6778 EQS G0000 EB 0007 - Painting

HPL Contract No.
Plant Client Contract Code Document ID

4010464
PROJECT Haldia HPL tkIS Contract No.

6778-EQS-G0000-EB-0007 66-6778
HAVEN Petrochemicals Ltd. OCU-CPU
GENERAL ENGINEERING SPECIFICATION

PAINTING
Rev 01 Page 1 of 6
Amol
Karmarkar
2023.10.04
Classifi 17:32:55
+05'30' Shrikrishna
Rawool
Shrikrishna
Rawool
04-Oct-23
cation:
Interna Revised as marked in BOLD & Italic 03-10-2023 AKR/ NLS 04-10-2023 SRL/ MDT 04-10-2023 MBM -
01
l and issued for engineering
00 First Issue 14-09-2023 AKR/ NLS 14-09-2023 SRL/ MDT 14-0-2023 MBM -
Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -
Barcode
© thyssenkrupp Industrial Solutions (India) Private Limited 2021
Classification: Confidential
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778

PAINTING
Rev 01 Page 2 of 6
Contents:
1 Scope .................................................................................................................................................. 3
2 General ............................................................................................................................................... 3
3 Approved Paint manufacturers ........................................................................................................... 4
4 Painting of Stainless steel surfaces .................................................................................................... 4
5 Painting of steel surfaces under fireproofing ...................................................................................... 5
Annexure-1 : Reference tkIS India Standards ...................................................................................................... 6
Annexure-2 : Reference Painting specification standards ................................................................................... 6
Appendix A Colour coding and lettering of Equipment and piping
Classification: Internal
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778

PAINTING
Rev 01 Page 3 of 6
1 Scope
This specification defines the general requirements for painting. Painting includes surface preparation,
clean up, supply and application of paint on external surfaces of equipments, pipelines and structurals
etc. This specification is applicable for all CS, SS & LAS surfaces.
Painting shall not applied on Non-ferrous alloys.
This specification does not include painting for electrical items such as motors, transformers etc. For
electrical items, painting shall be as per electrical specification except colour coding. Painting for rotating
equipments and concrete surfaces is not covered in this specification. Finish Colour coding shall be as
defined in this specification.
The touchup for damaged areas where equipment painting is not originally included shall be in painting
contractor’s scope. The same shall be carried out in co-ordination with site personnel and quantum of
area for touch up, if any, is to be mutually agreed up on during execution of painting work at site.
In case of imported items, wherever commissioning/erection or both are included in foreign vendor’s
scope, painting touch up is to be done by the foreign vendor. Otherwise, it will be done by painting
contractor as per instructions given by foreign vendor/tkIS India site office.
Internal lining and coating are not covered in this specification. Painting for underground pipelines is
also not covered in this specification.
In case of conflict between this specification and other related specifications, vendor shall notify tkIS
India.
2 General
All painting of steel surfaces shall be performed in accordance with standard Annexure -2 and
manufacturer’s recommendation.
For under insulation painting refer :Annexure -2

Document Ref no HPL/IMS/MECH/SMP/7.5.1/10/ANNEX-I-R-1.
For FRP coating specification refer : Annexure – 2

Document Ref no IP/G/GEN/IS_FRP COATING
All surface preparation shall be in accordance with detailed painting systems and respective latest IS
standards .
Quantity survey for painting shall be as per UN 9257-91.
Scope of painting for various equipment shall be as below:
• For all shop & site fabricated equipment , surface preparation and complete painting upto final
painting are in equipment manufacturer’s scope.
• For package unit and package items, derusting, primer and final painting is included in
package vendor’s scope of supply.
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778

PAINTING
Rev 01 Page 4 of 6
• Surface preparation and complete painting of piping is included in painting contractor’s scope.
• Surface preparation and primer painting of steel structures is included in steel fabricators
scope. Further painting is included in painting contractor’s scope.
• Various equipment, pipe lines, structural etc. to be painted as per this Technical specification
are separately listed and form part of the painting enquiry document.
• Technical requirements of Colour coding and lettering shall be as per Appendix -A.
For colour identification refer Annexure-2; HPL spec IP/ G/ Gen / IS_PAINT Rev-03
• Wherever blast cleaning is not possible, consult tkIS India for alternate surface protection
system.
3 Approved Paint manufacturers

