COLOUR BAND......................................................................................................... 26
SKETCH 3 - WITH PRIMARY & SECONDARY COLOUR BAND WITH DIRECTION BY ARROWS .................................................................. 27
SKETCH 4 - COLOUR BANDS WITH HAZARD MARKINGS............................................................................................................. 28
3.0
PAINTING PROGRAMME .................................................................................................................... 29
4.0
SCHEDULE OF QUANTITIES & RATES .................................................................................................... 29

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.
1.0

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 3 of 29
GENERAL INFORMATION:
M/s. Carlsberg India Pvt. Ltd.
5th Floor, Paras Twin Towers, Tower B,
: Sector-54, Gurgaon,
Harayana-122 002
1.0
Client
2.0
Plant location
3.0
Project
: Green Field Bihar
M/s. Carlsberg India Pvt. Ltd.

Patna , Bihar
4.0
5.0
Site data
Access to Site
Ambient data
(As per ISHARE)
DBT ( C)
WBT ( C)
RH (%)
Summer
42.2
25.6
26
Monsoon
32.2
28.3
78
Winter
10.0
6.7
60
By Road
: Patna
Railway Station
: Patna
Nearest Airport
: Patna

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 4 of 29
2.0
TECHNICAL SPECIFICATION FOR PAINTING
2.1
General
This engineering standard specification covers the requirements for painting including surface preparation,
method of application, inspection of paints / coating and painted surface for equipment, piping, structures,
electrical, instrumentation equipment for the plants engineered by KCPL
Building / Concrete Painting is not covered under this Specification. For Building / concrete Protection
Painting refer Civil Specification.
2.2
Scope
a.
Scope of work covered in the specification shall include, but not limited to the following:
This specification defines the requirements for surface preparation, selecting and method of application of
paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structure, electrical and
instrument items. In general all shop fabricated/manufactured equipment will be delivered to job site with
painting in accordance with the requirements of this Specification.
The entire painting job shall be done as per the paint materials specification and apply as per the
specifications for surface preparation, paint system and application method given in the specification.
b.
Extent of Work
All un-insulated CS and SS equipment like columns, vessels, drums, storage tanks, heat exchangers, pump
etc.
All un-insulated carbon and low alloy steel piping, fittings, flanges and valves (Including painting
identification marks), furnaces, ducts and stacks.
Equipment and piping contained in a package unit as necessary.
All structural steel work, pipe structural steel work, walkways, handrails, ladders, platforms etc.
Identification colour bands on all piping as required including insulated aluminium / galvanised clad,
galvanised, SS and non-ferrous piping.
Identification lettering/ numbering on all painted surfaces of equipment/ piping insulated aluminium /
galvanized clad galvanized, SS and non-ferrous piping.
Hazardous content marking/identification signs on painted surfaces of equipment/piping.
Supply of all primers, paints and all other materials required for painting other than owners supply.
Painting under insulation for carbon steel and stainless steel piping, vessels, storage tanks etc, if required.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 5 of 29
Equipment, piping inside pits or trenches.
Repair and repainting of damaged and defective painting of shop applied items as per the instructions of
engineer in charge of site.
All galvanised piping, structural and equipment to be repaired on damaged at site with suitable coating
materials as per the instruction of engineer in charge at site.
c.
The standard specification excludes the following
Painting of equipment, piping, mechanical structures or package items based on manufacturer

recommendation. (All package items shall be painted in accordance with this Spec.)
Non Ferrous materials like Aluminium.
Austenitic stainless steel & Galvanised iron.
Plastic and plastic coated materials.
Application of paints using methods other than brushing or spraying.
Painting for temporary installation.
Coating and lining
d.
2.3
Pipes and equipment shall be painted only after the mechanical completion, testing on systems are
completed including hydro testing as well as after completion of steam purging wherever required.
Codes & Standards
a.
The latest edition of the following standards including all revisions and addendum shall be applicable.
Works shall also be in accordance with the Paint Manufacturers recommendations.
IS-5
IS-101 Method of test for ready mixed paints and enamels.
IS-158 Spec. for ready mix paints.
IS-161 Heat resistant Paint
IS-2074 Specification for ready mixed paints, red oxide zinc chrome primer.
IS-2339 Aluminium paint for general purposes in dual container
IS-2379 Colour code for identification of pipelines
Colours for ready mixed paints and enamels.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 6 of 29
IS-2932 Specification for enamel, synthetic, exterior (a) undercoating (b) finishing
A 13.1 American standard scheme for identification of piping by colour coding.
BS-729, 1981 Hot Dip Galvanised Coatings on Iron and Steel Articles
BS-4800, 1981 Paint Colours for Building Purposes
b.
Surface Preparation Standards:
Steel Structure Painting Council (SSPC-SP)
Swedish Standards Institution (SIS) (SIS 05 5900-1967)
International Organisation for Standard (ISO) (ISO 8501-1) : 1988
NACE National Association for Corrosion Engineers
BS-4232 Surface finish of blast cleaned surface for painting.
IS 1477 Part I Code of Practice for Painting of Ferrous metal in building (Pre Treatment)
If there is any conflict between the requirements of the above mentioned codes and standards and this
engineering specification, the requirements of the specification shall prevail. All conflicts shall be referred
to KCPL/Owner for clarification before proceeding for the work.
c.
The paint manufacturers latest approved published instruction shall be followed as far as practicable at all
times. Particular attention shall be paid to the following.
Proper Attention to avoid exposure as well extremes of temperature
Surface preparation prior to painting
Mixing & thinning
Application of paints and recommend limit on time intervals between coats.
The paint materials for any paint system including primer, intermediate coating, finished coating and
thinner shall be from a single approved manufacturer.
d.
Any painting work (Including surface preparation) on piping or equivalent shall commence only after the
system tests have been completed and clearance for taking up painting work is given by the engineer in
charge in writing.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.
2.4

