No.

TECHNICAL SPECIFICATION I-ET-3010.00-1200-940-PPC-001

CLIENT OR USER SHEET
E&P – BACIA DE CAMPOS 1 of
14
JO B O R PRO JECT CC
PRODUCTION UNITS
PETROBRAS AREA O R UNIT
WITHOUT SCALE
TITLE

CENPES THERMAL SPRAY COATING APPLICATION OF ALUMINUM

MICROSOFT WORD / V. 7.0 / GTET-GEN14_D.DOC

INDEX OF REVISIONS

REV DESCRIPTION AND/OR REVISED SHEETS

0 ORIGINAL
A APPROVED BY E&P
B HEADER UPDATED
C INDEX INCLUDED, SECTIONS 5.4, 5.5, 7.2, 8, 9.1, 9.2 AND APPENDIX A - ITEM 3 REVISED
D GENERAL REVISION – IN ACCORDANCE WITH DIP-CENPES/DIPREX-028/2000

ORIGINAL REV. A REV. B REV. C REV. D REV. E REV. F REV. G REV. H

DATE 15/9/97 10/10/97 5/10/98 1/12/99 14/4/00
DESIGN CENPES CENPES CENPES CENPES CENPES
EXECUTION M. PIZA M. PIZA LLA M. PIZA M. PIZA
CHECK RIVADAVIA RIVADAVIA LHA LLA LLA
APPROVAL GOULART GOULART GOULART VGM CDV
THE DAT A, OR PART THEREOF, ARE PETROBRAS PROPERTY AND THUS MUST NOT BE USED IN ANY W AY W ITHOUT PERMI SSION
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1 - INTRODUCTION

2 - SCOPE

3 - DEFINITIONS

4 - REFERENCES

5 - GENERAL REQUIREMENTS

6 - HEALTH, SAFETY AND ENVIRONMENT

7 - SURFACE PREPARATION

8 - COATING APPLICATION

9 - INSPECTION AND TESTING

10 - REPAIRS TO COATING

APPENDIX A - OPERATOR QUALIFICATION TEST

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1 - INTRODUCTION

This specification outlines the detailed technical requirements to coating material and application
procedures including sealer coats.

2 - SCOPE

This document gives the requirements for coating materials, surface preparation, application
procedures and inspection for aluminum metal spraying to be applied during the construction and
installation of offshore installations and associated facilities, and for onshore installations exposed to
similar conditions.

3 - DEFINITIONS

In this specification the following definition is applicable:

TL V: Threshold Limit Value for chemical substances in the working environment.

4 - REFERENCES

ASTM D 4541 (1995) - Pull-off strength of coatings using portable adhesion testers.

ASTM C-633 (1993) - Adhesive or Cohesive Strength of Flame Sprayed Coatings.

ISO 8501 - Preparation of steel substrates before application of paint and related products - visual
assessment of surface cleanliness.

ISO 8503 - Preparation of steel substrates before application of paint and relates products - surface
cleanliness characteristics of blasted cleaned substrates.

ISO 8504 - Preparation of steel substrates before application of paints and related products - Surface
Preparation Methods Point 2 - Abrasive blast-cleaning.

BS 5493 (1977) - Code of practice for protection coating of iron and steel structures against
corrosion.

SSPC Vol.2 - Steel structure painting manual.

DIN 8566/2 (1984) - Zusätze für das thermische Spritzen.

DVS 2302 (1995) - Corrosion Protection of Steel and Cast Iron Materials by Thermally Spraying
Zinc and Aluminum Coatings.

ANSI/AWS-C-2.18 - Guide for the Protection of Steel with Thermal

Sprayed Coatings of Aluminum and Zinc and Their Alloys and Composites.
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5 - GENERAL REQUIREMENTS

5.1 Planning

All coating related activities shall be fully incorporated in the fabrication plan. Steel surfaces shall
normally be blast cleaned and coated prior to installation.

5.2 Scaffolding Staging Accessibility and Lighting

Scaffolding and lighting to allow for application and inspection shall be erected for all work.

Fixed scaffolding, staging, trolleys, cradles etc. shall be used as required for surface preparation and
painting. They shall be such that easy and sufficient access will be provided for correct painting and
inspection of all surfaces.

