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TITLE OF WORK
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
CONTENT Page Execution Work Procedure for Shop and Field Painting 1. General 1.1 Scope 1.2 References 2. Application 2.1 2.2 2.3 2.4 General Surface Preparation Painting Inspection 1 1 1 2 2 5 7 10
Appendix 1. Painting System and Painting Specification 2. Paint Product Data Sheet 3. Inspection Flow 4. Inspection Guide 5. Finishing Color Schedule
File : Anang\P-cedure\Shop&fld
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
Page : 1
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
2. APPLICATION 2.1 GENERAL ( 1 ) Typical painting work shall be performed according to the following construction : Items 1. Equipment Vessel, heat exchanger etc. Painting Surface Preparation Touch-up primer coating Intermediate coating Finish coating 2. Piping Piping General Surface Preparation Primer coating Intermediate coating Finish coating Surface Preparation Touch-up primer coating Intermediate coating Finish coating 3. Steel Structure Steel structure fabricated at manufacture. Surface Preparation Touch-up primer coating Intermediate coating Surface Preparation Touch-up coating Finish coating Surface Preparation Primer coating Surface Preparation Touch-up primer coating Intermediate coating Finish coating Surface Preparation Primer coating Intermediate coating Finish coating Surface Preparation Touch-up primer coating Touch-up intermediate coating Application Stage After installation ditto ditto ditto Before prefabrication ditto ditto After installation After pressure test ditto ditto ditto Before erection ditto ditto After erection ditto ditto Before prefabrication ditto After installation ditto ditto ditto Before installation ditto ditto ditto After installation ditto ditto
Welding portion
Support
Touch-up finish coating ditto Note : Surface which are not accessible for painting after erection shall be painted up to finish coat before erection.
Page : 2
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
( 2 ) Work Flow. ( P i p i n g ) ** Pipe / Fitting Storage Transportation (*) Paint Shop. 1) Sand-blasting. 2) Primer coat. 3) Intermediate. coat. 4) Color discri mination. Paint Shop 1) Sand-blasting. 2) Primer coat. (Support) Storage
Transportation (*) Pipe installation. (*) Prefabrication Shop. ( * ) 1) Support prefabrication. Support installa tion. ( * ) Information from piping group 1) Touch-up of welding por tion and da maged area. 2) Final coat. 1) Touch-up of welding por tion and da maged area. 2) Intermediate coat. 3) Final coat. Final inspection Visual and DFT Line Marking Note : ( * ) Action by Piping Subcontractor. (**) No coat of paint shall be applied for welding joint of piping before hydrostatic test and or pneumatic test. Page : 3 Final inspection Visual and DFT
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
Steel Structure
Sheet Pile
Shipping
Shipping
Shipping
Installation
Installation Installation 1) Touch-up of damaged 1) Touch-up of da maged portion and bolt-nutt. 2) Final coat. Final inspection Visual and DFT Final inspection Visual and DFT portion. Marking Final inspection Visual and DFT
Page : 4
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
2.2. SURFACE PREPARATION. ( 1 ) GENERAL. All steel surfaces shall be thoroughly cleaned prior to painting of any material which will be conducive to premature failure of the paint coating. The method of surface preparation cleaning or preparation shall be one of or a combination of : - Blast cleaning. - Power tool cleaning. - Hand tool cleaning. - Solvent cleaning. All crevices, corners and edges of shape steel, joint of steel plate, especially around bolt heads, weld bead etc shall be cleaned with special care. All cleaned surfaces shall be primed the same day the cleaning is performed. Cleaned surfaces left unprimed overnight shall be recleaned before priming. Surfaces contaminated with dirt or other foreign matter shall be cleaned and painted imme diately in a manner that adjacent wet paint surfaces are not marred by the cleaning operation. Appreciable amount of surface grease, oil, salt and similar matter shall be removed prior to blasting, power and hand tool cleaning or solvent cleaning. ( 2 ) SURFACE CLEANING METHOD. The following are definitions and requirements for the various methods of surface cleaning. Blast Cleaning. a ). The removal of mill scale, rust, rust-scale and foreign matter from the surface shall be by propelled through nozzle or by centrifugal wheels. The following three degrees of blast cleaning are used :
SSPC - SP 10 ( Near-white blast cleaning ) Blast cleaning nearly to white metal cleanliness until at least 95 % of each element of surface area is free of all visible residues. SSPC - SP 6 ( Commercial blast cleaning ) After blasting the surface shall be completely free of dirt, mill-scale, weld flux and other foreign matter. Page : 5
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
Rust not completely removed with irregular slight red staining is acceptable provided wire brushing will improve the condition. Rust which can be streaked and popped out from cavity shall be removed with brass tool. b) Steel structure shall not be blasted when surface temperature is less than 3 degree Centrigade above the dew point, and when the relative humidity is greater than 85 %, or when there is possibility that the blasted surface will be subject to wetting before the 1-st coat or primer can be applied . Surface shall be blown, wiped or vacummed and free of blasting abrasive before the surface is primed. c) d) The abrasive material used in blasting shall be silica sand ( Local supply ). Coating shall be done within 6 hours after sand blasting.
SSPC - SP 3 ( Power tool cleaning ) a) The removal of loose mill-scale, rust, foreign matter or paint from the surface shall be by power wire brushes, power impact tool, power grinder and power sander.
SSPC - SP 2 ( Hand tool cleaning ) a) The removal of loose mill-scale, rust, loosely adhering material and loose paint from the surface shall be by hand brushing, hand scrapping, hand chipping or by other impact tools.
SSPC - SP 1 ( Solvent cleaning ) a) The removal of foreign material such as oil, grease, soil drawing and cutting compound, and other contaminants from the surface shall be by the use of solvent, emulsion cleaning or any other similar material and method which involves solvent for cleaning action.
Slight Sanding a) b) The primed surface shall be thoroughly cleaned by waste cloth and completely dry. After cleaning, the primed surface shall be slightly scrubbed by sandpaper to make sure that the surface roughness is enough to adhere to finish paint.
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: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
2.3 PAINTING ( 1 ) GENERAL Weather Condition. Paint shall not be applied on surfaces when : - The surrounding athmospheric temperature is below 4.4 Centigrade degree. - The relative humidity is above 85 %. - The wind velocity is such that dust and dirty may be deposited in the paint film, or it will inter fere with spray painting. - The surfaces are wet or damp from water or condensation. A 75 mm ( 3" ) wide strip of uncoated, blasted surface shall be left between primed and un blasted surfaces to prevent damage to the newly dried coating when additional blasting. power tool or hand tool cleaning is done. Masking for edges of piping and fitting After surface preparation, a distance of 50 mm from edge to be welded shall be left unprimed by covering the space with masking tape. Marking of material painted at the field shop shall be restored to its original painting system and identification marks according to specification shall be applied. Drying - No coat of paint shall be applied until the preceeding coat has completely dried. - No drier shall be added to paint unless specified by client. - No primer or any paint on all welding joint of piping before hydrostatic or pneumatic test ( 2 ) PREPARATION FOR USE Before painting, the following items shall be checked : - Confirm the painting area after surface preparation. - Availability of materials ( paint, thinner, etc ) and equipment ( compressor, spray machine etc ) - Paint's product name, lot number, production date and consumption required. - Usage of paint and thinner.
