Reference: CC:PE102:2115 From: ABHIJIT SEN CTF(KUDGI TF) To:

Date:04-02-13 DOOSAN Mr. Jeong Won Lee, Office Ph No. 0124-439-8218, Ext. 8218,. Mob. : +91-8527-992958 Email ID : jeongwon.lee@doosan.com -

CC:

SUBJECT : KUDGI, STEAM GENERATOR Please find enclosed following drawings/documents for necessary action at your end as indicated in purpose code.
VENDOR DRG NO: NTPC DRG NO: REVISION NO: DRG TITLE: APP CATEGORY: RELEASE DATE: COMMENTS:

DT12001-GR-M5503 9573-102-PVG-X009 00 Painting scheme for Steel Structure I 04-02-13 No Comment.

DOCUMENT COVER SHEET

PROJECT NAME : KUDGI STPP (3 x 800MW) SG Package CONTRACT NO. : CS-9573-102-2-FC-COA-5658 ITEM : MISCELLANEOUS DOCUMENT TITLE : PAINTING SCHEME FOR STRUCTURAL STEEL

This document is vetted by Q.S.G.M S. W. K

A REV.

2013.02.01 DATE

First Issue
DESCRIPTION

R. Ramdoss

V.T. Bhanu Kiran

I. H. Lee

DGN

CHECK

REVW APPR

(A Government of India Enterprise)

CONTRACTOR

NTPC Limited.

DOOSAN POWER SYSTEMS INDIA PRIVATE LIMITED

Q.S.G.M

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION Co., Ltd. Korea

CATEGORY DOCUMENT NO. DOOSAN NTPC Approval DT12001-GR-M5503 9573-102-PVG-X009 SHEET 8 8 REV. A 00

PROJECT KUDGI STPP (3 X 800MW)

SUBJECT PAINTING SCHEME

Doc. No. DT12001-GR-M5503

Rev A

Sheet No. 1

TABLE OF CONTENTS
SL. NO. 1. 2. 3. 4. 4.1 4.2 5. 6. 7. 7.1 7.2 7.3 DESCRIPTION Scope Code and Standard General Requirement Application of Coating Surface Preparation Application of Coating General Painting System Touch-up Painting Coating System Paint Manufacturers, Products and Coating Systems General Coating Systems Detailed Painting Systems

PROJECT KUDGI STPP (3 X 800MW)

SUBJECT PAINTING SCHEME

Doc. No. DT12001-GR-M5503

Rev A

Sheet No.
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Scope This Procedure covers the surface preparation, application and protective coating of steel element for KUDGI 3 X 800MW Coal Fired Power Project. Code and Standard Power Plant shall be supplied in strict accordance with the latest issue in effect (unless otherwise noted), at time of purchase order, of code and standards or the following organization and societies. In addition, the contractor shall comply with Owners technical specifications. 2.1 ISO 12944 Corrosion Protection of steel structures by protective paint system 2.2 Steel Structure Painting Council (SSPC) 2.2.1 SSPC-PA 2 Measurement of Dry Paint Thickness with Magnetic Gauges 2.2.2 SSPC-SP 1 Solvent Cleaning (SP1 as per NTPC piping specification) 2.2.3 SSPC-SP 2 Hand Tool Cleaning (SP6 as per NTPC piping specification) 2.2.4 SSPC-SP 3 Power Tool Cleaning (SP3 as per NTPC piping specification) 2.2.5 SSPC-SP 7 Brush-Off blasting Cleaning 2.2.6 SSPC SP 8 Pickling 2.2.7 SSPC-SP10 Near White Blast Cleaning (SP4 and SP4* as per NTPC piping specification) 2.2.8 American Society of Testing and Materials (ASTM) 2.2.8.1 ASTM A123 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products 2.2.8.2 ASTM A780 Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