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 7 of 29
Equipment
a.
All tools, brushes, rollers, spray guns, abrasive materials, solvent, hand/power tools for cleaning,
scaffolding materials, shot/wet abrasive blasting, water blasting equipment, air compressors, industrial
vacuum cleaners etc. required to be used shall be suitable for the work and all in good order and shall be
arrange by the contractor at site and insufficient quantity.
b.
Mechanical mixing shall be used for paint mixing operations in case of two-pack system except engineer in
charge may allow the hand mixing of small quantity at his discretion.
2.5
Receipt and Storage
a.
Painting material shall be received, unloaded and stored in a room, which is well ventilated.
b.
In cases where paints are stored outside, adequate protection shall be provided to prevent damage to the
drums.
c.
Warning signboards shall be displayed at places where paints and solvents are stored.
d.
Paints shall not be stored in plant area where there is a fire risk.
e.
Paints and solvents shall be stored and records shall be maintained to ensure their usage before expiry
date.
f.
Containers shall be handled with care. Container of Paint, catalyst and thinners shall not be opened prior
to use except for spot inspection.
g.
Adequate number of fire extinguishers shall be provided in the stores where paint and solvents are stored.
h.
Adequate ventilation and gas masks shall be provided while painting in confined areas.
2.6
Surface Preparation, Coating Application
a.
Preparatory Work:
i.
The agency undertaking work shall estimate quantity of primer and paint required for the job and
arrange to procure the same prior to commencement of the job.
ii.
Approved brands of paints shall only be used (shall be mentioned supplier wise)
iii.
Check, verify the year of manufacture, Batch No. and expiry date of the paint before starting the work.
iv.
Read the paint manufacturers instruction regarding applications, Incase of conflicting requirement with
this specification, Engineer in charge shall be consulted.
v.
Necessary steel scaffolding, landing mats, etc. required to carry out the job is to be arranged.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 8 of 29
vi.
All workmen deployed on the job shall have personal protection gear such as safety shoes, helmets,
safety belts and goggles.
vii.
Paint shall not be mixed near electrical panels.
viii.
Arranged adequate quantities of consumables such as sand papers, wire brushes, paint brushes and
cloth.
ix.
Arrange sufficient number of air compressor of adequate capacities with spray guns and other
accessories.
x.
Ensure that calibrated DFT (Dry Film Thickness) tester/ elcometer is available at shop/ site.
xi.
Maintain testing and calibration certificate for elcometer.
xii.
Arrange to provide abrasive blasting equipment with all necessary accessories.
xiii.
Ensure that all electrical appliances are tested and properly earthed.
xiv.
Provide galvanised sheets, tarpaulins etc. to protect equipment and men during abrasive blasting
operation.
xv.
Provide adequate gas masks, goggles, hand gloves and other personal protection gear to the workmen
undertaking abrasive blasting.
b.
Surface Preparation:
In order to achieve maximum durability one or more of following methods of surface preparation shall be
followed, depending on the condition of steel surface and as instructed by engineer in charge. Adhesion of
the paint film to surface depends largely on the degree of cleanliness of the metal surface. Proper surface
preparation contributes more to the success of the paint protective system.
Manual or hand tool cleaning
Mechanical or Power tool cleaning
Blast cleaning
For the adequate performance of the painting system, it is absolutely essential that the surfaces to be
painted are adequately prepared. The surface should be dry and free from oil and grease, dust, weld
splatter, burrs, flux, rust, loose scale, dirt and any other foreign matter before any coating is applied.
All surface preparation will be carried out in accordance with the requirement set out in ISO 8501-1: 1988
Preparation of Steel Substrates before Application of Paints and Related Products Visual Assessment
for surface cleanliness