Page : 7
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
When opening paint container, paint content shall be checked as follows : - Skinning Where skinning has performed in the container, it shall be cut loose from the sides of con tainer, removed and discard. - Flooding If flooding is observed because of pigment type of storage conditions, etc., stir the paint thoroughly. If flooding still exists even after stirring, refrain from using the paint. - Gelation If gelation is observed, do not the paint since gelation tends to occur particularly in case of multicomponent product. Note : Hi-build epoxy paints areof thioxotropic state and appears to be high viscosity. However, the paint that becomes less viscosity by well stirring is acceptable. - Mixing Paint shall be thoroughly mixed immediately before application. Mixing shall preferably be done by mechanical stirrer, paddle mixer, can vibrator, or can shaker. If mechanical aids are not available, mixing by hand tool is acceptable. However, the container's vo lume is up to 5 gallons. Thinner - No thinner shall be added to the paint unless necessary for proper application. Paints to be applied by brush will usually require no thinning. Paints to be sprayed if not specifically formulated for spraying, may require thinning when proper adjustment of the spray equipment and air pressure does not result in satisfactory paint application. Special care shall be taken for high - build epoxy paint to prevent from exessive thinning when thinning is required. - When the use of thinner is permissible, thinner shall be added to paint during the mixing process. Painters shall not add thinner to paint after it has been thinned to the correct consistency. All thinning shall be done under supervision of one acquainted with the correct amount and type of thinner to be added to the paint. - Gasoline, kerosene or gas oil shall never be added to paint. Paint Application - The paint material shall be applied evenly to produce a smooth coating of the required uniform thickness. Page : 8
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
- Brush marks shall be avoided with priming paints. Each coat of paint shall be thoroughly dry before the next coat is applied. - Any oil, grease, soil, dust or foreign matter deposited on the surface after the surface preparation exist. The surface shall be again cleaned in accordance with the specified method. - Unless special protection is provided, paint shall not be applied in rainy, damp, windly, or dust weather, or when such unfavourable weather is predicated. - During painting, adjacent surfaces shall be protected from paint splashes and other blemishes. If blemishes or damages should occur, they shall be cleaned or repaired. - Defective painted surfaces, if any, shall be cleaned and repainted completely. - Excessive paint spots or streaks which may be formed shall be removed immediately. - Finish painted surfaces shall be uniform and smooth. Application Method a) Paint may be applied by one or a combination of the following methods of application : - Brush. - Roller coating. - Air spray. - Airless-spray. - Mill coating. b) The principal methods of application shall be in accordance with Appendix 1 ' Painting System ' and the following application criteria : Method - Brush Typical Subject to be Painted 1) Small area to be Painted. - minor area for touch-up. - handrail, ladder, cage. - small equipment. - small accessory.
- Cont'd Page : 9
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
2 ) Airless-spray
1 ) Large area to be pointed - Piping - Structure - Fired heater - Pipe rack - Equipment ( tower, vessel, stage )
- Roller Coating
1 ) Large, smooth, flat or slightly curved surface - Piping - Structure - Equipment ( tower, vessel, stage )
- Mitt Coating
1 ) May be used where spraying and/or brush method is not practicable. - Small pipe
Note : Roller Coating shall not be used for small area, corner and complicated structure surface. 2.4 INSPECTION ( 1 ) GENERAL Inspection shall be carried out in accordance with the requirement shown in appendix 3, work flow. ( 2 ) REPAIR Surface that fail to pass the inspection shall be corrected according to this procedure.
Page : 10
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
( 3 ) INSPECTION REPORT Inspection report shall be submitted to ICJV after the inspection is completed. (3).1 Inspection report for shop equipment shown in Appendix 4, Inspection Guide, sheet 2 / 7 (3).2 Inspection report for field equipment shown in Appendix 4, Inspection Guide, sheet 3 / 7 (3).3 Inspection report for shop piping and support shown in Appendix 4, Inspection Guide, sheet 4 / 7 (3).4 Inspection report for field piping and support shown in Appendix 4, Inspection Guide, sheet 5 / 7 (3).5 Inspection report for steel structure / other shown in Appendix 4, Inspection Guide, sheet 6 / 7 (3).6 Application for inspection shown in Appendix 4, Inspection Guide, sheet 7 / 7 ( 4 ) Corresponding designation of SSPC and visual standard shall be followed to spec. X - 1. ( 5 ) No. of dry film thickness check point for final inspection shall refered to appendix - 4 " Inspection Guide " ( 6 ) Detail of inspection shall be refered to appendix - 4 " Inspection Guide "
File : Anang\P-cedure\Shop&fld
Page : 11
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
APPENDIX The following appendix shall form part of this execution plan: No. of sheets 1 ) Painting System and Painting Specification 2 ) Paint Product Data Sheet 3 ) Inspection Flow 4 ) Inspection Guide 5) Finishing Color Schedule 11 16 1 9 8
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
APPENDIX - 1
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
PAINTING SYSTEM
( Option : A )
System no. 101 Work Volume Sqm 80,000 Temp. Cent. Deg. T<80 Surface Prep. SHOP PAINT Generic Type No. of coat 1 DFT ( mic ) 65 Surface Prep. FIELD PAINT Generic Type Product Name No. of coat 1 1 1 1 DFT ( mic ) 65 30 65 65 225 50 - 100 30 70 - 120 25 - 40 175 - 290 75 250 250 575 65 30 65 65 225 65 50 50 165 65 40 40 145 40 40
No.
SSPC-SP 10
SSPC-SP 3
T/U M M F
Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT Epoxy Zinc Rich Primer Epoxy Polyamide Primer Epoxy Polyamide Primer Aliphatic Polyurethane Total DFT Resist PH 4412 GT Penguard HB Penguard HB Hardtop AS
201
4,500
T<120
SSPC-SP 10
50 - 100
SSPC-SP 3
T/U M M F
1 1 1 1
303
12,938
T<60
SSPC-SP10
1 1 1
2 Equipment
101
6,250
T<80
SSPC-SP 10
65
SSPC-SP 3
T/U M M F
Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT
1 1 1 1
102
4,200
80<T<200
SSPC-SP 10
65
SSPC-SP 3
T/U Epoxy Zinc Rich Primer Resist PH 4412 GT M Silicon Acrylic Aluminium HR F Silicon Acrylic Aluminium HR Total DFT T/U Silicone Zinc M Silicone Aluminium F Silicone Aluminium Total DFT T/U Silicone Aluminium M Silicone Aluminium F Silicone Aluminium Silicone Aluminium Total DFT Resist PH 4412 GT Solvalitt Solvalitt
1 1 1
103
65
SSPC-SP 10 Welding Joint SSPC-SP 3 Other Parts SSPC-SP 10 Welding Joint SSPC-SP 3 Other Parts F = Finish Coat
1 1 1
104
200
T>350
SSPC-SP 10
1 1
20 20
Solvalitt Solvalitt
1 1 1 1
80 Sheet : 1 / 3 A
P = Primer
M = Midle Coat
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
No.
Application
Surface Prep.
No. of coat
DFT ( mic )
Surface Prep.