5.3 Equipment Protection and Clean up

All equipment and structures, and any other areas as required by BRASOIL, shall be fully protected
from mechanical damage due to, for example, ingress of abrasives from blast cleaning, damage from
the coatings operation.

The protection provided shall be strong enough to protect equipment during blast cleaning operations
and coating operations.

On completion of the work in any area, all masking, blast medium, equipment, etc. shall be removed
completely.

5.4 Ambient Conditions

No final blast cleaning or coating application shall be done if the relative humidity is more than 90%
and when the steel temperature is less than 3°C above dew point temperature.

No coating shall be applied at temperature below 0°C.

5.5 Coating Materials

The material to be used for metal spraying shall meet the following specification:

Aluminum of a quality at least equal to that of type Al 99,5 in DIN 8566/2.

All coating metals shall be supplied with quality control certificates and be marked as with:

Manufacturer’s name, Metal, Composition, Date of manufacturing standard, Batch or Cast no.

5.6 Steel Materials

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Steel subject to surface preparation on site shall, as a minimum requirement, be in accordance with
Rustgrade B according to ISO 8501-1.

5.7 Handling and Storing of Coating Materials

All materials used for steel pre-treatment and coating shall be stored and handled in accordance with
a procedure securing that climate or other injuries will not affect them.

5.8 Handling and Shipping of Coated Items

Coated items shall be handled to avoid damage to coated surfaces.

5.9 Pre-qualification of Personnel and Procedures

Prior to the start of coating, the coating operation shall be qualified as follows:

A detailed procedure shall be submitted to BRASOIL for acceptance. The procedure shall include
details of surface preparation, materials specification equipment and application.

A test shall be carried out to verify the suitability of the recommended coating procedure. A test
place shall be coated in accordance with the application procedure and under conditions simulating
those of the actual production coating. Contractor shall demonstrate that all requirements of this
specification are fulfilled in a repeatable manner.

The test results are subjected to BRASOIL’s acceptance in accordance with the requirements in this
document prior to any work start.

Curriculum Vitae shall be presented for supervisors, QC inspectors and operators.

All operators shall be qualified in accordance with Appendix A.

5.10 Documentation

The following documentation shall be recorded for all coating activities:

Before commencing work:

Details of facilities, management, inspectors, operators and equipment.

Written confirmation that pre-qualification tests as required in section 5.8 of this specification have
been carried out and found acceptable.

During the work:

A record shall be maintained daily and shall include but may not be limited to the following:
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Weather conditions, humidity, temperatures, blasting medium, activity (i.e., blast cleaning), method
of application, film thickness, batch numbers, together with details of inspections/test/corrective
actions carried out.

6 - HEALTH, SAFETY AND ENVIRONMENT

Before carrying out any work, CONTRACTOR shall recognize and evaluate all substances hazardous
to health. Exposure to these substances shall be prevented or adequately controlled by measures such
as: elimination, substitution, containment or control equipment, e.g. If none of these measures can
provide an effective solution, suitable personal protection shall be provided. Training shall be given
in the use of hazardous materials and personal protection equipment. In the case of toxic substances
medical surveillance may be required.

CONTRACTOR shall develop and implement procedures to maintain safety requirements for the
following:

Fire and explosion hazards, e.g., accumulation of metal dust.

Provision of equipment for personal protection.
Filters and breathing apparatus related to coating materials and the blast cleaning abrasives.
Use of high pressure equipment
Use of skin irritating chemicals
Earthing of equipment
TLV values given on Safety Data Sheets
Information on product tin labels
Explosion proof lighting equipment
Waste handling and deposition
Use of dangerous substances and preparations.
Entering of tanks and closed environments.
Scaffolding

7 - SURFACE PREPARATION

7.1 Pre-Blasting Preparations

Special attention shall be given to all weld areas for removal of weld flux, weld spatter and other
foreign objects before blast cleaning.

Sharp edges, fillets, corners and welds shall be rounded or smoothed by grinding (min R = 2 mm).

Any major surface defects, particularly surface laminations, slives 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 reblasted
to the specified standard. All welds shall be inspected and if necessary repaired to final blast cleaning
of the area.

Salt and soil shall be removed from the steel surface by using high pressure fresh water and when
necessary, by brushing.