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 9 of 29
Manual of hand tool cleaning
Manual or hand tool cleaning is used only where safety problems limit the application of other surface
preparation procedure and hence does not appear in the tables of paint systems
Hand tool cleaning normally consist of the following.
Hand descaling and /or hammering
Hand scraping
Hand wire brushing
On completion of cleaning, loose material shall be removed from the surface by clean rags and the
surface shall be brushed, swept dedusted and blow off with compressed air / steam to remove all
loose matter. Finally the surface may be washed with water and dried for effective cleaning.
Mechanical or Power tool cleaning (As per SSPC-SP3)

Power tool cleaning shall be done by non-sparking type brass mechanical striking tools, chipping
hammers, grinding wheels, rotating brass wire brushes. On completion of cleaning the detached rust,
mill scale etc. shall be removed by clean rag and/or washed by water or steam and thoroughly dried
with compressed air jet before application of paint.
Blast Cleaning (NOT APPLICABLE)

Surface Preparation prior to blast cleaning.
Prior to abrasive blast cleaning the surface shall be free from moisture, oil greases and heavy
deposits of rust. Excessive deposits of rust shall be removed using impact cleaning tools prior to
the commencement of abrasive blast cleaning.
Oil and grease shall be removed using an emulsifying solvent, and the surface shall be washed with
clean water and allowed to get dried completely prior to the commencement of abrasive blast
cleaning. Wiping with a rag soaked in solvent for the removal of oil and grease from the
contaminated surfaces shall not be accepted as adequate.
Equipment for Abrasive Blast Cleaning
The compressed air to be used for abrasive blast cleaning shall be dry and free from oil. Adequate
separators and traps shall be installed in the coolest part of the system; they shall be regularly
emptied to prevent the carry over of oil and water.
Accumulations of oil and water shall be removed from air received by regular purging. Blasting
nozzles shall be replaced when wear reaches 50%. Air compressors shall not deliver air at
temperatures in excess of 110oC.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 10 of 29
Abrasives to be used in Blast Cleaning
The abrasive used for abrasive blast cleaning may be selected from the following:
Steel grit
Steel shot
Malleable iron shot
Crushed or chilled iron grit
Chopped steel wire
Aluminium oxide
Blast furnace slag
Copper Slag
Vasilgrit (a proprietary grade based on inert aluminium silicate)
Sand: Should sand be considered as the blasting medium, it shall be delivered to site in
sealed bags. Each bag shall be identified against a Batch No. and each batch has a third party
certificate. The test certificate shall confirm that the blast medium conforms to the
requirements of US-MIL-S-22262 with a maximum chloride level of 0.03%.
Abrasive Blast Cleaning

The surface shall be blast cleaned using the abrasives at pressure of 7 kg/cm2 (g) at appropriate
angle and distance depending on nozzle size maintaining constant velocity and pressure.
Abrasive Blast Cleaning shall remove all mill scale, rust and other corrosion products, paint and any
other foreign matter to achieve a surface cleanliness of SA 2, accordance with ISO 8501-I with a
surface roughness not exceeding
Surfaces, which become wet due to rain or moisture, shall be re-blasted prior to application of the
primer. Abrasive blast cleaning shall overlap by at least 25 mm on any adjacent painted surface.
Environmental Conditions for Surface Preparation
Surface preparation by abrasive blast cleaning shall not be carried out when the following
conditions prevail:
The surface temperature of the substrate is less than 3oC above the ambient dew point and
when the relative humidity is greater than 85%. Or the substrate temperature is more than
60oC.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 11 of 29
Abrasive blast cleaning shall not be carried out during the hours of darkness unless
adequately equipped facility for the purpose is available.
Surface preparation after abrasive blast cleaning: All surfaces that have been prepared using
abrasive blast cleaning will normally have traces of blast debris and dust removed from the
surface. The surface including all pockets and corners shall be cleaned by vacuum cleaning, blowing
with dry oil free compressed air, or brushing with a clean brush made from hair, bristle or fiber.
Surface preparation for hot dipped galvanised steel, stainless steel and non-ferrous metals.
Generally these surfaces are not painted.
If, however painting is required on these surfaces, they shall be lightly abrasive blast cleaned using
aluminium oxide or inert aluminium silicate. Copper from furnace slag shall not be used on
stainless steel. Any zinc salts that have formed on galvanised surfaces shall be removed using clean
water or a solvent wash and thoroughly dried before the abrasive cleaning is undertaken.
Surface Preparation of Concrete Surfaces (NOT APPLICABLE):
Concrete surfaces that require painting shall be clean, dry and free from laitance and have a
degree of roughness to ensure proper adhesive of the paint. The surface shall be blast cleaned or
power wire brushed to obtain the degree of roughness required.
Etching with dilute hydrochloric acid and washing with excess water shall be accepted as a last
choice only. Painting shall not commence on concrete surfaces until the surface has dried to
humidity of 4% by wt or less.
Surface preparation classification is indicated in Table-I below
Surface prepared shall be compared with relevant standard using a comparator.
After surface preparation and prior to any coating application the substrate shall be checked for
soluble salt contamination using a suitable salt contamination meter. Maximum allowable is 5
gm/cm2