No. of coat 1 1 1
DFT ( mic ) 0 500 - 550 500 - 550 1000 - 1100 65 30 65 65 225 50 - 75 100 - 175 150 - 350
SSPC-SP 10
P Bisphenol Polyester Resin M Polyester Resin with inert Baltoflake Flake F Polyester Resin with inert Baltoflake Flake Total DFT P M M F Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT Amine Epoxy Primer Amine Epoxy Total DFT Penguard Primer Penguard HB
3 Tank
101
959
T<80
SSPC-SP 10
1 1 1 1
117
610
T<60
SSPC-SP 10
P F
1 1
174 39,500 T<80 SSPC-SP 10 P M M F Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT 1 1 1 1 65 30 65 65 225 65 50 50 165 65 40 40 145
102
4,100 80<T<200
SSPC-SP 10
P Epoxy Zinc Rich Primer Resist PH 4412 GT M Silicon Acrylic Aluminium HR F Silicon Acrylic Aluminium HR Total DFT P Silicone Zinc M Silicone Aluminium F Silicone Aluminium Total DFT Resist PH 4412 GT Solvalitt Solvalitt
1 1 1
103
1,020 200<T<350
SSPC-SP 10
1 1 1
P = Primer
M = Midle Coat
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
No.
Application
Surface Prep.
No. of coat
DFT ( mic )
Surface Prep.
No. of coat 1 1 1 1
DFT ( mic ) 40 40 0 0 80 40 - 50 40 - 50 80 - 125 80 - 125 0 500 - 550 500 - 550 1000 - 1100 65 30 65 65 225 65 30 65 65 225 65 30 65 65 225
SSPC-SP 10
P Silicone Aluminium M Silicone Aluminium F Silicone Aluminium Silicone Aluminium Total DFT P Epoxy Primer Total DFT Inorganic Zinc Primer Total DFT
Solvalitt Solvalitt
116
6,015
T<0
SSPC-SP 10
Penguard Primer
118
2,900
T<120
SSPC-SP 10
Resist PH 4412 GT
301
19,451
T<60
SSPC-SP 10
P Bisphenol Polyester Resin M Polyester Resin with inert Baltoflake Flake F Polyester Resin with inert Baltoflake Flake Total DFT P M M F Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT
1 1 1
5 Pipe Support
101
7,437
T<80
SSPC-SP 10
1 1 1 1
6 Electric Support
101
850
T<80
SSPC-SP 10
P M M F
1 1 1 1
7 Instrument Support
101
850
T<80
SSPC-SP 10
P M M F
1 1 1 1
1 lot T/U = Touch Up. P = Primer M = Midle Coat F = Finish Coat Sheet : 3 / 3 A
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
PAINTING SYSTEM
( Option : B )
Work System Volume no. Sqm 101 80,000 Temp. Cent. Surface Prep. Deg. T<80 SSPC-SP 10 P SHOP PAINT Generic Type No. of coat 1 DFT ( mic ) 65 Surface Prep. FIELD PAINT Generic Type Product Name No. of coat 1 1 1 1 DFT ( mic ) 65 30 65 65 225 50 - 100 30 70 - 120 25 - 40 175 - 290 75 250 250 575 65 30 65 65 225 65 50 50 165 65 40 40 145 40 40
No.
SSPC-SP 3
T/U M M F
Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT Epoxy Zinc Rich Primer Epoxy Polyamide Primer Epoxy Polyamide Primer Aliphatic Polyurethane Total DFT Resist PH 4412 GT Penguard HB Penguard HB Hardtop AS
201
4,500
T<120
SSPC-SP 10
50 - 100
SSPC-SP 3
T/U M M F
1 1 1 1
303
12,938
T<60
SSPC-SP10
1 1 1
2 Equipment
101
6,250
T<80
SSPC-SP 10
65
SSPC-SP 3
T/U M M F
Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT
1 1 1 1
102
65
SSPC-SP 3
T/U Epoxy Zinc Rich Primer Resist PH 4412 GT M Silicon Acrylic Aluminium HR F Silicon Acrylic Aluminium HR Total DFT T/U Silicone Zinc M Silicone Aluminium F Silicone Aluminium Total DFT T/U Silicone Aluminium M Silicone Aluminium F Silicone Aluminium Silicone Aluminium Total DFT Resist PH 4412 GT Solvalitt Solvalitt
1 1 1
103
65
SSPC-SP 10 Welding Joint SSPC-SP 3 Other Parts SSPC-SP 10 Welding Joint SSPC-SP 3 Other Parts F = Finish Coat
1 1 1
104
200
T>350
SSPC-SP 10
1 1
20 20
Solvalitt Solvalitt
1 1 1 1
80 Sheet : 1 / 3 B
P = Primer
M = Midle Coat
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
No.
Application
No. of coat
DFT ( mic )
Surface Prep.
No. of coat 1 2 1
DFT ( mic ) 50 - 100 750 - 1000 375 - 500 1175 - 1600 65 30 65 65 225 50 - 75 100 - 175 150 - 350
SSPC-SP 10
P Bisphenol Polyester ResinML 3000 U/C M Polyester Resin with inert ML 3000 I/C Flake F Polyester Resin with inert ML 3000 T/C Flake Total DFT P M M F Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT Amine Epoxy Primer Amine Epoxy Total DFT Penguard Primer Penguard HB
3 Tank
101
959
T<80
SSPC-SP 10
1 1 1 1
117
610
T<60
SSPC-SP 10
P F
1 1
174 39,500 T<80 SSPC-SP 10 P M M F Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT 1 1 1 1 65 30 65 65 225 65 50 50 165 65 40 40 145
102
4,100 80<T<200
SSPC-SP 10
P Epoxy Zinc Rich Primer Resist PH 4412 GT M Silicon Acrylic Aluminium HR F Silicon Acrylic Aluminium HR Total DFT P Silicone Zinc M Silicone Aluminium F Silicone Aluminium Total DFT Resist PH 4412 GT Solvalitt Solvalitt
1 1 1
103
1,020 00<T<350
SSPC-SP 10
1 1 1
P = Primer
M = Midle Coat
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
No.
Application
FIELD PAINT No. of coat DFT Surface Prep. ( mic ) SSPC-SP 10 Generic Type No. of coat Solvalitt Solvalitt 1 1 1 1 DFT ( mic ) 40 40 0 0 80 40 - 50 40 - 50 80 - 125 80 - 125 50 - 100 750 - 1000 375 - 500 1175 - 1600 65 30 65 65 225 65 30 65 65 225 65 30 65 65 225
P Silicone Aluminium M Silicone Aluminium F Silicone Aluminium Silicone Aluminium Total DFT P Epoxy Primer Total DFT Inorganic Zinc Primer Total DFT
116
6,015
T<0
SSPC-SP 10
Penguard Primer
118
2,900
T<120
SSPC-SP 10
Resist PH 4412 GT
301
19,451
T<60
SSPC-SP 10
P Bisphenol Polyester ResinML 3000 U/C M Polyester Resin with inert ML 3000 I/C Flake F Polyester Resin with inert ML 3000 T/C Flake Total DFT P M M F Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT Epoxy Zinc Rich Primer Resist PH 4412 GT Vinyl Chloride CopolymeVinyproof Primer Vinyl Chloride CopolymeVinyproof HB Vinyl Acrylic Vernyl Top Coat Total DFT
1 2 1
5 Pipe Support
101
7,437
T<80
SSPC-SP 10
1 1 1 1
6 Electric Support
101
850
T<80
SSPC-SP 10
P M M F
1 1 1 1
7 Instrument Support
101
850
T<80
SSPC-SP 10
P M M F
1 1 1 1
1 lot T/U = Touch Up. P = Primer M = Midle Coat F = Finish Coat Sheet : 3 / 3 B
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
PAINTING SYSTEM
( Option : C )
System no. 101 Work Volume Sqm 80,000 Temp. Cent. Deg. T<80 Surface Prep. SHOP PAINT Generic Type No. of coat 1 DFT ( mic ) 65 Surface Prep. FIELD PAINT Generic Type Product Name No. of coat 1 1 1 1 DFT ( mic ) 65 30 65 65 225 50 - 100 30 70 - 120 25 - 40 175 - 290 75 250 250 575 65 30 65 65 225 65 50 50 165 65 40 40 145 20 20 20 20 80 Sheet : 1 / 3 C
No.