General Requirement 3.1 Surface preparation, painting and coating shall be applied in accordance with painting procedure approved by Owner. Application of Coating 4.1 Surface Preparation 4.1.1 All surfaces of carbon steel & alloy steel shall be blasted to near white metal finish, unless otherwise specified, using dry blasting abrasive only. 4.1.2 Thin sheet metal surface requiring painting may be chemical treatment by a suitable phosphating process or solvent (SP1), hand tool (SP2) and power tool cleaning (SP3), if cannot blast. 4.1.3 The surface shall be prepared in a suitable manner for coating according to Manufacturers data sheets. Chemical derusters or rust converters may not be applied. 4.1.4 Blasting The surface of the component shall be blasted within 6 hours prior to coating the component. If the relative humidity is greater than 80%, blast immediately prior to coating.

PROJECT KUDGI STPP (3 X 800MW)

SUBJECT PAINTING SCHEME

Doc. No. DT12001-GR-M5503

Rev A

Sheet No. 1 3

Blast cleaning shall not be conducted when the temperature of the surface is less than 3 above dew point of the surrounding air. The surface profile shall not conflict with the paint manufactures recommendations. The blast profile shall be measured with a Keane-Tator Surface Profile Comparator or equivalent. A surface profile tape such as Press-O-Film by TESTEX, Inc. may be used. The results of each measurement shall be recorded. When stainless steel needs to blast, non-metallic abrasive shall be used. 4.1.5 Cleaning : Removal of impurities: Impurity Removal Dust, loose deposits Vacuum-cleaning, brushing Adhesive deposits Power brushing Oils, greasy impurities Solvent Cleaning Salt deposits Rinsing with fresh water Organic solvents to Manufacturers specifications e.g.: Trichlorotrifluoroethane and solvents containing Markings (e.g. felt tip pen) acetone (renew solvent and rag frequently). The coating may not be damaged. Damages, Burns, Weld Smoke, Disc Sanding to SP 3 according to SSPC or abrasive Markings, Corroded areas sweeping to SP 7 according to SSPC. White Rust Fresh water hosing and scrubbing with stiff brushes. 4.1.6 Surfaces to be coated must be dry and free of all dirt, mildew, chalk, spent abrasive and any other contaminant of foreign material that could inhibit adhesion. 4.1.7 Any oil and grease on the surface shall be removed by SSPC-SP 1, Solvent Cleaning. 4.1.8 Steam drums may be blasted by steel grit (not sand blasted) after final heat treatment but before final assembly. And then, its interior shall be cleaned by using the compressed air and recorded the inspection result. 4.1.10 All machined surfaces including flange faces shall be suitably covered to prevent damage during surface preparation 4.2 Application of Coating 4.2.1 General (Application Conditions) 4.2.2 The primer shall be applied to properly prepared surfaces only. Apply the paints in accordance with the paint manufacturers recommendation as to the application, humidity, weather, temperature conditions and coating thickness. Paint shall be applied when the metal temperature shall be at least 3 above dew point and the relative humidity shall not exceed 80%. 4.2.3 Paint shall not be applied on the interior surface of pressure parts such as steam drum, tanks, wall, tube and pipe, unless otherwise specified. 4.2.4 The carbon steel surfaces will be painted as indicated in the technical specification for painting system according to temperature range in that particular area. 4.2.5 To be welded in the field shall not be coated 50mm from the welds. The 50mm areas will

PROJECT KUDGI STPP (3 X 800MW)

SUBJECT PAINTING SCHEME

Doc. No. DT12001-GR-M5503

Rev A

Sheet No. 4 1

be coated with Weldable inorganic zinc silicate primer.