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 12 of 29
Table I
Surface Preparation Classification
Method of
Cleaning
Solvent Cleaning
Through Hand
Tool Cleaning
Classification
Cleaning with solvents, vapour alkali, emulsion or

steam to remove oil, grease, soil, salts.
Hand and
Power Tool
Cleaning
Thorough scrapping and wire brushing machine

brushing- grinding etc. The treatment shall remove
loose mill scale, rust and foreign matter. Finally,
the surface is cleaned with a vacuum cleaner, clean
dry compressed air or a clean brush. It should then
have a faint metallic shine.
Very thorough scrapping and wire brushing,
machine brushing-grinding etc. The treatment shall
remove loose mill scale, rust and foreign matter.
Finally, the surface is cleaned with a vacuum
cleaner, clean dry compressed air or a clean brush.
After removal of dust, the surface shall have a
pronounced metallic shine.
By using oxy acetylene flame dehydrate and
remove rust loose mill scales and tight mill scales
followed by wire brushing
By using wheel or nozzles (dry or wet) using grit or
shot all visible rust, mill scales and foreign matter is
removed.
St 2
Thorough blast cleaning. Almost all mill scale, rust

and foreign matter shall be removed. Finally, the
surface is cleaned with a vacuum cleaner, clean dry
compressed air or a clean brush. It shall then be
grayish in colour.
Blast Cleaning of all except tightly adhered residue
of mill scales rust, coating exposing numerous
flecks of underlying metal
Acid pickling or electrolytic pickling to complete
remove mill scales (may reduce resistance of the
surface to corrosion if not primed immediately)
Weathering to remove all particle of mill scale
followed by blast cleaning to one of the above
method.
Very thorough blast cleaning. Mill scale, rust and
foreign matter shall be removed to the extent that
the only traces remaining are slight stains in the
Sa 2 Nearly
80%
Hand and
Power Tool
Cleaning
Flame Cleaning
of new steel
Blast Cleaning to
usually clean
steel
Through Blast
Cleaning
Reference Standard
SIS / ISO
St 1
Grease and Oil

cleaning
Very thorough
Hand and Power
Tool Cleaning
Procedure & Degree of Steel Surface finish
Removal of
rust, loose mill
scale
Removal of all
visible rust,
mill scales by
blast.
Commercial
Blast Cleaning
Light Blast
Cleaning
Blast Cleaning
Pickling
Pickling
Weathering
followed by
blast cleaning
Very through
blast cleaning
Weathering
Near White
Blast Cleaning
St 3
F1
Sa 3 100% Pure
Surface
Sa 1
Sa 2
95%
Pure

Tel.: 91-22 61547800. Fax.: 91-2225111092

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 13 of 29
Doc. No.
Revision No.
Method of
Cleaning
Classification
Procedure & Degree of Steel Surface finish

form of spots or strips. Finally, the surface is
cleaned with a vacuum cleaner, clean dry
compressed air or a clean brush.
Note :- Nearest equivalent of above can be used

Legends :
SIS :
Swedish Standard Institution SIS 05-5900-1967
ISO :
International Organisation for Standardisation ISO 8501-1:1998(E)
Reference Standard
SIS / ISO

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.
2.7

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 14 of 29
Protective Coating & Painting Material

Contractor shall furnish from paint manufacturer, all the characteristics of paint materials on printed
literature, along with test certificate for all the specified characteristics given in this specification for the
supplied batch of material. All paint material shall be first quality and conform to the characteristic
mentioned in this specification.
Refer to Annexure-I
2.8
Painting material index
Painting System
The paint system should vary with the type of environment envisaged in and around plant, the service
temperature and the cost effectiveness. These parameters are defined as part of this specification.
Refer to Annexure II
2.9
Painting System Schedule.
Painting Colour Codes

The colour codes recommended in this specifications as per Indian standards.
Refer to Annexure III: Painting colour codes.
The basic identification colours as indicated in Annexure III are applied to the entire surface of equipment
except on precision-machined surfaces, non-ferrous and threaded parts. On the pipes, the basic colour is
applied over the entire surface of uninsulated pipes and further identification of service, colour bands as
defined in Annexure shall be painted.
2.10
Identification of Equipment, Piping Etc.

Equipment number shall be stenciled in black or white on each equipment after painting.
Line number in Black or White shall be stenciled on all pipelines at more than one location as directed by
engineer in charge.
a.
Flow Direction
Flow direction bands are described in Sketch 1 and 2.
Arrows can also be used to indicate the flow direction as described in Sketch 3
The arrows shall be in white or black colour. Following sizes are recommended:
For pipes diameter 1 to 6 dia., arrow to fit in a 25 mm x 100 mm rectangle.
For pipes diameter 8 dia and above, arrow to fit in a 80 mm x 150 mm rectangle.