SSPC-SP 10
SSPC-SP 3
T/U M M F
Epoxy Zinc Rich Primer Epicon Zinc HB - 2 Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Acrylic HIVI No. 100 Total DFT Epoxy Zinc Rich Primer Epoxy Polyamide Primer Epoxy Polyamide Primer Aliphatic Polyurethane Total DFT Epicon Zinc HB - 2 Epicon Marine HB Epicon Marine HB Unymarine
201
4,500
T<120
SSPC-SP 10
50 - 100
SSPC-SP 3
T/U M M F
1 1 1 1
303
12,938
T<60
SSPC-SP10
1 1 1
2 Equipment
101
6,250
T<80
SSPC-SP 10
65
SSPC-SP 3
T/U M M F
Epoxy Zinc Rich Primer Epicon Zinc HB - 2 Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Acrylic HIVI No. 100 Total DFT
1 1 1 1
102
65
SSPC-SP 3
T/U Epoxy Zinc Rich Primer Epicon Zinc HB - 2 M Silicon Acrylic Silicon IZ F Silicon Acrylic Silicon IZ Total DFT T/U Silicone Zinc M Silicone Aluminium F Silicone Aluminium Total DFT Epicon Zinc HB - 2 Silicon IZ Silicon IZ
1 1 1
103
65
SSPC-SP 10 Welding Joint SSPC-SP 3 Other Parts SSPC-SP 10 Welding Joint SSPC-SP 3 Other Parts
1 1 1
104
200
T>350
SSPC-SP 10
1 1
20 20
P = Primer
M = Midle Coat
T/U Silicone Aluminium M Silicone Aluminium F Silicone Aluminium Silicone Aluminium Total DFT F = Finish Coat
Silicon 700 Silver Silicon 700 Silver Silicon 700 Silver Silicon 700 Silver
1 1 1 1
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
No.
Application
Surface Prep.
No. of coat
DFT ( mic )
Surface Prep.
Generic Type
No. of coat 1 2 1
DFT ( mic ) 50 - 100 750 - 1000 375 - 500 1175 - 1600 65 30 65 65 225 50 - 75 100 - 175 150 - 350
SSPC-SP 10
P Bisphenol Polyester ResinML 3000 U/C M Polyester Resin with inert ML 3000 I/C Flake F Polyester Resin with inert ML 3000 T/C Flake Total DFT P M M F Epoxy Zinc Rich Primer Epicon Zinc HB - 2 Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Acrylic HIVI No. 100 Total DFT Amine Epoxy Primer Amine Epoxy Total DFT Epicon Primer CL Epicon Finish HB
3 Tank
101
959
T<80
SSPC-SP 10
1 1 1 1
117
610
T<60
SSPC-SP 10
P F
1 1
174 39,500 T<80 SSPC-SP 10 P M M F Epoxy Zinc Rich Primer Epicon Zinc HB - 2 Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Acrylic HIVI No. 100 Total DFT 1 1 1 1 65 30 65 65 225 65 50 50 165 65 40 40 145
102
4,100 80<T<200
SSPC-SP 10
P Epoxy Zinc Rich Primer Epicon Zinc HB - 2 M Silicon Acrylic Silicon IZ F Silicon Acrylic Silicon IZ Total DFT P Silicone Zinc M Silicone Aluminium F Silicone Aluminium Total DFT Epicon Zinc HB - 2 Silicon IZ Silicon IZ
1 1 1
103
1,020 200<T<350
SSPC-SP 10
1 1 1
P = Primer
M = Midle Coat
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
No.
Application
Surface Prep.
No. of coat
DFT ( mic )
Surface Prep.
No. of coat 1 1 1 1
DFT ( mic ) 20 20 20 20 80 40 - 50 40 - 50 80 - 125 80 - 125 50 - 100 750 - 1000 375 - 500 1175 - 1600 65 30 65 65 225 65 30 65 65 225 65 30 65 65 225
SSPC-SP 10
P Silicone Aluminium M Silicone Aluminium F Silicone Aluminium Silicone Aluminium Total DFT P Epoxy Primer Total DFT Inorganic Zinc Primer Total DFT
Silicon 700 Silver Silicon 700 Silver Silicon 700 Silver Silicon 700 Silver
116
6,015
T<0
SSPC-SP 10
Epicon Primer CL
118
2,900
T<120
SSPC-SP 10
Galbon S - HB - I
301
19,451
T<60
SSPC-SP 10
P Bisphenol Polyester ResinML 3000 U/C M Polyester Resin with inert ML 3000 I/C Flake F Polyester Resin with inert ML 3000 T/C Flake Total DFT P M M F Epoxy Zinc Rich Primer Epicon Zinc HB - 2 Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Acrylic HIVI No. 100 Total DFT Epoxy Zinc Rich Primer Epicon Zinc HB - 2 Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Acrylic HIVI No. 100 Total DFT Epoxy Zinc Rich Primer Epicon Zinc HB - 2 Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Chloride CopolymeVinyl PR - HB - I Vinyl Acrylic HIVI No. 100 Total DFT
1 2 1
5 Pipe Support
101
7,437
T<80
SSPC-SP 10
1 1 1 1
6 Electric Support
101
850
T<80
SSPC-SP 10
P M M F
1 1 1 1
7 Instrument Support
101
850
T<80
SSPC-SP 10
P M M F
1 1 1 1
1 lot T/U = Touch Up. P = Primer M = Midle Coat F = Finish Coat Sheet : 3 / 3 C
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
APPENDIX - 2
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
APPENDIX - 3
"INSPECTION FLOW"
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
INSPECTION FLOW
Inspection
No
Final Inspection
No
Yes Completed
Sheet : 1 / 1
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
APPENDIX - 4
"INSPECTION GUIDE"
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
INSPECTION GUIDE
1. SCOPE This guide provides information and data relating to inspection procedures, tools and techniques required during the inspection of coating contained with in and data in relation to : a ) Inspection procedures for surface preparation, application, environment and surface conditions. b ) Inspection tools and their utilization for coating. c ) General coating inspection requirements. 2. INSPECTION GUIDE FOR BLASTING The surface preparation are defined to SSPC or NACE standards to ensure long and succesful coating life. Entire blasted surface shall be visually checked to make sure that the blasting surface conforms to the specified surface preparation by using visual standard of NACE and SIS. 3. INSPECTION GUIDE FOR PAINTING 3.1. Wet film thickness measurement WFT is reciprocal to DFT. The total paint film thickness over the surface is determined by previous measurement of the wet film thickness. 3.2. Dry film thickness DFT is generally determined after priming of the protective coating system. The DFT should be in accordance with the job specification. No. of dry film thickness check point for final inspection shall be as follows : Surface Tower Drum Reactor Heat exchanger Air cooled exchanger Fired heater Rotating equipment Stack Piping Structural steel Electrical and instrument component No. of Check Point 5/1 5/1 5/1 5/1 5/1 5/1 5/1 5/1 1 / 100 1 / 100 1 / 100 unit unit unit unit unit unit unit unit m-2 m-2 m-2 Sheet : 1 / 9
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
4. EQUIPMENT FOR INSPECTION For Blasting For Painting - SIS standard - Wet Film Thickness Gauge - Dry Film Thickness Gauge - Temperature Gauge and Humidity - Surface Temperature Gauge - Lupe ( Microscope ) - Pressure Gauge FOR BLASTING SIS and standard a). Method of Inspection - Surface blast cleaned, hand and power tool cleaned surface are compared with fitted pho determine work standard. FOR PAINTING 1) Wet Film Thickness Gauge a)- Purpose The wet film thickness is measured as a basis to determine the total film thickness ( the surface. b)- Method of Inspection WFT gauge has a depth for every settled space. It shows the measurement by press gauge per pendicular through the amount of adhesion of the paint film. 2) Dry Film Thickness gauge a)- Method of Inspection Dry film thickness gauge indicates the paint film thickness on the surface. This is f copper of substrate by magnetic force to point of contact of gauge. FOR COMMON USE 1) Temperature Gauge
cont'd
otograph to
( DFT ) of
sing the
from sheet
Sheet : 2 / 9
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
a) Purpose Temperature gauge is used for taking temperature and humidity in relation to painting condition and to the stiffening time of paint. b) Method of Inspection The temperature gauge has a dry and wet bulb which indicate the measurement of temperature and humidity by brandishing the unit for about several minutes in the area. 2) Surface Temperature Gauge Purpose The surface temperature gauge is used for taking the temperature of the surface in relation to painting, ie., paint adhesion, thinning and stiffening Method of Inspection The surface temperature gauge is placed on the surface for paint application where temperature is indicated on the meter. 3) Lupe is used for inspection on blasted and painted areas when the surface cannot be seen through with a naked eye.