Any oil and grease contamination shall be removed by solvent or alkali cleaning prior to blasting
operations, in accordance with SSPC-SP-1.
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7.2 Blast Cleaning

The compressed air supply shall be free from moisture and oil.

Blast abrasives shall be aluminum oxide for the final blasting (95% pure aluminum oxide can be
used) in case of hand applied coatings. If the coating application process is an automatic type other
abrasives such as steel grit or corundum may be used and even recycled. Size of abrasive particles for
blast cleaning shall be such that, except where otherwise specified, the prepared surface profile
height (anchor pattern profile) is in accordance with Grade Coarse (G) (85-130 µm, Ry5) as specified
in ISO 8503-1, Section 5, Table 2. The method of grading of the surface profile shall be in
accordance with ISO 8503-4. Also this abrasive shall provide Ra>6µm and Sm<300µm in
accordance with DVS 2302.

Roughness field control shall be made by measuring the Ry5 on at least 3 points at the start of each
shift.

Blasting abrasives shall be dry, clean and free from contaminants, which will be detrimental to the
performance of the coating.

Precautions shall be taken to avoid accumulation of foreign materials in re-cycled blast cleaning
abrasives.

The cleanliness of the blast-cleaned surface shall be Sa 3 (if flame spray process is to be used) or at
least Sa 2 1/2 (for arc spray process) in accordance with ISO 8501-1, at the time of coating
application.

After blasting, no visible dust, loose blast abrasives etc. shall remain on the surface.

Any blasted surface that has become wet by rain or moisture shall be reblasted.

Significant laminations or other steel surface defects exposed by the blast cleaning process shall be
marked by the operators, corrected and then rebasted.

Abrasive blasting operations shall be separated from thermal-spraying, sealer, or overcoat application
operations and previously sealed or over coated surfaces that are not dry.
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8 - COATING APPLICATION

8.1 Selection of Processes

Blast cleaned surfaces shall be thermal-sprayed immediately after blast-cleaning and in any other
case within 4 hours of blast cleaning. Surfaces which show rust-bloom, surface oxidation, or other
surface coloration shall be reblasted prior to thermal-spraying.

Wire electric arc spraying shall always be the preferred process for coating with aluminum.
Automated process is preferred for large areas especially for external tubular coating.

Use of wire flame spraying is subject to BRASOIL acceptance, especially for small areas which are
otherwise difficult to coat. External powder flame spray processes shall not be used under any
circumstances.

The surface part which is to be manually thermal-sprayed using the wire flame spray process shall be
preheated to 50-70ºC using the flame gun with a neutral flame.

The thermal spray systems shall be capable of uniform spray application for a continuos 20 minutes
and during start and stop operation cycles. Wire fusing, sputtering or globular spitting is not
acceptable.

Compressed air shall be free of oil and condensed moisture. Filters, dryers, separators and traps shall
be used as necessary to remove moisture.

The air pressure shall be adjusted to atomize the metal to the smallest possible size.

8.2 Application of Thermal Sprayed Coating

Each coat shall be applied uniformly. The coat shall be applied in multiple layers and shall overlap
on each pass of the gun. For items that will be welded after spraying, a minimum 25 mm and
maximum 100 mm measured from the bevel area shall be left uncoated.

The coating shall be firmly adherent. After spraying, the surface shall be uniform and free of lumps,
loosely adherent spattered metal and uncoated spots.

Spray guns used to apply thermal-spray aluminum coatings shall be held approximately
perpendicular to the surface and with a standoff distance within 150-300 mm. Passes shall overlap by
at least 50%.

Before the application of any further coat, any damage to the previous coat shall be repaired.
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8.3 Coating Thickness

Coating metal thickness shall be 225µm minimum and 400µm maximum before sealing. When
maximum value is exceeded the knife peel test shall be performed in accordance with ANSI/AWS-C-
2.18.

Metal spray coatings shall not be applied before the surfaces have been inspected and the preparatory
work approved. Prepared surfaces shall not be allowed to come into contact with any contaminant
during handling including bare hands, handling devices and other oily or greasy surfaces.

8.4 Application of Sealer

The sealer must be thinned to enable through porosity penetration. Seal until absorption is completed.
Sealer coats shall be thinned using the manufacturer’s recommended thinner to a 1:1 ration of mixed
product and solvent before application.