The paints intended for use in this specification are classified on the basis of pigments and binders.
Approved equivalent products of listed manufacturer’s conforming to the specified paint are to be used.
Refer Annexure -2 ; Ref No -IP/G/Gen/IS_PAINT Rev-03 for approved paint manufacturers.
4 Painting of Stainless steel surfaces

Coating materials used in direct contact with austenitic stainless steels, shall meet the following
requirements:
• The inorganic halogen content shall be less than 200 ppm by weight.
• The total halogen (inorganic and organic) content shall be less than 1% by weight.
• The sulfur content shall not exceed 1% by weight.
• Low melting point metals (lead, bismuth, zinc, mercury, antimony, cadmium, and tin) shall not
be intentionally added to the coating material. This includes inorganic zinc and zinc rich epoxy
coatings.
Painting of SS surfaces which are under insulation shall be as follows.
MOC Insulated Operating Degree of Degree of Abrasive Prime Total
temperature cleanliness roughness coat (DFT in
(microns- microns)
(No of
Peak to
coats X
valley)
DFT in
µm)
Stainless Yes Above 50°C SSPC 25 to 30 Only Aluminium Inorganic 250
steel upto 175°C SP5/ISO oxide shall be co-
8501-1 Sa3 used as blasting polymer
medium as per
(2 X125µ)
ISO 11126-7
Note : 1)Insulated austenitic SS surfaces which are outside above specified temperature range does not
require painting.
2)Uninsulated austenitic SS surfaces does not require painting.
3) Stainless steel items under cold insulation shall not be painted but shall be wrapped with aluminum foil
before application of cold insulation unless specified otherwise.
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778

PAINTING
Rev 01 Page 5 of 6
5 Painting of steel surfaces under fireproofing

Refer below table.
MOC Operating Surface Surface First coat Finish coat Total (DFT in
temperature cleanliness Profile microns)
(No of coats X (No of coats X
(Peak to
DFT in µm) DFT in µm)
valley)
Carbon steel Upto 200°C SA 2 ½ 50-75 Epoxy or Epoxy or 200-300
under µm Epoxy phenolic Epoxy phenolic
fireproofing
(1 X 100-150 (1 X 100-150
µm) µm)
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778

PAINTING
Rev 01 Page 6 of 6
Annexure-1 : Reference tkIS India Standards
Standard No. Part Title Issue Dt
UN 9257-91 - ERECTION – QUANTITY SURVEY OF PAINTING 04-2009
UN 9250-01 1 (M) ERECTION – WAREHOUSING 08-2008
Annexure-2 : Reference Painting specification standards
IP/ G/ Gen / 2nd June,

Standard for Protective Coating (Painting) System
IS_PAINT Rev-03 2021
HPL/IMS/MECH/S
MP/7.5.1/10/ANN S-1 Annexure -I : Material Specification
EX-I-R-1
IP/ G/Gen/
S-1 FRP Coating specification 10/6/2023
IS_FRP COATING
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778
Appendix A
COLOUR CODING & LETTERING OF EQUIPMENT
AND PIPING Rev 01 Page 1 of 5
Amol
Karmarkar
Classifi 2023.10.04
17:33:12
+05'30'
Shrikrishna
Rawool
Shrikrishna
Rawool
04-Oct-23
cation:
Interna Revised as marked in BOLD & Italic 03-10-2023 AKR/ NLS 04-10-2023 SRL/ MDT 04-10-2023 MBM -
01
l and reissued
00 First Issue 14-09-2023 AKR/ NLS 14-09-2023 SRL/MDT 14-09-2023 MBM -
Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -
Barcode
© thyssenkrupp Industrial Solutions (India) Private Limited 2021
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778
Appendix A
Contents:
1 Procedure of Colour Coding of Pipelines ........................................................................................... 3
1.1 Application of Colour Band on uninsulated carbon steel surfaces ..................................................... 3
1.2 Application of Base Colour and Colour Bands on galvanised steel, stainless steel surfaces and
Aluminium Cladding and other non-ferrous piping but excluding plastics .......................................... 3
2 Marking by Lettering & Symbols ......................................................................................................... 3
2.1 Lettering .............................................................................................................................................. 4
2.2 Application of the markings ................................................................................................................ 5
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778
Appendix A
1 Procedure of Colour Coding of Pipelines