Sheet : 3 / 9
: : Bontang LNG Expansion Project Train G : X-1(B.1.3 ) JOB No. Paint System DATE Equipment No. Equipment Name Surface Area : : : : : : m-2
DPS
3-rd coat microns 4-th coat microns Total DFT microns DFT = Minimum Dry Film Thickness. Signature : Prepared by, Signature : Witnessed/Reviewed by, Signature : Witnessed/Reviewed by,
DPS Date :
ICJV Date :
PKP Date :
Sheet : 4 / 9
: JOB No. : Bontang LNG Expansion Project Train G : X-1(B.1.3 ) Paint System DATE Equipment No. Equipment Name Surface Area : : : : : : m-2
DFT = Minimum Dry Film Thickness. Signature : Prepared by, Signature : Witnessed/Reviewed : Signature : Witnessed/Reviewed :
DPS Date :
ICJV Date :
PKP Date :
Sheet : 5 / 9
Ref. No. Client Project Title Name of Equipment & Identification No.
: JOB No. : : : Paint System Lot No. Diameter Total Length Surface Area : : : : : : : m-2 Pcs
DFT = Minimum Dry Film Thickness. Signature : Prepared by : Signature : Witnessed/Reviewed : Signature : Witnessed/Reviewed :
DPS Date :
ICJV Date :
: JOB No. : Bontang LNG Expansion Project Train G : X-1(B.1.3 ) Paint System Lot No. Diameter Total Length Surface Area : : : : : : : m-2 Pcs
DFT = Minimum Dry Film Thickness. Signature : Prepared by, Signature : Witnessed/Reviewed : Signature : Witnessed/Reviewed :
DPS Date :
ICJV Date :
PKP Date :
Sheet : 7 / 9
: Marking No.
:
: Bontang LNG Expansion Project Train G : X-1(B.1.3 ) Total Area (M2) :
3-rd coat microns 4-th coat microns Total DFT microns DFT = Minimum Dry Film Thickness. Signature : Prepared by, Signature : Witnessed/Reviewed : Signature : Witnessed/Reviewed :
DPS Date :
ICJV Date :
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
: : : We would like to have your presence for Inspection according to the following schedule TIME INSPECTION ITEM PLACE IKPT/ CHIYODA PKP
PREPARED by,
APPROVED by,
DPS
IKPT / CHIYODA
File : Anang\p-cedure\shop&fld
Sheet : 9 / 9
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
APPENDIX - 5
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
No.
Substrate
Painting Schedule
1.1 Uninsulated Parts 1.1.1 Shell, Head, Nozzle, Manhole, Skirt, Leg, Saddle T < 80 C 80 C < T < 200 C 200 C < T < 350 C 350 C Same as item 1.1.1 T < 80 C 101 102 103 104 101 101 Grey (N 5.0) Grey (N 5.0) Silver Silver Silver
1.1.2
1.1.3 Platform, Stair, Walkway, Ladder, Shell Davit, Other Accessary not to be 1.2 Insulated Parts
Primer Color
2.
Tank
2.1. Uninsulated Parts 2.1.1. Shell ( including annular plate to exposed weather and inside exposed weather of floating roof tank ) 2.1.2. Parts to be welded to Shell ( 1 ) Wind / Girder ( 2 ) Except Wind Girder ( e.g. nozzle manhole, bracket ) 2.1.3. Roof 2.1.4. Parts to be Welded to Roof ( e.g. nozzle, manhole, bracket, pontoon, exposed weather ) T< 80 C 80 C < T < 200 C 101 102 Grey ( N5.0 ) Silver T< 80 C 80 C < T < 200 C T< 80 C 80 C < T < 200 C 101 102 101 102 Grey ( N5.0 ) Silver Grey ( N5.0 ) Silver T< 80 C 80 C < T < 200 C 101 102 Grey ( N5.0 ) Silver
Sheet : 1 / 8
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
2.1.5 Legs and Parts to be Welded to Legs 2.1.6 Platform, Stair, Walkway, Ladder, Rolling Ladder, Other Accessory not to be Welded 2.2 Insulated Parts
T < 80 T < 80
101 101
Primer Color
3. 3.1
Rotary Machine Uninsulated Parts Pump Compressor Fan Blower Filter Press Oil Console, ( Oil Pump, Driver Tanks, Oil Filter, Oil Cooler, Control Valve, etc) Motor Boxes Turbine Coupling Guard Crane Insulated Parts
80 C < T < 200 C Manufacturer STD Silver T < 80 C Manufacturer STD Orange (2.5. YR6/14) T < 80 C Manufacturer STD Yellow (2.5. YR6/14) -100 C < T < 0 C T < 120 C 120 C < T 116 118 Not Painted Primer Color Primer Color
3.2
4. 4.1
Piping Uninsulated Parts T < 80 C 80 C < T < 200 C 200 C < T < 350 C 350 C < T 101 102 103 104 Grey (N 5.0) Silver Silver Silver Sheet : 2 / 8
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
4.1.2. Parts to be Welded to Item 4.1.1. 4.1.3. Valve /Steam Trap 4.1.4. Item 4.1.1., 4.1.2, and 4.1.3 for Fire Fighting Item 4.1.1., 4.1.2, and 4.1.3. for Cooling Water Line Item 4.1.1. for Interior Surface of Cooling Water Line 4.2 Insulated Parts
Same as item 4.1.1. Same as item 4.1.1. T < 80 C 101 Red (7.5. R 4.0/4)
4.1.5.