For ambient temperatures lower than 50ºC, resins shall be 2 component epoxy polyamide (maximum
20% of solids per volume). For components which will be immersed in seawater environment the
sealer thickness shall not exceed 25 µm above the sprayed layer, when a cathodic protection effect is
required. For subsea components which are to be inspected while in service, color should only be
matt white or yellow.

For ambient temperature higher than 50ºC a silicone resin shall be used. Thickness shall not exceed
25 µm.

The sealer shall be applied within 24 hours after completion of the aluminum thermal spray.

Sealer application may be performed only when the environmental conditions fall within the
humidity and temperature constraints recommended by the coating manufacture. In no case is sealer
application permitted when the temperature is less than 3ºC above the dew point.

Dry film thickness gages shall be calibrated at the start of each component which they are to be used.

8.5 Field Coating of pipes and coating of infill steel

The sealing coat shall stop 20 -30 cm away from the weld area. Before the metal coating operation
starts, the metal coated area 30 - 40 cm in distance from the weld zone shall be sweepblasted to
ensure that all contaminations are removed. The uncoated welding zone shall be blast cleaned to Sa3
or Sa21/2 according to section 7. The metal coating shall be performed according to section 8, and
the metal coating operation shall always start in the weld zone, not on the previously metallized area.
After the application of the sprayed coating to the weld area the sealing shall be applied overlapping
the already sealed area in at least 50 mm. A procedure according to section 5.8 shall be subject to
acceptance by BRASOIL before work start.
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9 - INSPECTION AND TESTING

9.1 General

Aluminum Thermal sprayed coatings shall be inspected after blasting and after spraying but before
sealing and top coating.

Testing and inspection shall be carried out and recorded in accordance with Table 9.1 and section 9.2.
and 9.3. Surface shall be accessible until final inspection is carried out.

Table 9.1. - Inspection and testing

Test type Method Frequency Acceptance Consequence Remarks

Criteria s
Environmental Ambient and Before start of In accordance No Blasting
Conditions steel each shift + with specification or coating
temperature. Twice pr.
Relative shift
humidity. Dew
point
Visual Visual for sharp 100% of all No defects, ref. Defects to be
examination of edges, weld surface spec. repaired
blasted surface spatter, slivers, requirements
rustgrade etc.
Cleanliness ISO 8501-1 100% visual In accordance Reblasting
of all surfaces with specification
Roughness Comparator or Each Specification Reblasting
Stylus component
Instrument (ISO and min. once
8503-4) pr. 10m2
Visual 100% of No defects, Repair The coated
Examination surface after scratches, dents, surface
of coating coating cuts, bubbles, ash shall be of
formation or uniform
uncoated areas appearance
are acceptable

Film Thickness See section 9.3

Adhesion See section 9.2

9.2 Adhesion

Method

The adhesion tests shall be carried out in accordance with ASTM D 4541 for production tests and
ASTM C-633 for qualification tests. All specimen shall be unsealed.

Test equipment is subject to acceptance by BRASOIL.

Frequency
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On all items during qualification (five specimen for each component, according to ASTM C-633). On
one test plate for each 10 first shifts and spot checks during coating application (two production test
for each component, according to ASTM D-4541).

Acceptance Criteria

The acceptance criteria for adhesion during qualification shall be minimum 9,0 Mpa. Adhesion
measured during production shall be minimum 7,0 Mpa. All requirements shall be fulfilled and no
single test values shall be below the specified value.

Consequence

Coating to be rejected.

9.3 Film Thickness

Method

The dry film thickness of individual coats and the coating system shall be checked by means of an
electromagnetic thickness gauge.

Calibration

The thickness gauge shall be calibrated at least once every 4 hours during use. The thickness gauge
shall be calibrated using foils in the thickness range being checked, on smooth (unblasted) steel.

Frequency

Large areas: Make 5 separate spot measurements (spot is average of 3 reading approximately 25 mm
apart) spaced evenly out each 10 m2 of area to be measured.

Other items: Make 1 spot measurement on each coated surface (plane), min. 30 mm from
edges/corners, on beams etc. up to 2 m length, and for each 2m length.

All measurements shall be recorded.

Acceptance Criteria

No single spot measurement shall be less than the specified thickness. Any one of the three readings
that are averaged to produce each spot may under-run by 10%.