4.2.6 For structural steel, only Inorganic zinc silicate primer or Weldable inorganic zinc silicate shop primer shall be used on all friction-type (slip-critical) bolted connections for all structural steel. All structural bolted surfaces shall be masked in accordance with APPENDIX 1(Painting Scheme of Steel Structure); this area shall be coated in accordance with the specified painting system after bolting. 4.2.7 In case of top coat are required on the inorganic zinc silicate primer, Mist coating shall be performed in order to avoid coating failure. 4.2.8 The coats shall be applied as a continuous film of uniform thickness and free of pores. Overspray, skips, runs, sags, and drips should be kept to a minimum. 4.2.9 Paint shall not be applied on the following surfaces, unless otherwise specified. 4.2.9.1 Non ferrous metal such as Nickel, Bronze, Copper, Aluminum 4.2.9.2 Stainless steel 4.2.9.3 Galvanized Steel 4.2.9.4 Nameplate and other identification plates or label 4.2.9.5 Machined surfaces 4.2.11 Galvanizing 4.2.11.1 Galvanizing work and thickness shall be applied according to ASTM A123 except for handrail, toe plate, grating, stair tread, ladder and checkered plate. 4.2.11.2 Vent holes and drain holes shall be provided to avoid high internal pressures and air lock during immersion and to ensure that molten zinc is not retained in pockets during withdrawal. 4.2.11.3 All defect of the steel surface, including crack, surface laminations, laps and folds, shall be removed. All drilling, cutting, welding, forming and final fabrication of unit member and assemblies shall be completed, where feasible, before galvanized. 4.2.11.4 Damaged area shall be restored in compliance with ASTM A780. 4.2.12 Application Procedure
Paints can be applied by Airless spray, Roller or Brush. For structural steel members application of primer, intermediate, final coat shall be done by airless spray technique for painting works done in the shop as per technical specifications. Dry film thickness of each coat shall be checked and measured as per the procedure Specified in paint application standard no. 2 by SSPC: The Society for Protective Coating. 4.2.13 All threaded and other surfaces of foundation bolts and its materials, insulation pins, Anchor channels, sleeves, etc. shall be coated with temporary rust preventive fluid and during execution of civil works, the dried film of coating shall be removed using organic solvents.

PROJECT KUDGI STPP (3 X 800MW)

SUBJECT PAINTING SCHEME

Doc. No. DT12001-GR-M5503

Rev A

Sheet No.
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General Painting System 5.1 All steel structures (except those embedded in concrete) shall be provided with painting as given below which is designed for a minimum maintenance free life of Ten (10) years (expected life, long range Ten(10) to (20) years, as per ISO 12944) Carbon steel and low alloy Surfaces to be subjected to ambient Temperatures (up to 95), not insulated, in service erected at outdoor. Min. Surface Min. Dry film No of Solid by Material Preparati Paint Type coat Volume thickness () on (%) Inorganic Zinc Silicate 1st 75 60 Primer C.S Mist or SP 10 40 Polyamide Epoxy MIO 60 Coat Low alloy 2nd 120 Polyamide Epoxy MIO 60 rd 3 40 Polyurethane 40 Total Dry Film Thickness() 275 -

5.2

5.3

Carbon steel and low alloy Surfaces embedded in concrete. (Except for Anchor bolt) Surface No Dry film Material Preparatio of Paint Type Remark thickness () n coat C.S Chlorinated Rubber st or SP 10 1 50 based Zinc Phosphate Low alloy Primer Total Dry Film Thickness() 50

Touch-up Painting The supplier shall provide touch-up paint with thinner at least 5% for site repair. The amount of touch-up paint, 5% shall be determined by the design area and 40% of loss rate. 6.1 Repairing Damage/Touch-up in the Shop or in the Field Surfaces to be subjected to ambient Temperatures (up to 95) in service erected at outdoor and indoor.

PROJECT KUDGI STPP (3 X 800MW)

SUBJECT PAINTING SCHEME

Doc. No. DT12001-GR-M5503

Rev A

Sheet No. 6 1

6.1.1 Damaged parts caused by burns, welds, scratches, or impact etc. during fabrication, handling, storage, shipping, and erection shall be touched up as follow : Min Solid Surface No Min. Dry film By Material Preparatio of Paint Type Volume thickness () n coat (%) Self Priming Epoxy 1st 100 60 C.S primer or SP 1/2/3 2nd 135 Polyamide Epoxy MIO 60 Low alloy 3rd 40 Polyurethane 40

6.1.2 The application method for the touch up painting is specified by brush or spray. 6.1.3 The surface preparation grade of damaged part depends on the area of damaged surface. When the areas needed to repair are large, repair areas shall be treated by blast cleaning.