T < 80 C
301
Grey (N 6.5)
4.1.6
T < 80 C
301
Grey (N 6.5)
-100 C < T < 0 C T < 120 C 120 C < T Same as Item 4.2.1. Same as Item 4.2.1. Same as Item 4.2.1
Parts to be Welded to Item 4.1.1 Valve/Steam Trap Others Steel Stack Shell Plate, Shell Flange
T < 80 C 80 C < T < 200 C 200 C < T < 350 C 350 C < T
5.2 5.3
Parts to be Welded to Item 5.1 Platform, Stair, Walkway, Ladder, Other Accesory not to be Welded
Sheet : 3 / 8
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
6. 6.1 6.1.1
Duct Uninsulated Parts Shell Plate, Nozzle, Manhole T < 80 C 80 C < T < 200 C 200 C < T < 350 C 350 C < T 101 102 103 104 Grey (N 5.0) Silver Silver Silver
6.1.2 6.1.3
Parts to be Welded to Item 6.1.1 Platform, Stair, Walkway, Ladder, Other Accessory not to be Welded Insulated Parts
6.2
Primer Color
7.
Steel Structure (Column, Beam, brace, tie-rod, gusset plate, base plate , etc) Pipe Rack, Pipe Support, Pipe Stanchion Steel Structure for Drum, Column, Reactor, Heat Exchanger, Air Cooled Heat Exchanger Steel Structure for Stack, and Chimney Steel Structure for Rotary Machine Steel Structure for Machinery Platform, Stair, Walkway, Ladder, Other not to be Welded Trolley Beam T < 80 C T < 80 C 101 101
7.1 7.2
Grey (N 5.0)
7.7
T < 80 C
101
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
8. 8.1
Electrical Equipment Cable Duct, Cable Tray Inside Surface Outside Surface T < 80 C 101 Light blue grey (N 7.0)
8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13
Power Generator Motor Switchboard Distribution Panelboard Busduct Terminalboard Transformer Capacitor Resistor Fire Alarm Receptable Lighting Fixture Indoor Outdoor
T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C
Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD
Green (2.5.G 3/9) Green (2.5.G 3/9) Light Grey (N 7.0) Light Grey (N 7.0) Light Grey (N 7.0) Light Grey (N 7.0) Light Grey (N 7.0) Manufacturer STD Manufacturer STD Red (5R 4/13) Manufacturer STD Manufacturer STD
8.14
T < 80 C
101
8.15 8.16
T < 80 C T < 80 C
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
9. 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 10. 10.1 10.2
Instrument Control Panel Control Valve Instrument Device Conduit Local Panel Terminal Box/Wire Way DCS Cubicle Analyzer House HMS Cubicle Fire Fighting Fire Extinguisher Hydrant T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C 101 101 101 101 101 101 101 101 Red (7.5R 4.0/14) Red (7.5R 4.0/14) Yellow (2.5Y 8/12) Red (7.5R 4.0/14) Red (7.5R 4.0/14) Red (7.5R 4.0/14) Red (7.5R 4.0/14) Red (7.5R 4.0/14) T < 80 C Variable Variable T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C T < 80 C Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Manufacturer STD Ligth Grey (N 7.0) Ligth Green (5G8/6) Pale Green (10GY5/4)
Manufacturer STD Pale Yellow (2.5Y8.4/62) 101 101 White (N9.0) Red (7.5 R 4.0/14)
10.2.1. Foam Hydrant 10.3 10.4 10.5 10.6 10.7 Box for Fire Extinguisher Box for Fire Hose Fire Engine Monitor Storage Cylinder for Halon and Proportional Others
10.8
T < 80 C
101
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
10.9
Spray
T < 80 C T < 80 C
101 101
11. 11.1
Utility Equipment Boiler T < 80 C 80 C < T < 200 C 200 C < T < 350 C 350 C < T T < 80 C 80 C < T < 200 C 200 C < T < 350 C 350 C < T Same as Item 2 T < 80 C T < 80 C Manufacturer STD 101 Manufacturer STD Grey (N 5.0) 101 102 103 104 101 102 103 104 Grey (N 5.0) Silver Silver Silver Grey (N 5.0) Silver Silver Silver
11.1.3. Service Oil Tank 11.1.4 Control Panel 11.1.5 Platform, Stair, Walkway, Ladder, other accessory not to be welded 11.2 Air Dryer and N2 Generator Unit
11.2.1. Body, Manhole, Nozzle 11.2.2 Piping and Valve 11.2.3 Support 11.2.4 Instrument 12. Refrigerator
Grey (N 5.0) Grey (N 5.0) Grey (N 5.0) Manufacturer STD Grey (N 5.0)
Sheet : 7 / 8
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
13.
Package Equipment Other than above Building Plaster Wall/Board Wall Door and Window
------------
Manufacturer STD
Manufacturer STD
Grey (N 5.0) Pale Yellow (2.5Y8/15) Light Greyish Green (2.5G7/2) Manufacturer STD Manufacturer STD (Pale Greyish Color)
14.3 14.4
T < 80 C T < 80 C
Sheet : 8 / 8
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
APPENDIX - 5
"SAFETY CONTROL
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
CONTENTS
SAFETY CONTROL REGULATION 1. GENERAL Chapter 1 Chapter 2 Chapter 3 Safety Control Safety Device and Protection Gear Work Limitation
2. SAFETY STANDARD Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Passage Way and Working Floor Scaffolding Prevention of Fall and Crash Electricity Fire-fighting and Explosion Prevention
MANUAL FOR SAFE EXECUTION OF WORK A. GENERAL 1. Scope 2. Observation Duty 3. Safety Instruction 4. Restriction of Work 5. Working Wear and Protective Measures 6. Supervisor B. WORKING STANDARD 1. Working General 2. Moveable electric sander ( Surface Preparation ) 3. Scaffolding 4. Working at place where poisoning gas, dirt and dust are present 5. Handling of flammable material 6. Fire protection 7. Others Page : 1 / 14.
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
SAFETY CONTROL REGULATION 1. GENERAL CHAPTER 1 - SAFETY CONTROL Article 1 This regulation for safety control defines the matters as regard to safety control of : PT. Dharma Pratama Sejati. Article 2 The company or staff must observe to follow these regulations strictly in order to bring about a healthy working athmosphere, accident free around the worksite. Article 3 Safety controlling organization is comprised as follows : 1 ) Safety Control System - ( In case of contractor ) In principle, The Project Manager designated the General Safety Manager or his duly nominated Site Manager or any other person appointed by him who shall be responsible for the overall control of safety matters in the jobsite. 2 ) Safety Manager The safety manager shall perform according to this regulation the following tasks : a ) Make a thorough study about the jobsite, client's requirements and prepare a working plan on safety for the guidance of all. b ) Initiate safety programs for orientation. c ) Periodic inspection of construction equipment, protective gear, firefighting equipment, etc. d ) Safety check of paint material, tools and scaffolding to ensure that each are in proper order for use. e ) Attend to other matters necessary to safety and environment control.
Page : 2 / 14.
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
3 ) Safety Officer The Project Manager shall appoint a qualified staff to meet the client's requirements, one who can well assist the site manager in the implementation of all safety rules and regulations in the jobsite. 4 ) Safety Staff Supervisor shall act at the same time as the safety who shall execute the tasks assigned him by the safety manager with respect to guiding and implementing effectively the safety rules go verning around the worksite as follows : - Shall train and instruct the safety procedure to be followed by subcontractor and should at all times in contact with the safety officer. - Shall make a daily safety patrol around the jobsite to ensure that safety rules are being adhered to or otherwise to direct and promote safe execution of work. - Shall coordinate with client's supervisor with regard with safety. - Shall make physical investigation when accident occurs and prepared a detailed account of accident outlining its causes and initiate counter measure or corrective actions to pre vent repeatition of the same. The general safety manager and/or the site manager shall select the appropriate persons who shall take charge of the different accident preventions as follow : 1 ) Fire prevention in the jobsite. 2 ) Worker assigned in hazardous area. 3 ) Scaffolding erection ( specifically 5 mtrs, high or more ).