10 - REPAIRS TO COATING

Flame spraying may be used for repair work of aluminum coating when the use of arc-spraying
equipment is difficult (limited accessibility), subjected to BRASOIL approval on a case-by-case
basis.

Where only the sealer coating has been damaged, the surface shall be prepared by abrasion with #60
abrasive paper until a clean bright surface is evident and edges of existing coatings are feathered. The
sealer shall then be reapplied on the damaged area
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When the underlying thermal sprayed coating has been damaged to the substrate, coatings shall be
removed completely in the damaged area by blast cleaning (to Sa 3 or Sa21/2 according to section 7
in this specification) and the full coating system replaced in that area.

Edges of the coating around the damaged area shall be feathered and cleaned where any overlap of
thermal sprayed aluminum is anticipated. Sealer material shall be overlapped onto existing coating
around the repaired area, and care shall be taken to ensure that no cracked or poorly overlaps exists.

The repairs shall be coated with metal according to section 8 of this specification.

Coatings repair shall be reinspected. After the repair, the coating shall have a uniform appearance
with a smooth transition between the repaired and previously coated area.

Repairs shall be inspected and tested for thickness according to section 9 of this specification.
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APPENDIX A

OPERATOR QUALIFICATION TEST

1) SCOPE OF TESTING

This test shall be performed to verify operator’s ability to perform the metal spraying according to
the applicable qualify standards.

All operators shall be qualified according to this test regardless of previous experience.

2) QUALIFICATIONS

Operators shall have an experience of at least 3 years relevant to coating application and 2 years to
blast cleaning as applicable.

The list of operators nominated for work shall be submitted to company for acceptance before start of
qualification. The list shall identify experience and qualification for each operator.

3) TEST

3.1) Preparation of Test Specimens

3.1.1) Specimens for visual and bend tests

Four panels of a comparable grade to be used in production and of minimum dimension 75 by 50 by

1,25 mm shall be sprayed on one of the large faces using the appropriate spraying procedure. The
coating thickness shall be within 225-400 µm. The same panel may be used for visual and bend test.

3.1.2) Specimens for the adhesion tests

Five specimens shall be prepared, according to the requirement of ASTM C 633 for the qualification
tests, and the average value calculated. The ASTM D-4541 shall be applied for the production tests.
Examination of the test specimens shall be conducted after rupture to determine the cause of failure.
A new specimen or test shall be conducted if examination concludes that the failure occurred at the
adhesive-coating interface. Adhesives shall be well selected to minimize such event. All tests shall be
performed on a nonsealed surface.

3.1.3) Specimens for shape test

One specimen shall be manufactured in relevant T, H or I shape and as a pipe spool. The specimen
material shall be the applicable substrate and shall be coated using the appropriate procedure.
Thickness measurements and visual inspection shall be conducted to evaluate the operator ability
with more complex geometry’s.

One of the above specimens shall be prepared with a Sa21/2 blasting grade to be used for microscope
cross section evaluation.
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3.2) Visual Examination

The surface appearance of each of the panels shall meet requirements of section 8.2.

3.3) Bend Test

The sprayed panels shall be bent minimum 180 degrees around a 13 mm diameter mandrel. The
coating shall be on the tensile side of the bend. No disbonding, delamination, or gross cracking of the
coating shall occur due to bending. Small hairline cracks or alligatoring of the coating near the bend
is permissible.

3.4) Thickness Testing

The thickness of the sprayed metal coating shall be measured in different areas to determine that the
coating thickness is within the requirement across the specimen surface.

3.5) Cross Section Examination

Cross section examination shall be conducted with a minimum 50X magnification in two sections of
a representative area of the Sa 2 1/2 blasted shape test specimen to ensure penetration of the sealer
into the aluminum. The examined cross section shall have less than 12% porosity and the maximum
dimension of any void shall not exceed 50% of the thermal sprayed aluminum thickness.

3.6) Test Results

The results of all tests and examinations shall be documented and presented to BRASOIL for
acceptance.

4) RE-TEST OF OPERATORS

An operator failing the initial certification tests may be permitted to perform one re-test for each type
of test failed. If the operator fails the re-test, he shall not be allowed to carry out testing until
completion of training or retraining and subsequent complete re-testing. The test results are valid for
max. 6 months without regular coating work.