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Microsoft Word 05 1 EPC GE PTC M PR 00166 PFP Application Procedure Rev D2 SAO VANG AND DAI NGUYET DEVELOPMENT PROJECT Type of Document Procedure Page 1 of 21 PASSIVE FIRE PROTECTION APPLICATION PROCE.
SAO VANG AND DAI NGUYET DEVELOPMENT PROJECT Type of Document: Procedure Page: of 21 PASSIVE FIRE PROTECTION APPLICATION PROCEDURE D2 Re-approved for Construction 17 Dec 2019 P.Q.Huy H.M.Dung N.B Hoang D1 Approved for Construction 28 Oct 2019 P.Q.Huy H.M.Dung N.B Hoang C2 Re-issued for Approval 20 July 2019 P.Q.Huy H.M.Dung N.B Hoang C1 Issued for Approval 21 June 2019 P.Q.Huy H.M.Dung N.B Hoang B1 Issued for comment 28 Jan 2019 P.Q.Huy H.M.Dung N.B Hoang Rev review Purpose of Issue and Issue Date Prepared Reviewed Approved By By By EPCIC Contractor Document No.: 05-1_EPC-GE-PTC-M-PR-00166 EPCIC CONTRACTOR: PTSC MECHANICAL & CONSTRUCTION Approved By IKC Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 Rev.: D2 Date: 17 Dec 2019 Page: of 21 Revision Record Sheet Rev No Description Date of Rev B1 C1 Issued for review and comment Issued for Approval Jan 28, 2019 June 21, 2019 C2 D1 D2 Re-issued for Approval Approved for Construction Re-approved for Construction July 20, 2019 Oct 28, 2019 17 th Dec, 2019 Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 Rev.: D2 Date: 17 Dec 2019 Page: of 21 TABLE OF CONTENTS SCOPE DEFINITIONS & ABBREVIATIONS CODES, STANDARDS AND REFERENCES PERFORMANCE CRITERIA AND MATERIAL REQUIREMENTS PAINTING APPLICATION 5.1 APPLICATOR 5.1.1 BLASTER AND PAINTER 5.1.2 PFP OPERATOR 5.2 PRE-BLASTING PREPARATIONS 10 PFP APPLICATION 14 6.1 MATERIAL PRE-HEATING 14 6.2 PLURAL COMPONENT QUIPMENT 14 6.3 ENVIRONMENTAL CONDITION 15 6.4 PFP APPLICATION 15 6.5 FINAL COAT APPLICATION 16 INSPECTION/ QUALITY CONTROL 17 SAFETY 20 APPENDICES 21 Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 D2 Rev.: D2 Date: 17 Dec 2019 Page: of 21 SCOPE This procedure covers all the requirements for surface preparation and Passive Fire Protection (PFP)- intumescent coating type of new built offshore structure It also describes CONTRACTOR’s practice and specific quality programs in achieving highest quality standard for all products and services as to meet CONTRACTOR or COMPANY’s requirements PFP intumescent coating type shall be applied to the structural member, fire/blast wall, vessel, and not applied to piping, shell of Condensate Stabilizer column, ESDV valves as per Passive Fire Protection Schedule and Listing Document No 05-1_EPC-SV-AEI-S-LA-00003 DEFINITIONS & ABBREVIATIONS Company/ IKC Contractor/ PTSC Sub-Contractor Sub-Contractor/ Vendor Idemitsu Kosan Co., Ltd PTSC Mechanical & Construction Co., Ltd Contractor’s sub-contractor party for any part of the EPCIC work scope The party who supply the equipment or material the necessary for Contractor to fulfill the EPCIC work scope SVDN Project PMT PFP QA/QC IRN PTW ASTM ISO NACE NFPA CPS CPT ITP CSDS DFT RAL RH CS SS DSS SDSS HDG VOC TDS Sao Vang Dai Nguyet Project Project Management Team Passive Fire Protection Quality Assurance/ Quality Control Inspection Release Note Permit To Work The American Society for Testing and Materials International Organization for Standardization National Association of Corrosion Engineers National Fire Protection Association Coating Procedure Specification Coating Procedure Test Inspection and test plan Coating System Data Sheet Dry Film Thickness Color definitions issued by RAL Relative Humidity Carbon Steel Stainless Steel Duplex Stainless Steel (22% Cr) Super Duplex Stainless Steel (25% Cr) Hot Dip Galvanized Volatile Organic Compound Technical Data Sheets Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 MSDS Rev.: D2 Date: 17 Dec 2019 Page: of 21 Material Safety Data Sheet CODES, STANDARDS AND REFERENCES Code, Specification, Standard and Reference Title 05-1_EPC-SV-AEIM-SA-00001 Coating and Painting Specification 05-1_EPC-SV-AEIS-SA-00003 Specification for Passive Fire Protection 05-1_EPC-SV-AEIS-LA-00003 Passive Fire Protection Schedule and Listing 05-1_EPC-GE-PTCQ-PR-00103 Coating and Painting Qualification Test Procedure (CPT) 05-1_EPC-GE-PTCQ-MX-00001 Coating Procedure Test Dossier 05-1_EPC-GE-PTCQ-TA-00111 ITP for Passive Fire Protection Coating 05-1_EPC-GE-PTCQ-LA-00101 05-1_EPC-GE-PTCM-PR-00158 Project Coating and Painting Matrix Coating Procedure NORSOK S-001 Technical Safety NORSOK M-501 Surface Preparation and Protective Coating ISO 4624 Paints and varnishes – Pull-off test for adhesion ISO 8501-1 Preparation of steel substrates before application of paints and related products – Visual assessment of surface cleanliness – Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings ISO 8501-3 Preparation of steel substrates before application of paints and related products – Visual assessment of surface cleanliness – Part 3: Preparation grades of welds, edges and other areas with surface imperfections ISO 8502-3 Preparation of steel substrates before application of paints and related products – Test for the