Tel.: 91-22 61547800. Fax.: 91-2225111092

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 15 of 29
Doc. No.
Revision No.
b.
In case of flow of fluid is possible in either direction; two arrows shall be indicated one above the other
and both in same colour.
Arrows and band markings shall be made at the unit battery limits and then on convenient location at
the point of use. It is recommended to adopt one method for the entire plant.
Hazardous Mediums
Where the piping system carries a hazardous product, a panel of equal diagonal stripes (black and yellow
colours) shall be superimposed on the pipe on both ends of the basic identification panels as detailed in
Sketch-4.
c.
Details of Code Indications
Colour:
The Line nos. and equipment nos. shall be painted either in white or in black in order to contrast
clearly with the colour of paint on the pipe or equipment. For insulated lines, the code indications
shall be painted over the cladding of the insulation.
Requirements:
The full name or well-known abbreviations of chemical and symbol of fluid flowing (as per Project
Spec.) inside a pipeline shall be indicated. The line number shall also be painted on the pipelines. The
pressure or temperature of the fluid inside the pipeline shall not be indicated.
Location:
The code indication as described above shall be painted at following locations or such other places
where quick identification is deemed necessary.
Pipelines: At all junctions, both sides of valves, both sides of service appliances and at intervals of 25
m on straight pipe lengths.
Note: For long straight lengths of pipelines e.g. transfer lines, the interval of 25 m for code indication
may be varied at the discretion of the Client/KCPL
d.
Size:
The recommended size of lettering to be used for code indications on the insulated as well as uninsulated
pipes shall be as per following:
For Pipes
Diameter 2
25 mm letters
For Pipes
Diameter 2 4
40 mm letters
For Pipes
Diameter 6 and above
80 mm letters

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.
e.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 16 of 29
Code Indication for Small Diameter Pipes:

Code indication marking by paint may not be done for uninsulated pipelines of nominal diameter 1 and
below and for insulated lines less than 1 diameter. For such pipes, the indication markings shall be
punched on lead tags and then secured to the pipe. Such tags shall be provided at locations as described
earlier. The size of the tag and the method of tying it with pipeline shall be as per advice of Engineer in
charge.
f.
Lettering for Equipment:

Lettering for the equipment should be marked on each equipment at a clearly visible location.
The letters should have following minimum height:
2.11
For Equipment with Diameter 1 m
50 / 80 mm
For Equipment with Diameter 1 m to 5 m
100 mm
300 mm
600 mm
For Equipment with Diameter more than 50 m
900 mm
Inspection & Testing
a.
Inspection of various stages during painting is essential to ensure quality of painting. Inspection shall be
performed by owner authorized Field Superintendent.
b.
Surface preparation shall be as per specification; the prepared surface shall be compared with standard
comparator charts available in standards such as SIS or ISO. The basis of acceptance shall be based on
visual comparison only.
c.
Standard surface finish comparator specimens are available, which are approved by reputed test house,
these may also be used after obtaining clients or consultant approval.
d.
Visual examination of the painted surface shall be conducted to check for flaws such as unfinished surface,
drips, wrinkles, blisters, peels, cracks, stains, pin holes, crawls, dust settlement and air pockets.
e.
Area where such defects are noticed shall be marked using some paint of different colour.
f.
Areas where there are no such defects shall be accepted after visual examination.
g.
Thickness of primer and finish coats shall be measured using dry film thickness meter or elco-meter or
owners accepted equal. Thickness shall be measured in accordance with specification of SSPC-PA-A-73T.
h.
Location for verifying thickness shall be decided by engineer-in-charge depending on the size and shape of
the item painted.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 17 of 29
i.
Total three sets of readings shall be carried out at a location, one at the main location and two at the
adjacent points. The average of these three measurements shall be taken as the measured value.
j.
The coating thickness shall be deemed to be accepted if the following conditions are satisfied:
Wet Film Thickness

Use steel type (or disposable type for one day only) each. Wet film thickness measured by using a wet
film gauge of steel or aluminium calibrated to read in mils or microns (25 microns 1 mil).
When using this gauge, the applicator divides the desired dry film thickness by the % volume solids of
the coating as expressed in a decimal (taking into account the amount of thinning done) to yield the
necessary dry film thickness.
Dry Film Thickness:

An Elometer, or mikrotest, or similar approved gauge is used to measure thickness to the nearest
micron. It shall be calibrated against a standard sand blasted surface to SA 2-1/2.
The acceptable tolerance in dry film thickness shall be in accordance with SSPC-PA2.
The Piping Contractors Superintendent shall have in his possession at all times a wet film thickness
gauge for continuous check of the west film as applied.
k.
Consultants/ Client may draw sample of paint before or during application for analysis.
l.
Adhesion test shall be performed after the finish coating has dried up, using a scraper comb with 1 mm gap
between teeth. Adhesion shall exceed 80%.
m.
All painting material including primers and thinners brought to site by contractor for application shall be
procured directly from the manufacturer as per the specification and shall be accompanied by
manufacturers test certificates. Paint formulations without certificates are not acceptable.
n.
Engineer in charge at his discretion, may call for tests of paint formulation. Contractor shall arrange to
have such tests performed including batch wise test of wet paints for physical and chemical analysis. All
cost incurred in carrying out tests shall be borne by the contractor. Defective work shall be corrected by
the Painting/Coating Contractor at his sole expense.
2.12
Field Safety and Hygiene

While performing surface preparation and painting, safety and hygiene conditions shall be observed by the
contractor. Following care shall be observed.
a.
Workmen should be provided with all personal protective gears such as safety shoes, safety goggles/
masks, hand gloves, aprons, safety belts, helmets etc.
b.
Smoking should be totally prohibited in and around painting area and paint storage area.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 18 of 29
c.
Adequate ventilation and lighting shall be provided while painting in a confined area.
d.
While performing shot blasting activity, the area shall be covered adequately so that no shots fly around.
e.
Proper tubular double scaffolding with metallic clamps and landing mats shall be used while working on
higher elevations.
f.
If painting has to be carried out in an almost airtight environment, workmen shall use gas masks.
2.13
Guarantee
The contractor shall guarantee that the chemical and physical properties of paint materials used are in
accordance with the specifications contained herein / to be provided during job execution. The painting
work shall be guaranteed for at least 2 years without any detrimental failures such as loss of adhesion,
under film corrosion, corrosion spots and blisters etc. under the corrosive conditions prevailing in the
plant.
The contractor shall produce test reports from manufacturer regarding the quality of the particular batch
of painted surface. The Engineer in charge shall have the right to test wet samples of paint at random for
quality as per the paint materials specification given in this specification. Batch test report of the
manufacturer for each batch of paints supplied shall be made available by the contractor.
2.14
Qualification Criteria of Painting Contractor

Painting contractor who is awarded any job under this specification must have necessary equipment,
machinery, tools and tackles for surface preparation, paint application and inspection. All the paint
materials should be supplied from approved manufacturer. The contractor must have qualified, trained,
experienced surface preparator, paint applicator, inspector and supervisors. The contractors supervisor,
inspectors, surface preparators, paint applicators must be conversant with the standards referred in this
specification. The contractors capacity, capability and competency requirement for the job shall be
quantified in the tender document and shall be assessed by Client/ KCPL before awarding contract.
2.15
Documentation:
The following documents shall be complied and forwarded to consultant. This shall be equipment wise/
line wise:
a.
Type and Make of primer applied
b.
Type and Make of paint applied (Intermediate & Final)
c.
Batch Certificate Number
d.
Expiry date of paint
e.
Surface Preparation Examination Report

Tel.: 91-22 61547800. Fax.: 91-2225111092

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 19 of 29
Doc. No.
Revision No.
f.
Dry Film Thickness Readings for Primer Coats
g.
Dry Film Thickness Readings for Intermediate & Finish Coats
h.
Check List
i.
Final Acceptance Certificate
j.
Paint Manufacturers QA/ QC Report
k.
Name of the manufacturer
l.
Factory Location
m.
Date of manufacturer
n.
Batch No.
o.
Product Name
p.
Drying Time
q.
Hold up Property
r.
Glossiness
s.
Specific Gravity
t.
Viscosity
u.
Generic Name
v.
Key Composition
Resin
Pigments
Curing Agent
Solvent Name
w.
Density
x.
Fineness
y.
Colour

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 20 of 29
z.
Date of Expiry
aa.
Pot Life

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 21 of 29
Annexure I - Painting Material Index

Application
Type
Dry film
thk.
Description
Max.
Humidity
Temp.
High
Temp. Low
35
85%
45oC
10oC
35
85%
45 C
10 C
PRIMER
01
Zinc Chromate Primer
II
INTERMEDIATE COAT
02
Synthetic Enamel Paint
III
FINAL COAT
03
Synthetic Enamel Paint
35
85%
45oC
10oC
04
High Build Epoxy For SS
100
85%
45oC
10oC
MAKES :- ASIAN PAINTS / BERGER PAINTS
Annexure II Painting System Schedule

I Coat
Sr.
No.
Description of Surface
01
II Coat
III Coat
Final
Coat
Total DFT
(SHOP)
(FIELD)
Structural Steel Work
120
02
Piping System
120
03
Tanks
120
04
Bands for SS Piping
100
Remarks

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 22 of 29
Annexure III Colour Code

1. Colour Code for Equipments & Structural
Sr.
No.
Contents
Tankages
Structural Steel Work
Colour
Light brown
2.1
Frame work, Columns, Beams and Pipe Supports (Unless galvanized)
Light grey
2.2
Stairs, platforms, Floor plates, Kickplates (Unless galvanized)
Light grey
2.3
Ladder, Ladder Cages, Handrails (Unless galvanized)
Black with yellow bands
2. Colour Code for Piping:

Sr.
No.
Contents
Ground Colour
Second Colour
Band
First Colour Band
WATER
1
Cooling
Sea green
French blue
Boiler feed water
Sea green
Gulf red
Condensate
Sea green
Light brown
Drinking
Sea green
French blue
Signal red
Treated
Sea green
Light orange
Fire water
Fire red
Crimson red
Cold water down service from Sea green

storage tanks
French blue
Canary yellow
Domestic, hot
Sea green
Light grey
Sea, river, untreated
Sea green
White
10
Filtered water
Sea green
Light brown
11
Soft water
Sea green
Light brown
Signal red

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 23 of 29
12
Chilled water
Sea green
Black
Canary yellow
13
Sprinkle and hydrant water
Sea green
White
Signal red
14
Waste water
Sea green
Canary yellow
Signal red
AIR
15
Compressed, up
including 15 Kg/cm2
to
and Sky blue
16
Plant air
Sky blue
Silver grey
17
Instrument air
Sky blue
French blue
18
Dry vacuum
White
19
Wet vacuum
White
Dark violet
20
Very high pressure steam
Aluminium to IS 2339
Signal red
21
High pressure steam
French blue
22
Medium pressure steam
Gulf red
23
Low pressure steam
Canary yellow
24
Drainage
Black
OIL
25
Light diesel fuel
Light Brown
Brilliant green
26
High speed diesel fuel
Light Brown
27
Furnace fuel
Light Brown
French blue
OTHERS
28
Ammonia
Canary Yellow
Dark violet
29
Chlorine
Canary Yellow
Dark violet
Light Orange
30
Acetylene
Canary Yellow
Service Brown
31
Freon
Canary Yellow
Light grey
Dark violet

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 24 of 29
32
Nitrogen
Canary Yellow
Black
33
Oxygen
Canary Yellow
White
34
Ethylene Glycol
Dark Admirality grey
Brilliant green
35
Ethylene Di-chloride
Gulf red
36
Acetone
Black
37
Methanol
Deep buff
38
Sulphuric Acid
Dark violet
Brilliant green
Light orange
39
Hydrochloric Acid
Dark violet
Signal red
Light orange
40
Brine
Black
White
41
Mercury
Black
White
Brilliant green

Tel.: 91-22 61547800. Fax.: 91-2225111092

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 25 of 29
Doc. No.
Revision No.
Sketch 1 - With Primary Colour Band

B
Basic Identification Colour
Primary Colour Band
Colour Band B (Same Colour as Band

A) located in the down-stream of band
A indicates the direction of flow.
In case of both direction flow, BandB should be located each side of BandA
Pipe
Size of Letters for

Line No.
100
50
100
25 mm
2 4
100
50
100
40 mm
6 16
D/2
80 mm
For the pipes sizes more than 16

A = 1 x 400 = 400 Max.
B = 400 / 2 = 200 Max.
C = 1 x 400 = 400 Max.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 26 of 29
Sketch 2 -With Primary & Secondary Colour Band

G

Secondary Colour Band - F
Primary Colour Band - E
Colour Band G (Same
Colour as Band E)
located in the downstream of Band E
indicates the direction
of flow.
In case of both
direction flow, Band-G
should be located each
side
E
Size of Letters for

Line No.
100
50
50
50
25 mm
2 4
100
50
50
50
40 mm
6 16
D/2
D/2
80 mm
Pipe
For the pipes of area > 16

E
400 Max.
200 Max.
G =
200 Max.
400 Max.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 27 of 29
Sketch 3 - With Primary & Secondary Colour Band With Direction By Arrows
J

Secondary Colour Band K
Primary Colour Band (J)
For pipes 1 6 arrow size
should be 25 mm x 100 mm
For pipes 8 and above
arrow size should be 80 x
150 mm
Size of Letters for

Line No.
100
50
25 mm
2 4
100
50
40 mm
6 16
D/2
80 mm
Pipe
For the pipes of sizes more than 16 the dimensions

J = 400 Max.
K = 200 Max.

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 28 of 29
Sketch 4 - Colour Bands with Hazard Markings

R
P/2
11-001-16-BBCIH
Hazard Marking Strips of

Black & Yellow B
Secondary Colour Band - M
Primary Colour Band - L
Direction of Flow N as
shown in sketch 1 & 2
(same colour as L)
The colour band N can be
replaced by arrow as shown
in sketch 3
Size of Letters for

Line No.
100
50
50
100
100
25 mm
2 4
100
50
50
100
100
40 mm
6 16
D/2
D/2
80 mm
Pipe

Tel.: 91-22 61547800. Fax.: 91-2225111092
Doc. No.
Revision No.