CHAPTER 2 - SAFETY DEVICE AND PROTECTION GEAR Article 4. Workers shall observe marks and signs posted in areas designed as safety devices for the prevention of accident. 1 ) Safety devices installed on equipment shall not be removed that will caused to reduce its function. 2 ) Where safety devices need removal, prior approval or permission from the safety manager must be obtained.
Page : 3 / 14.
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
3 ) On completion of work, safety devices shall be returned to the same place where it was ori ginally installed. 4 ) Any malfunctioning noted in the safety device after its removal, such shall be reported imme diately to the safety officer for corrective action. Article 5 The following are machines and tools that shall not be used : 1 ) Compressor with no safety cover. 2 ) Pressure equipment with improper condition. 3 ) Other machines and tools with inferior condition. Article 6 Safety devices requiring secure installations : 1 ) Motor pulley, belt and other rotation shaft in danger of contact. Installation shall be under 1.8 mtrs. high from flooring. 2 ) Switch board ( panel board ). 3 ) Outside work areas. Article 7 Protective devices and gears shall be used for works as follow : 1 ) Works using organic solvent. 2 ) Works where dirt and dust are present, ie., blasting work. 3 ) Presence of poison gas, vapor, dust and dirt. 4 ) Any type of work that requires use of protective gear.
CHAPTER 3 - WORK LIMITATION Article 8 Persons under eighteen ( 18 ) years of age are prohibited to perform works such as : 1 ) Scaffolding work. 2 ) Work area having more than 5 mtrs. high. 3 ) Works that are not allowable for minors. Page : 4 / 14.
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
2. SAFETY STANDARD CHAPTER 1 - PASSAGE WAY AND WORKING FLOOR Article 9 Passage way shall be provided and always be available at work areas. Article 10 Pathways in work areas shall be free from all dangers, eg.,slides, opening and etc. Article 11 Scaffolding of wood shall be erected according to following standards : 1 ) Standard shall be erected less than 1.8 mtrs. apart from each other. The first ledger from the bottom shall be installed at lower than 3 mtrs. high. 2 ) Bottom of standard shall be firmly fixed. 3 ) Spacing of transoms shall be less than 1.5 mtrs. 4 ) A crossing point of standards, ledger and transom shall be tied securely with wire. 5 ) Scaffolds shall be reinforced with brace. 6 ) Scaffolds shall be jointed tightly to wall joint fitting and not to be supported with rigger. Article 12 Slung scaffolding shall be erected according to the following items : 1 ) Wire rope having undermentioned elements shall not be used : - The decrease of wire's diameter is over 7 % of nominal diameter. - Kink wire whose capacity is up to 56 %. - Number of cutted wire % of total wire number of rope is more than 10 % within one twist. - Extreme deformation and corrosion. Page : 5 / 14.
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
2 ) Chain having the undermentioned elements shall not be used : - The length of chain exceeds 5 % of that at the time of production. - The decrease of ring's diameter is over 10 % of nominal diameter at the time of production. - Cracked chain. 3 ) Fiber rope having the undermentioned elements shall not be used : - The rope whose 10 % yarn are cutted. - Remarkable corrosion and deformation. 4 ) Sling wire and stell belt shall have no remarkable damage, deformation or corrosion. 5 ) Work floor shall be more than 40 cm wide and have no opening. 6 ) Scaffold board shall be fixed to the three or more transoms at more than two points so it shall not be displace and fall. 7 ) In case of erection of slung shelf scaffoldings used building interior, crossing and jointing point of ledgers shall be tied strictly with wire and metal tie and/or joint fitting. Article 13 Usage of stepladder, ladder, etc. on slung scaffolding shall not be permitted.
CHAPTER 3 - PREVENTION OF FALL AND CRASH Article 14 Safety handrail higher 75 cm around the boiler hopper and pit, etc. shall be provided to prevent burn and suffocation which are cases caused of falls over people working below and passers-by. However, where a worker uses safety belt, the above mentioned handrail need not be used. Article 15 Work area having more than 2 mtrs high with no safety work floor, a safety rope shall be provided tightly where safety belt could be locked securely by worker.
Page : 6 / 14.
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
Article 16 Works on elevated places having more than 2 mtrs. high where the execution of work is not possible due to bad weather condition, eg., strong wind, rain, etc., work shall be halted until such time the weather has improved. Article 17 Work place having more than 1.5 mtrs. high or in depth shall be provided with necessary equipment to mobilize the workers safely in going up and down. Article 18 When portable ladder is used, the following are required : 1 ) Firm structure. 2 ) Ladder material shall be free from damage and corrosion. 3 ) Width should be 30 cm over. 4 ) Installation of skid proof device. Substansial portion of ladder must be fastened by rope. 5 ) Where the portable ladder be installed at high elevation it must be tied securely by rope so it shall not be swing, displace and fall. Article 19 When stepladder is used, the following are required : 1 ) Firm structure. 2 ) Free from damage and corrosion. 3 ) The trestle shall be at the angle of below 75 deg. with horizontal plane. The collapsible type shall be provided with metal fittings ensuring the angle between trestle and horizontal plane. 4 ) The step of the ladder shall have adequate area. Article 20 Persons other than those authorized are not allowed in places where there are signs of danger such as falls, crash, etc. Article 21 Throwing of wastes or any other form of particles from an elevate place ( above 3 mtrs. ) shall not be allowed. Site supervisor shall arrange the placement or disposal of waste matters to proper place.
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: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
Article 22 When gondola is used, the following shall be observed : 1 ) Supervisor in-charge shall check at all times the method of installation of gondola head to ensure its safety. 2 ) Inspection shall be carried out with a use of a check list before its operation and to be conducted every each week.
CHAPTER 4 - ELECTRICITY Article 23 Primary side electrical work shall be done only by a qualified person. Article 24 Dangerous parts of place of electrical facilities and equipment shall be marked and displayed. Fence shall be provided at the place where execution of work is considered dangerous by reason of electric contact accident. Article 25 When a check or repair work is performed where electrical shock is likely to occur, switch shall be put off immediately and lock the switch box to prevent accidental switching by other person. Notice of "DON'T SWITCH ON " shall be displayed conspicuously while prompt action to repair the line shall be made immediately.
CHAPTER 5 - FIREFIGHTING AND EXPLOSION PREVENTION Article 26 Equipment necessary for firefighting such as fire extinguisher, sand, bucket shall be installed at places where stoves, gas, electricity, smoking room, etc. are located.
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: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
Article 27 Paint material stored in the jobsite shall at the minimum extent be provided with fire extinguisher with warning signs posted conspicuously to read as : KEEP OUT ", " FLAMMABLE AREA ", etc. Article 28 Smoking or lighting in places where there are signs of fire hazard shall be strictly prohibited. Article 29 Practical preventive measures shall be observed on oil permeated rags, waste paper and other simi lar items that combustible to fire. Article 30 Works that induce fire shall be debarred from equipment or facilities such as oxygen/acetylene gas tanks, generator, tower and vessel, etc., which are suceptible to fire and explosion. Article 31 Air compressor prior to operation shall be checked of the following : 1 ) Operation manual and procedure. 2 ) Fuel and lubricating oil supply. 3 ) Joint of air hose and other connections relevant to operation.