assessment of surface cleanliness – Part 3: Assessment of dust on steel surfaces prepared for painting (pressure sensitive tape method) ISO 8502-6 Preparation of steel substrates before application of paints and related products – Test for the assessment of surface cleanliness – Part 6: Extraction of soluble contaminants for analysis – The Bresle method Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 Rev.: D2 Date: 17 Dec 2019 Page: of 21 ISO 8502-9 Preparation of steel substrates before application of paints and related products – Test for the assessment of surface cleanliness – Part 9: Field method for the conductometric determination of water-soluble salts ISO 8503 Preparation of steel substrates before application of paints and related products – Surface roughness characteristics of blast cleaned substrates ISO 8504-2 Preparation of steel substrates before application of paints and related products – Surface preparation methods – Part 2: Abrasive blast cleaning ISO 12944-4 Paints and varnishes – Corrosion protection of steel structures by protective paint systems – Part 4: Types of surface and surface preparation ISO 12944-5 ISO 19840 ISO 20340 SSPC PA2 SSPC-SP SSPC-SP SSPC-SP Paints and varnishes – Corrosion protection of steel structures by protective paint systems – Part 5: Protective paint systems Paints and varnishes – Corrosion protection of steel structures by protective paint systems – Measurement of, and acceptance criteria for, the thickness of dry film on rough surfaces Paints and varnishes – Performance requirements for protective painting systems for offshore and related structures Paint Application Specification No 2, Measurement of Dry Coating Thickness with Magnetic Gauges Solvent Cleaning Hand Tool Cleaning Power Tool Cleaning SSPC-SP 10 / NACE No Near-White Blast Cleaning Carboline Paint Pyroclad X1- Fire barrier system application manual PERFORMANCE CRITERIA AND MATERIAL REQUIREMENTS In terms of fire rating, there are three main performance criteria throughout a prescribed time of exposure to heat: Stability - the structure shall fulfil its load bearing capacity throughout the fire exposure period, Integrity - partitions shall prevent spread of flames and hot fumes throughout the fire exposure period, Insulation - the unexposed side of partitions shall not reach surface temperatures in excess of a certain level throughout the fire exposure period Fire rating and Area application will be defined in accordance with document No 05-1_EPC-SVAEI-S-LA-00003 Passive Fire Protection (PFP) Schedule and Listing and No 05-1_EPC-SVAEI-S-SA-00003 Specification for Passive Fire Protection All materials will be installed & durable in offshore marine environment Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 Rev.: D2 Date: 17 Dec 2019 Page: of 21 Reinforcement mesh of the insulation (if required) is to be of non-metallic fiber carbon type using an attachment method appropriate to the form of structure member, applied in strict accordance with Manufacturer’s specification and appropriate Certifying Authority approval System including Pyroclad X1 + High Temperature Mesh from Carboline paint manufacturer has been qualified and chosen as intumescent PFP coating for SVDN Project Carboline shall provide the required thickness and reinforcement systems on the basis of the fire protection requirements detailed in the specification Details shall be provided of all relevant calculations to support the proposed PFP product and associated thickness/ application of the material This shall include, but not necessarily be limited to, details of the product with respect to strain limits, maximum deflection characteristics and the transmission of heat for each size of beam The PFP systems must have a current certificate from Lloyd’s, DNV or other equivalent classification bodies if necessary and be tested using acceptable international methods by a recognized testing agency The original materials for testing and applying on product are manufactured at the premises of manufacture that certify on the Type approval certificates In the selection and proposal of the PFP material, attention shall also be paid to: The compatibility of the PFP material with the final coating product (i.e polyurethane) as indicated in Coating and Painting Specification (05-1_EPC-SV-AEI-M-SA-00001) Smoke generation and toxicity of the PFP Surface/Operating temperature of the piping or vessel to be PFP If structure elements are to be PFP-ed, it is assumed highest ambient temperature Weather ability and mechanical impact strength of the product The PFP material is required to survive to the offshore environmental conditions1 as defined for SV-CPP Its resistance to chemicals (salts, solvents, acids, bases) Fire performance, with regard to the duration and type of fire, to provide evidence acceptable to COMPANY that the PFP product proposed has been tested and shown to provide adequate protection Test details will also be required Anti-corrosion performance if applied directly on substrate