6.2

Repairing Damage/Touch-up in the Field Galvanized surface. 6.2.1 Damaged parts caused by burns, welds, scratches, or impact etc. during fabrication, handling, storage, shipping, and erection shall be touched up painted as follow : 6.2.2 Galvanized Item to be coated at Indoor & Outdoor Surface Preparat ion SP 1/2/3 No of coat 1st Dry film thickness () Depending on Galvanizing thickness

Material

Paint Type

Remark Min. DFT shall not be less than the DFT corresponding to Galvanisation of 610 gms/m2

Galvanized Steel

Epoxy Zinc Primer

6.3

The coating failure such as run, sags, drips or over-spray shall not be permitted because it will be affected by the root cause by loss of adhesion, blistering, peeling, mud-cracking or rust of substrate. Defective area shall be re-blasted and re-coated.
A. For Coatings damaged up to metal surface

6.4

Surface preparation shall be carried out by Manual Cleaning. Minimum 6 inches adjoining area with existing Coating shall be roughened by Wire brushing, emery paper rubbing etc., for best adhesion of patch Primer. Primer Coat of self-priming Epoxy Touch-up Primer applied by brush immediately after the surface preparation. (Minimum DFT 100 Microns).

PROJECT KUDGI STPP (3 X 800MW)

SUBJECT PAINTING SCHEME

Doc. No. DT12001-GR-M5503

Rev A

Sheet No. 7 1

Over this Primer Coat, 2nd and 3rd coat shall be done in accordance with Clause 6.1.1.
B. For

Coatings damaged up to Intermediate Coatings (i.e. where Primer Coat is intact).

Damaged area including Minimum 6 inches adjoining area with existing Coating should be roughened by wire brushing, emery paper rubbing etc., for best adhesion of patch Primer without damaging the Primer Coat. Other painting coat after touch up primer shall be done in accordance with Clause 6.1.1..

6.5
Coating systems

General Coating Systems

No. of Coat 1st Paint Type Inorganic Zinc Silicate Primer Polyamide Epoxy MIO Polyamide Epoxy MIO Polyurethane Chlorinated Rubber Based Zinc Phosphate Primer Min. D.F.T () 75 40 275 120 40 50 50 60 40 Total Min. D.F.T () Min. Solid By Volume (%) 60 60

B1

Mist Coat 2nd 3rd

B7

1st

6.6
No.
1

Detailed Painting systems

Description Material C.S Contact with Air Surface Temp. ( ) AMB
Surface

Prep. (SSPC) SP 10

Painting System B1

Work Scope Shop

Steel Structure - Handrail & Post - Toe Plate - Gratings - Stair Tread - Ladder - Checkered Plate Foundation Material (Except for Anchor bolt) Buckstay

C.S

Air

AMB

SP 10 or SP 8

Hot-dip Galvanizing (Min. 610 Gms/Sq)

Shop

3 4

C.S C.S/ A.S

Concrete Air

AMB AMB

SP 10 SP 10

B7 B1

Shop Shop

PROJECT KUDGI STPP (3 X 800MW)

SUBJECT PAINTING SCHEME

Doc. No. DT12001-GR-M5503

Rev A

Sheet No.
8 1

APPENDIX #1 Painting Scheme of Steel Structure

Note : 1. All paint free area shall be protected using masking tape located relative to bolt hole and faying surface. 2. Outside line of masking tape shall be not less than 50mm away from center of bolt hole and 25mm away from edge of connection material. (e.g. clip angle, connection plate, etc.) 3. Legend : Area to be fully painted

...... ......

: Area to be painted with only Inorganic zinc silicate primer