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: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
MANUAL FOR SAFE EXECUTION OF WORK A. GENERAL 1. Scope This manual suplements the regulations for safety control. The primary purpose of this manual is to prevent occurence of accidents that lead to cause damage to personnel, properties and work stoppage. 2. Responsibility Supervisors and workers should adhere to follow strictly this manual in order to minimize or totally eradicate worksite accidents. 3. Safety Instruction Field supervisor are tasked to orientate and educate the workers on safety work procedure in the jobsite and conduct a daily check and direct the proper method of its application. 4. Field supervisor shall see to it that worker is qualified to perform work assigned such as those type of work requiring skills and registered license. 5. Preventive measure / protective wear a ) Workers shall be required to be in suitable working wear. b ) Worker shall put on safety shoes with proper condition at all times used in jobsite. c ) Safety helmet - Safety helmet must meet with client's standard. - Jaw string of helmet shall tied to protect helmet from falling off especially when working at high elevation place. d ) Safety belt Safety belt shall be used in areas having more than 2 mtrs high and where there appears a danger of fall as follows : - Works floor with a width up to 40 cm. - Work floor with no handrail. - Work requiring body thrust forward. e ) Other protective gears - Worker shall put on goggle, face mask with safety glass where it is necessary for pro tection of eyes againts dust or any other foreign body. - Protective gears such as mask against poisoning shall be inspected prior to use. Any defect noted shall be disposed. - Ear plug shall be used in work places where high resonation is detrimental to hearing.
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: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
h ) Supervisor - Supervisor shall have the overall responsibility for the effective implementation of the safety rules and regulations at the work site. He shall likewise keep in close contact with all the parties concerned and get involved in all safety activities being undertaken from time to time - Supervisor is tasked to convey, educate and make workers aware of the safety rules and draw out a working plan that shall serve as a guideline for everyone to follow. B. WORKING STANDARD 1. GENERAL The person to be delegated as the overall in-charge for safety shall be of high moral integrity and knowledgeable in all aspects on safety. Make workers understand on matters concerning paint material to be used, its quality, content, usage and its harmfull effects, if any. Protective wear and gear shall at all times be used in work areas where it is necessary. Display of warning signs at conspicuous place to serve as precaution againts accident. Paint and solvent shall be stored in special box separate from other things to protect from unsafe matters. Ample ventilation shal be provided in indoor works such as tanks to prevent poisoning, ignition or explosion. Where there is required an environmental measurement for gas, oxygen and concentration, prior approval from the client's safety officer for the execution of work shall be obtained. Fire extinguisher shall remained in good working condition and available at places designated by client. 2. Moveable electric sander ( surface preparation ) Electric sander shall be inspected and tested before operation. Defect of any kind noted shall not be used unless fixed and repaired. Power switch shall be put off when not in use and/or work is completed. Page : 11 / 14.
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
3. Scaffolding A. Material and work floor Scaffold shall have strong structure and material shall be free from deformation and corrosion. Wood use in erection of scaffold shall be of good quality, debarked, straight-grained and free from splits, knot and worm bores that reduce the structural strength. Steel pipe used for the pipe scaffold shall conform to client's standard and attachments therewith shall have passed the authorized specification. The load of work floor shall not exceed over the maximum capacity of the material and struc ture of the material and structure of the scaffold. Work floor ( scaffold board ) shall be provided at the working place where scaffoldis higher than 2 mtrs except putlog scaffold. - The work floor shall be more than 40 cm. wide with less than 3 cm wide opening interval between scaffold boards except slung scaffold. - Places where there is sign of fall, guard rails shall be provided. - Handrails shall have : Strong structure. Free from damage and corrosion and 75 cm in height. Transom, ledger, beam, step ladder and the other support of work floor shall not easily collaps from loads. Planks shall be fixed with two or more supports to prevent from shifting or fall. The projection of the plank beyond the supporting point shall not be less than 10 cm and not to exceed 1/18 of the whole plank length. The dimension of plank shall be uniform. Minimum thickness and width must be 3.5 cm and 20 cm respectively. When planks are lapped in the longitudinal direction laps shall be more than 20 cm at the support.
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: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
B. Erection, disassembling, and changing scaffolds Supervisor shall personally direct work method to workers. Supervisor shall make workers aware of procedure for erection, disassembling and changing of scaffolding. Person other than authorized are not allowed to enter working area. Work on elevated places shall not be allowed during bad weather such as strong wind, rain etc. Use of safety belt at elevated place. C. Inspection Scaffolding shall be subject to inspection by a duly competent person during after heavy rain, wind and any defects noted shall be corrected or repaired prior to its use.
4. Place of work where poison gas, dirt and dust are present : Following are precautionary measures : a) b) c) d) e) f) g) Protective mask/gear shall at all time be put on. Locked containers with organic solvent content. Sufficient amount of organic solvent for worksite consumption. Works on organic solvents shall take place in open air to prevent absorption of solvent vapor. Never have physical contact with organic solvent. Provide sufficient ventilation when working inside tanks. Prepared shelter, safety rope, equipment capable of mobilizing hanging scaffold, ladder and etc. shall allways be available to workers in the event of accident.
h ) Presence of vapor of organic solvent inside tank shall be extinguyished by way of fan ventilation or if vapor can not be totally exhausted, worker shall wear on a hose mask. i ) In case where a worker is poisoned, subject worker shall be taken out to a well-ventilated place laying back flat totally against the floor and with head facing sideways to allow warmth air. Check and remove any poissonous substance inside the mouth and consult a doctor for proper medical care. 5. Handling of flammable material Flammable material shall be exercised with maximum care by observing the following : a ) Flammable item shall not be exposed to direct sunlight, high temperature places and other sources where fire is susceptible. Page : 13 / 14.
: PT DHARMA PRATAMA SEJATI : BONTANG LNG EXPANSION PROJECT TRAIN G : PGG - CR - X - 001 : FIELD PAINTING WORK
b ) Smoking or lighting in areas where flammable material is highly combustible that induce flow of vapor ( gas ) within 4 and 5 mtrs. shall be strictly prohibited. c ) Proper handling of flammable material containing mixed gas and air that tends to explode. d ) Only sufficient quantity of consumption shall be issued out for a particular work area. e ) Person in-charge of storage shall on regular basis check the condition of each material perfectly arranged to avoid spills or waste. 6. Fire Protection a ) Waste cloth, such as oil, rag and paint shall be placed in designated area. b ) Lighting and smoking where waste cloth are stored shall be strictly prohibited. c ) Used cloth shall be disposed regularly at designated place only. 7. Others a ) Worker shal adhere to follow strictly the rules and regulations for safety as required of by the client. b ) Handling of heavy objects at elevated work place : - Ensure that no persons are present below when moving or transfering heavy objects such as blast machine, gondola, etc. - Worker shall not attemp to perform any signs of communication while in the process of moving lifting or transfering heavy object. - Wire rope shall be provided when installing or moving heavy object. - Signal rope shall be used for marking purposes. c ) Manual blasting operation working procedure, its preparation inspection shall be directed properly to worker. d ) Following are calculation formula for strength of wire rope and manila rope : Wire Rope : - Breaking load = ( D/8 ) 2 X 3 ( ton ). - Strength = Breaking load X 1 / 6 ( ton ). Manila Rope : - Breaking load = ( D/8 ) 2 X 1 / 3 ( ton ). - Strength = Breaking load X 1/6 ( ton ).
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