or compatibility and adhesive strength to underneath anti-corrosion coatings Weight limitation imposed by the strength of the supporting structure The weight limitation will be achieved by the use of optimum PFP thickness that commensurate with the required level of protection Adhesive strength and durability, providing evidence that the proposed PFP product has performed satisfactorily, with regards to adhesive strength and durability, under comparable environmental conditions Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 D2 Rev.: D2 Date: 17 Dec 2019 Page: of 21 Ease of application and repair The appropriate type of PFP for each Vessels and structure The intumescent epoxy shall not be used in enclosed area where personnel could be present such as LQ and buildings The buildings shall be protected by inactive insulation that does not release toxic material The proposed PFP material shall be approved for low smoke emission and non-toxicity and shall be submitted to COMPANY for acceptance PFP Material Document shall have minimum: - Fire Approval Certificate - Certificate of Quality including Type/Designation, Batch Number, Name of Supplier, Manufacturer - Certificate of Origin, - Quantity and Identification in accordance with delivery documentation - Batch Numbers, Manufacture Date and Expiry date - MSDS - Product Datasheet PAINTING APPLICATION 5.1 APPLICATOR 5.1.1 Blaster and Painter Operators shall be qualified to tradesman level as blast-cleaner, painter, applicator etc The personnel shall have relevant knowledge of health and safety hazard, use of protection equipment, coating materials, mixing and thinning of coatings, coating pot-life, surface requirements etc Personnel not qualified to tradesman level, shall document training and experience to the same level as a formalized tradesman education 5.1.2 PFP Operator Personnel qualified will be selected for PFP coating sprayer qualification Only personnel have passed the qualification test as described in below or trained by the PFP coating manufacturer are allowed to spray the PFP coating during production on the project Each sprayer shall select the airless spray tip, mix components of the coating and add thinner according to the manufacturer’s instructions in use Adjust the spray pressure suitable for the coating manufacturer’s recommendations, carry out spraying of the coating in overlapping or crossing passes onto the surfaces to be coated The areas that cannot be properly coated by spraying will be trowel applied and rolled Measure WFT to ensure that the required coating thickness has been achieved Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 Rev.: D2 Date: 17 Dec 2019 Page: of 21 Install the mesh reinforcement into the wet coated surface, overlap between the adjacent mesh pieces approximately 50mm to 150mm and roll thoroughly into the wet coated surface with the short nap roller lightly dampened with the coating manufacturer’s recommended thinner Continue to apply PFP coating by trowel in the corners or areas that cannot be properly coated by spraying, then carry out spray application Measure WFT to ensure that the required coating thickness has been achieved Areas applied by trowel will be rolled by using the short nap rollers lightly dampened with the coating manufacturer’s recommended thinner to remove trowel marks After the coating application is completed, the following inspection items shall be carried out: Inspection item Extent Extent Acceptance criteria Visual inspection of coating 100% of surface Coating shall be uniform without sagging, trowel marks or missed areas Dry film thickness 10 measurements Obtain the specified thickness If the operators have not been working with the type of application or material within a period of 12 months, the applicator shall document that necessary supplementary training have been given before start of any work 5.1.3 Paint Manufacturer Support at Site Irrespective of the Work Site or contracting entity, the paint manufacturer’s technical representative shall be present during the following operations: Attending the painting / coating procedure qualification process to verify correct application of materials and use of equipment, Attending the pre-start meeting, Attendance on Site at the start of each different painting / coating system application, Providing technical advice in the event of painting / coating problems with painting/coating materials and their application, Site surveillance visits during the painting /coating execution period to ensure that the coating/painting systems are being applied in accordance with the manufacturer’s recommendations, Providing a written report confirming satisfactory performance of painting/coating operations following each Site visit Technical support described above shall be applied to all Work Site locations managed by the main fabrication Site including all subcontracted Work Any technical concerns raised by the painting / coating manufacturer shall be addressed to the satisfaction of paint manufacturer