KCPL:P1064:00:M05:119
Date
14-05-2013
R0
Page No.
Page 29 of 29
3.0
PAINTING PROGRAMME
a.
Equipment and Piping Painting work is required to be completed within the time stipulated in the main
Contract.
b.
Key completion dates of various areas of work shall be specified at the time of award of Contract.
c.
The Site Planning Engineer of the Contractor shall be required to work out detailed erection programme
periodically as per completion requirements indicated by Consultant.
d.
The dates of completion for various milestones will be worked out by the Contractor jointly with the
Consultant. It will be the Contractors responsibility to execute the job totally as per agreed programme.
e.
Bi-monthly review meetings will be held at SITE to assess the progress and revise the schedule to ensure
completion as per Contract.
f.
Contractor mobilization to Site is to suit the completion targets and other than Force Majure, no excuses
for delay in completion is acceptable.
g.
The contract envisages liquidated damages (mentioned elsewhere in this document) for delay in
completion and the Contractor to bear the same in mind.
4.0
SCHEDULE OF QUANTITIES & RATES
a.
Schedule Of Equipment For Painting
- Annexure I
b.
Schedule Of Piping For Painting
- Annexure II
c.
Schedule Of Miscellaneous Items For Painting
- Annexure-III

P1064-00-M05-119-R0 Painting Work

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

P1064-00-M05-119-R0 Painting Work

Uploaded by

Copyright:

Available Formats

Knexir Consultants Pvt. Ltd.

TENDER DOCUMENT FOR PAINTING WORK

Knexir Consultants Pvt. Ltd.

TENDER DOCUMENT FOR PAINTING WORK

GENERAL INFORMATION: ..................................................................................................................... 3

TECHNICAL SPECIFICATION FOR PAINTING ............................................................................................ 4

CODES & STANDARDS .............................................................................................................................................. 5

RECEIPT AND STORAGE............................................................................................................................................. 7

SURFACE PREPARATION, COATING APPLICATION .............................................................................................................. 7

PROTECTIVE COATING & PAINTING MATERIAL .............................................................................................................. 14

PAINTING SYSTEM ................................................................................................................................................ 14

PAINTING COLOUR CODES ....................................................................................................................................... 14

IDENTIFICATION OF EQUIPMENT, PIPING ETC. ............................................................................................................... 14

INSPECTION & TESTING .......................................................................................................................................... 16

FIELD SAFETY AND HYGIENE ..................................................................................................................................... 17

QUALIFICATION CRITERIA OF PAINTING CONTRACTOR ...................................................................................................... 18

ANNEXURE I - PAINTING MATERIAL INDEX ............................................................................................................................ 21

PAINTING PROGRAMME .................................................................................................................... 29

SCHEDULE OF QUANTITIES & RATES .................................................................................................... 29

Knexir Consultants Pvt. Ltd.

TENDER DOCUMENT FOR PAINTING WORK

: Green Field Bihar

M/s. Carlsberg India Pvt. Ltd.

Knexir Consultants Pvt. Ltd.

TENDER DOCUMENT FOR PAINTING WORK

TECHNICAL SPECIFICATION FOR PAINTING

Equipment and piping contained in a package unit as necessary.

Hazardous content marking/identification signs on painted surfaces of equipment/piping.

Knexir Consultants Pvt. Ltd.

TENDER DOCUMENT FOR PAINTING WORK

Equipment, piping inside pits or trenches.

The standard specification excludes the following

Painting of equipment, piping, mechanical structures or package items based on manufacturer

Non Ferrous materials like Aluminium.

Austenitic stainless steel & Galvanised iron.

Plastic and plastic coated materials.

Application of paints using methods other than brushing or spraying.

Painting for temporary installation.

Coating and lining

Codes & Standards

IS-101 Method of test for ready mixed paints and enamels.

IS-158 Spec. for ready mix paints.

IS-161 Heat resistant Paint

IS-2339 Aluminium paint for general purposes in dual container

IS-2379 Colour code for identification of pipelines

Colours for ready mixed paints and enamels.

Knexir Consultants Pvt. Ltd.

TENDER DOCUMENT FOR PAINTING WORK

A 13.1 American standard scheme for identification of piping by colour coding.

BS-4800, 1981 Paint Colours for Building Purposes

Surface Preparation Standards:

Steel Structure Painting Council (SSPC-SP)

Swedish Standards Institution (SIS) (SIS 05 5900-1967)

International Organisation for Standard (ISO) (ISO 8501-1) : 1988

NACE National Association for Corrosion Engineers

BS-4232 Surface finish of blast cleaned surface for painting.

Proper Attention to avoid exposure as well extremes of temperature

Surface preparation prior to painting

Mixing & thinning

Application of paints and recommend limit on time intervals between coats.

Knexir Consultants Pvt. Ltd.

TENDER DOCUMENT FOR PAINTING WORK

Receipt and Storage

Surface Preparation, Coating Application