and Company Title: Passive Fire Protection Application Procedure Doc No.: 05-1_EPC-GE-PTC-M-PR-00166 Rev.: D2 Date: 17 Dec 2019 Page: 10 of 21 5.1.4 Role of Inspector and Qualification The Contractor inspector, Paint manufacturer shall be present in the fabrication yard during execution of painting activities Minimum 01 inspector from Contractor and 01 inspector from Paint manufacturer and minimum qualification requirements for inspectors is NACE or equivalent approved by Company 5.1.5 Qualification of supervisors, foremen and QC personnel The Contractor’s foremen, supervisors and coating inspectors shall be present during Qualification and Training of PFP coating sprayers to ensure that coatings are being applied in accordance with the approved procedures Personnel carrying out inspection and verification shall be certified as NACE coating inspector level II or a Company approved equivalent Inspection personnel shall have a minimum of five (5) years of painting/coating experience On completion of PFP coating sprayer qualification test, the Contractor’s coating inspector shall issue and submit the sprayer qualification test to Company for review and approval 5.2 PRE-BLASTING PREPARATIONS Sharp edges, fillets, corners and welds shall be rounded or smoothened by grinding to grade P3 as defined in ISO 8501-3 (minimum radius mm) Hard surface layers (e.g resulting from flame cutting) shall be removed by grinding prior to blast cleaning The surfaces shall be free from any foreign matter such as weld flux, residue, slivers, oil, grease, salt etc prior to blast cleaning All surfaces should be washed with clean fresh water prior to blast cleaning Any major surface defects, particularly surface laminations or scabs detrimental to the protective coating system shall be removed by suitable dressing Where such defects have been revealed during blast cleaning, and dressing has been performed, the dressed area shall be re-blasted to the specified standard All welds shall be inspected and, if necessary, repaired prior to final blast cleaning of the area Surface pores, cavities etc shall be removed by suitable dressing or weld repair Material list and IRN (if required) is available before blast cleaning 5.3 SURFACE PREPARATION 5.3.1 Blast cleaning The surface preparation for each system shall comply with the requirements detailed in 051_EPC-GE-PTC-Q-LA-00101 Project Coating and Painting Matrix Suitable abrasives for use in blast cleaning are: HIGH TEMP MESH INSTALLATION Application Manual Revision Dated: May 2014 47 of 61 ACCEPTABLE FINISH Application Manual Revision Dated: May 2014 48 of 61 APPENDIX G PYROCLAD X1 SIMPLIFIED APPLICATION PROCEDURES Application Manual Revision Dated: May 2014 49 of 61 SIMPLIFIED APPLICATION PROCEDURES Surface Preparation A Surface must be clean, dry and free of any dirt, oil, grease or other contamination prior to blasting B Clean surface to specified standard, typically SSPC-SP1 C Steel surfaces must be blasted to SSPC-SP6 (onshore and SSPC-SP10 (offshore), ISO 8501-1 / Sa ½ with a minimum blast profile of 37-50 microns (1.5-2.0 mils) Primer Application A All surfaces must be clean, dry and properly prepared as stated above prior to primer application B All primers must be approved by Carboline prior to use under Pyroclad X1 C Ensure primer is applied within manufacturer’s stated ambient conditions, steel temperature and relative humidity specifications D The primer shall be applied in accordance with the manufacturer's and project’s specification E The primer thickness range shall be between 75-150 microns (3-6 mils) DFT per SSPC-PA2 Any other final DFT in excess of this value shall be agreed upon by Carboline in writing Pyroclad X1 Application (Plural Component Heated Airless Equipment) (Environmental) A Before applying Pyroclad X1, confirm that proper environmental conditions are met Minimum ambient temperature: 5˚C (41˚F) and rising, maximum relative humidity 85%, steel surface temperature must be 3˚C (5˚F) above the dew point B Confirm that the surface has been prepared to specification C Verify that a Carboline approved primer has been correctly installed to correct thickness and is properly cured Ensure that the application is within the primer’s recoat window D Confirm that all blockouts and areas that may receive overspray are properly masked off (Plural Component Equipment) E Set tank heaters: Part A 60˚C (140˚F) / Part B 60˚C (140˚F) F Set inline fluid heaters and line heaters to 60-71˚C (140-160˚F) G Check ratio to ensure a 1:1 ratio mix by volume H Verify gun exit temperature of 50-55˚C (123-132˚F) I Displacement pump pressure should be between 175-310 bar (2500-4500 psi) J Verify that the spray tips are not worn and in the range of 0.027 – 0.035” (Application) K Spray Pyroclad X1 to point of mesh placement Trowel material in order to uniformly wet surface if required L Apply pre-cut High Temp Mesh reinforcement into the wet coating where required (refer to section for details) M Build material to final thickness in as many coats required using solvent moistened mohair rollers to smooth any imperfections in the coating Surface finish must meet project specifications High Temp Mesh Reinforcement Application A B C D Only use Carboline High Temp Mesh For exact design details on mesh placement and requirements refer to the Pyroclad X1 Application Manual Pre-cut all High Temp Mesh prior to commencing the application of Pyroclad X1 For hydrocarbon pool fire ratings only, wide flange sections require mesh around the flanges terminating 50 mm (2”) on the inside of the flange If the web depth is greater than 355 mm (14”), the web must also be meshed with the mesh terminating a 12.5 mm (½”) from the web radius Overlaps with adjacent mesh pieces must be a minimum of 50 mm (2”) Application Manual Revision Dated: May 2014 50 of 61 E All hollow sections require a complete (100%) wrap with High Temp Mesh with a 50 mm (2”) overlap at all seams F All jet fire applications require a complete (100%) wrap with High Temp Mesh with a 150 mm (6”) overlap at all seams G Apply the High Temp Mesh into the wet Pyroclad X1 at the approximate mid-point to the 2/3 point of the coating (dependent on specific design) ± mm (40 mils) H Ensure that the High Temp Mesh is completely embedded into the wet Pyroclad X1 using trowels and/or solvent resistant mohair rollers Lightly mist rollers with a Carboline approved solvent to aid in back rolling I After the installation of the High Temp Mesh, a light 1mm (40 mils) coat of Pyroclad X1 should be spray applied to fully encapsulate the mesh or continue building the next full coat of Pyroclad X1 Metal Mesh Reinforcement Application A Metal mesh type shall be 12.5 mm x 12.5 mm (½”x ½”) square opening, 1mm (0.04”) diameter, galvanized wire mesh (19 gauge) B For exact design details on mesh placement and requirements refer to the Pyroclad X1 Application Manual C Metal mesh is mechanically attached to the surface of the steel by welding pins to the substrate D For I-sections the metal mesh is installed around each flange and extended in 50 mm (2”) from the outer flange edges For I-sections with a web depth of 355 mm (14”) or greater, a strip of metal mesh must also be placed in the webs terminating 25.4 mm (1”) from the radius of the flange E All hollow sections require a complete (100%) wrap with metal mesh F All jet fire applications require a complete (100%) wrap with metal mesh G Where any seams are present, the metal mesh can be butted together or overlapped by 25 mm (1”) minimum H All seams and adjacent pieces of mesh must be laced together with tie wire at a maximum spacing distance of 250 mm (10”) I Metal mesh shall extend as close as possible to the termination point of the Pyroclad X1 to the steel J Pins shall be 2-3 mm (0.08”- 0.12”) diameter copper coated mild steel Length shall be 25-50 mm (1”-2”) Spacing between pins shall not exceed 300 mm (12”) on center and shall form a diamond or irregular pattern rather than straight lines Adhesive pins are not allowed K Preferably, pins shall be attached prior to blasting and priming If pins are attached after priming, the weld area must be thoroughly cleaned and primer reinstated prior to Pyroclad X1 application L After the installation of the metal mesh, the first coat of Pyroclad X1 should be spray applied and trowelled in multiple directions to fully encapsulate the mesh then continue building the next full coat of Pyroclad X1 Topcoat Application A Carboline approved topcoats or topcoat systems can be used to meet project specifications for color, finish, service requirements and UV protection B Ensure that the Pyroclad X1 system has been properly installed and the High Temp Mesh is properly embedded into the material C Confirm that Pyroclad X1 has been applied to the specified dry film thickness by using an electronic or magnetic dry film thickness gauge D The Pyroclad must be sufficiently cured and be clean, dry and free of any contamination prior to topcoat application E All topcoats must be approved by Carboline prior to use with Pyroclad X1 F Ensure topcoat is applied within manufacturer’s stated ambient conditions, temperature and relative humidity specifications G The topcoat shall be applied in accordance with the manufacturer and project specification Refer to the topcoat product data sheet for thickness requirements Safety A B C D Only trained and qualified applicators should install PyrocladX1 Follow all safety precautions on the Pyroclad X1 MSDS when applying this material Always use appropriate personal protective equipment and wash with hot soapy water if necessary Ensure proper maintenance and cleaning of the equipment For complete application procedures refer to the Pyroclad X1 Application Manual (latest revision) Application Manual Revision Dated: May 2014 51 of 61 APPENDIX H APPLICATION QC FLOW CHART REMEDIAL PROCEDURES GUIDE TYPICAL INSPECTION EQUIPMENT TEST DETAILS OF INSPECTION POINTS Application Manual Revision Dated: May 2014 52 of 61 APPLICATION QC FLOWCHART Number Procedure/Operation Hold Point Inspection Document Acceptance/ Compliance Yes Yes Yes Yes Yes Yes Surface Preparation Profile Preparation Standard Profile: Min 40microns according to ISO 8503 or ASTM D 4417 Preparation Standard: Minimum of Sa according to ISO 8501-1 or SSPC-SP6 or Din 55928 Acceptable? Yes Primer Coat Go to Type(s) Thickness Cure Adhesion Type: Document compliance with Carboline & Project requirements Thickness: Maximum 110 microns d.f.t., measurements according to ISO 2808 No Yes Yes Yes Back to Step No Yes Yes Yes Yes No Visual Inspection: Contractor to document personnel qualifications and have necessary data available Remedial Procedures Back to Step No No No No No QC personnel in possession of appropriate qualification? Key operatives trained? No No No No No Yes Yes Yes Yes Yes Acceptable Yes Equipment Yes Yes Yes Yes Go to Up to date/latest Rev PYROCLAD X1 manual available? Up to date project specification available? Supervisor in possession of appropriate qualification? Remedial Procedures Acceptable Cure: A 70% of full cure according to manufacturer's data Adhesion tests to ISO 4624 to confirm Min acceptable value = 5.0 Mpa Adhesion: As above, tested to ISO 4624 (ASTM D4541) Site Organization/Personnel No No Go to Remedial Procedures Back to Step Compliance with Carboline manual and project specifications No No Yes Maintenance log/records for pumps No No Yes Calibration records for inspection equipment No No Yes Application Manual Revision Dated: May 2014 53 of 61 Acceptable Yes Application Conditions No Go to Temperature (air) Humidity Temperature (substrate) Adequate weather protection Adequate environment control Yes Yes Yes Yes Yes Air Temp and Humidity: To be recorded prior to the start of production and periodically during application (minimum times per hour shift) Remedial Procedures Back to Step Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Acceptable? Substrate Temp: To be recorded at start of shift Yes Material storage Temperature Control Cleanliness Protection from Environment Visual checks only No Go to No No No Remedial Procedures Back to Step Yes No No Yes No Yes Acceptable? Yes Raw Material Record Batch Numbers Certificates for Solvent No Go to Back to Step No No Certificates of conformity to be provided where required by project Remedial Procedures No No Yes Yes Acceptable? Visual checks only Yes No Go to 8 Installation of pins (when & where required) Material, diameter and length of pin Pattern and distance between centres Pin test conducted? First 50 pins, bend to 45o and return to vertical No Yes Yes Update records Back to Step Yes Yes Yes Yes Yes Yes Acceptable? Yes Pre-Application (1st Coat) Go to Cleanliness of Substrate Ratio Check (plural equip) Yes Yes Application Manual Revision Dated: May 2014 No Remedial Procedures Back to Step Yes Yes Yes Yes 54 of 61 Pre-mix (single component) Yes Qty of solvent added (Not for plural application) No Cleanliness of Substrate: Check for Salts, Oil Spillage, Foreign matter and/or Dust Yes No Acceptable? Yes Application (1st Coat) 10 Yes Yes No Go to 10 Thickness Thickness: Measure with wet film gauge and record on daily logs Yes Remedial Procedures Back to step Yes Yes Acceptable? Yes Reinforcement 11 No Go to 11 Type complies with Spec Elapsed Time from 1st coat installation Overlaps with adjacent layers Area coverage and position in the finished coating verses profile Type: Visual check and record on daily logs Remedial Procedures Back to step 10 Yes No No Yes Yes Yes Yes Yes Yes No Yes Yes Acceptable? Yes Subsequent Coat(s) 12 Elapsed Time from mesh installation Condition of base coat(s) Elapsed Time from previous coat installation Thickness Overcoat conditions: Visual checks Record specification No Go to 12 No Yes Yes Yes compliance Remedial Procedures Back to step 11 No Yes Yes Yes Yes Yes Yes Yes with Acceptable? Thickness: Measure with wet film gauge and record on daily logs Yes Final Coat 13 14 Go to 13 Thickness Yes Aesthetics Yes Thickness: Measurements according to ISO 2808 if using electronic dft gauge Drill checks an acceptable alternative Record and check against specification Aesthetics: Visual check: No exposed mesh, ”birds nests” or pinholes An even finish with no sagging is the target Topcoat Elapsed time from final coat of Pyroclad X1 application Condition of Pyroclad X1 Type Thickness Application Manual Revision Dated: May 2014 No Back to step 12 Yes Yes Yes Yes Acceptable? Yes Go to 14 No Yes Yes Yes Remedial Procedures No Remedial Procedures Back to step 13 No Yes Yes Yes Yes Yes Yes Yes 55 of 61 Elapsed time: Check with manufacturer's data sheets and document compliance with Carboline requirements Condition of Pyroclad X1: Record compliance with Carboline/ maunufacturer’s requirements Type: Document compliance with Carboline requirements Thickness: Measurements according to ISO 2808 Acceptable? Yes No Remedial Procedures Back to step 14 Application Manual Revision Dated: May 2014 56 of 61 REMEDIAL PROCEDURES GUIDE Number Non Compliance/ Conformity Procedure/Operation Surface Preparation Insufficient Profile Inadequate Cleanliness Primer Coat Unqualified Primer Unacceptable Primer Over thickness (a) Re-prepare to achieve minimum 40 micron Profile Sa (onshore) Sa 2½ (offshore) Insufficient adhesion (a) Insufficient adhesion (b) Contact Carboline for acceptance Re-blast and use qualified primer Re-blast and recoat Mechanically remove surface coating until thickness is within tolerance Allow further time to cure If PYROCLAD X1 is applied, it must be removed and the entire area reinstated Allow further time to cure Remove and reinstate No Manual on site No Specification on site Personnel not trained Personnel not trained Obtain from Carboline Obtain from Carboline/Project Source trained personnel Conduct training Non-conforming Calibration of Equip Maintenance records Source Carboline approved equipment Re-calibrate and retain certification Introduce recording system and logs Air Temp too low Introduce heating or postpone application Dehumidify or introduce dry heat or postpone application Dehumidify/postpone application Introduce heating/ventilation where necessary or postpone application Over thickness (b) Uncured primer (a) Uncured primer (b) Remedial Measure Site Organization/Personnel Equipment Application Conditions Dew point Humidity too high Substrate temp too high/Low Inadequate weather protection Inadequate environment control Application Manual Revision Dated: May 2014 Create microclimate or postpone application Create microclimate or postpone application 57 of 61 Number Non Compliance/ Conformity Procedure/Operation Material Storage Temperature extremes Environment extremes Fail during bend test Cleanliness (b) No ratio records Out of ratio Mixing (Out of spec.) Over thickness Apply further coat, observing over coating instructions Record and adjust target for subsequent coats Reinforcement Wrong type (a) Wrong type (b) Elapsed Time from Pyroclad X1 application Insufficient overlaps Wrong Position (a) Wrong Position (b) 12 Reinstate surface Re-prepare surface under extreme circumstances Review QC procedures and include Initiate check of applied material Halt production and service equipment Production not to resume until ratio check is acceptable Change mixer/blade Increase time allocated for mixing Initiate check of applied material Thickness (1st Coat) Under thickness 11 Mark-out and install extra pins Maximum 300 mm centers Adjust welding settings and repeat test until 100% pass Pre-application Cleanliness (a) 10 Remove to controlled environment Remove to controlled environment Pin Welding Pattern/Spacing Remedial Measure Remove and reinstate with correct type Install additional PYROCLAD X1 on top and incorporate correct mesh and arrangement Install minimum thickness of PYROCLAD X1 and roll mesh into wet material Install strips of mesh to achieve required overlaps Remove and reinstate Install additional PYROCLAD X1 on top and incorporate correct mesh arrangement Subsequent coats Overcoat Interval exceeded (a) Reference Section 8.7.1 - RECOAT INTERVALS Contaminated base coat Depending on extent and type of contamination, solvent washing or mechanical abrasion Thickness Record and adjust target for subsequent coats Application Manual Revision Dated: May 2014 58 of 61 Number 13 Procedure/Operation Final coat Non Compliance/ Remedial Measure Conformity ***Procedures in Number 10 also apply here*** No action unless required by project Mechanical Over thickness removal is the only repair procedure Under thickness Install additional material Aesthetics (a) Install additional material to required standard Aesthetics (b) Mechanically rework surface Topcoat 14 Elapsed over coating time Non approved topcoat Incompatible topcoat Over/under thickness Solvent reactivation or mechanical abrasion depending on condition of surface Contact Carboline for approval Remove and reinstate with compatible system Contact Carboline for approval ***ONLY TO BE USED IN CONJUNCTION WITH SITE QC FLOW CHART*** Application Manual Revision Dated: May 2014 59 of 61 TYPICAL INSPECTION EQUIPMENT LIST Typical Inspection Equipment List Equipment Type Comments DFT Gauge Electronic, probes Keep probe clean and free of wet paint and PYROCLAD X1 Not suitable for thicknesses suitable for use in conjunction with wire mesh reinforcement up to 20mm WFT Gauge Metallic Do not use plastic types Do not clean gauge with grinding paper or similar mechanical action Always clean immediately after each measurement e.g with thinner Measurements should be made immediately (within minutes) after application Temp/humidity/ dew Electronic Calibrated regularly With two fixed Make sure that the wet thermometer is moist with preferably distilled thermometers water Sling for two (2) minutes, read, sling for another ½ minute, point meter Sling Psychrometer read, continue until two consecutive readings give the same results Dew Point Calculator The disc-type is Consists of two overlapping discs with the same rotation centre recommended Surface Thermometer Mechanical or Calibrated regularly, able to read substrate and liquid surface Electronic temperatures Ruler/tape measure Steel Measuring size of steel for calculation purposes Vernier Caliper Steel Precise measurements Knife Folding or safety fitted High quality steel, sharp Preferable with attachment to conduct cross hatch adhesion test where necessary Marking Chalk Yellow or white, non-grease Filling Knife (Spatula) Keep clean and sharp Camera, Flash and Film Digital pocket size with Minimum megapixels built-in electronic flash and video enabled Note Book and Ball Pen Carboline Note Book Use waterproof pens for writing Marking Pens Permanent Ink Types Thick felt types, black, red and green Sealable plastic bags Application Manual Revision Dated: May 2014 Isolation of material samples if required 60 of 61 DETAILS OF INSPECTION POINTS Hold Point Inspection Document Acceptance/ Compliance Surface Preparation Y Y Y Primer Coat Y N Y Site Organization / Personnel N N Y Equipment N Y Y Application Conditions Y Y Y Material storage Y Y Y Raw Material N N Y Pre-Application (1st Coat) Y Y Y Contractor must document that the surface is acceptable for over coating with PYROCLAD X1 and that plural machinery is functioning on the correct ratio Pin welding/attachment Y Y Y Contractor must conduct a pin bend test on the first 50 pins on a production run 100% pass required before initiating production Application (1st Coat) Y Y Y Wet film thickness checks taken during application and recorded Procedure/Operation Reinforcement Y Y Y Subsequent Coat(s) Y Y Y Final Coat Y Y Y Topcoat Y Y Y Application Manual Revision Dated: May 2014 Details All aspect of preparation of the substrate to be verified as in accordance with specifications and Carboline requirements This includes methods of preparation and the standards achieved + confirmation that the necessary standards of cleanliness and environmental control were achieved The specific type of primer coat(s) used must be approved by Carboline The applied DFT cure of primer and/ or adhesion characteristics are to be verified as acceptable Contractor must verify that key site personnel are qualified to apply PYROCLAD X1 Different projects require a higher % of trained operatives but as a minimum the Site Supervisor, Lead Applicator and QC representative should be able to confirm and document their application qualifications The accepted equipment is listed in the PYROCLAD X1 application manual(s) The contractor shall demonstrate and document that the equipment is in the proper order This applies to both production and the calibration/operation of measuring / inspection equipment The ambient, substrate and general conditions for the working environment are listed in the Application Manual for PYROCLAD X1 It is the responsibility of the application contractor to adequately show that these have been followed during the application periods for PYROCLAD X1 The storage condition for PYROCLAD X1 is listed for both general and preproduction situations in the Application Manual for PYROCLAD X1 The application contractor must be able to show that these conditions have been achieved Contractor must record batch numbers and document those used in production, showing that the material is correct and within the specified shelf life Confirming also that any ancillary materials used are of the correct type Contractor must document that the reinforcement used is of the correct type and positioned within the PYROCLAD X1 to comply with Fire Test Certification The condition of the underlying PYROCLAD X1 is specified in the Application manual and the contractor must be able to document that this has been complied with Overcoat conditions, especially elapsed time between coats should be recorded as complying with the Application manual If not the final coat then the thickness should be checked with a wet film gauge and recorded Overcoat conditions should be recorded as complying with the Application manual If not the final coat then the thickness should be checked with a wet film gauge during application and then with an approved device or method once sufficiently cured The final thickness must comply with fire test certification Specific topcoats are required for certain duties These are detailed by Carboline and the contractor must be able to document that these requirements have been followed together with the proper application conditions for the topcoat itself 61 of 61 ... PMT PFP QA/QC IRN PTW ASTM ISO NACE NFPA CPS CPT ITP CSDS DFT RAL RH CS SS DSS SDSS HDG VOC TDS Sao Vang Dai Nguyet Project Project Management Team Passive Fire Protection Quality Assurance/ Quality... Design and thickness of Pyroclad X1 for fire protection of divisions and supporting structure for Sao Vang Central Process Platform (CPP) – Rev.3.2 – 27 Oct 19 Definitions of fire rated divisions... DNVGL-CP-0338, Section Form code: TA 1411a Revision: 2015-05 www.dnvgl.com Page of Project – Idemetsu Sao Vang Dai Nguyet Cellar Deck Pyroclad X1 Loadings Date: 18/07/2019 Ref: MJO PFP Contractor: PTSC