1.1 Application of Colour Band on uninsulated carbon steel surfaces
Colour bands will be located as mentioned below except that ground colour being continuous,
colour bands will be located at 15000 mm, pitch. Also colour bands will be marked at junctions,
near valves, joints, service appliances, bulkheads, walls etc. Finish (Top Coat) will be ground
colour in this case.
1.2 Application of Base Colour and Colour Bands on galvanised steel, stainless steel
surfaces and Aluminium Cladding and other non-ferrous piping but excluding
plastics
Ground or Base Colour (only for piping) will be a patch of width equal to 600 mm, at a pitch of
15000 mm. Ground colour will also be applied near valves, junctions, joints, service appliances,
bulk heads, walls etc.
First and second (if applicable) colour bands will be of 75 mm width. In case of single colour
band, the same will be at the centre of the round colour patch. In case of two colour bands,
they will be at the centre of the ground colour patch but with a gap of 75 mm between each
other.
The portion required to be painted shall be degreased and roughened by 180 grit sand paper.
After roughening surfaces, wash primer will be applied. Synthetic Enamel paint will be applied
as a base colour after drying of the wash primer. Colour bands will be put if applicable.
2 Marking by Lettering & Symbols

In addition to the colour coding according to Para 1.0 & Annexure-2; HPL spec IP/ G/ Gen /
IS_PAINT Rev-03, equipment and piping will be marked with lettering, colour bands or symbols
(e.g. arrows for indicating flow direction).
These markings will be lettering (e.g. Vessel No. identification of volume) and colour bands (e.g.
fluid marking, arrows for indicating flow direction).
Pipes of less than 3 M length shall not receive lettering, but one colour band only. Colour bands
for pipes shall be arranged maximum 1.5 M away from equipment. The blank space between
lettering and the symbols (e.g. arrows) shall be approximately 150 mm.
Table 1 Colours for Lettering and Symbols
Surface Lettering / Symbol

Yellow Black
Orange Black
Red White
Blue White
Green White
Grey Black
White Black
Black White
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778
Appendix A
2.1 Lettering
Lettering for equipment shall be placed on each item at a clearly visible location. The letters
should have the following sizes. The equipment dimensions considered below are for the
horizontal cross section.
- 50 mm or 80 mm for equipment with dimensions of <= 1 M
- 100 mm for equipment with dimensions of > 1 M to 5 M
- 300 mm for equipment with dimensions > 5 M to 15 M
- 600 mm for equipment with dimensions > 15 M to 50 M.
- 900 mm for equipment with dimensions > 50 M.
Lettering for piping shall be placed at clearly visible locations near the points where the piping
leaves the ground or the pipe bridge. Decisions about any further lettering required shall be
taken on site.
The letters should have the following sizes:
- 10 mm for pipes of <= DN 25
- 20 mm for pipes of > DN 25 to DN 80
- 100 mm for pipes of > DN 1000
The blank spaces between the letters shall be approximately 10% of the letter size. The type
of letters shall be determined on site. For the colour of the letters, Table 1 shall apply.
Lettering for tanks shall be placed at a height of approximately 4/5 of the shell height. Lettering
for horizontal vessels, spherical vessels and piping shall be placed at the height of the centre
line.
For the size of arrows for indicating flow direction the following shall apply.
Nominal Size Dimensions of Arrow in mm

DN Inch W1 W2 L1 L2
< 20 <¾ 3 9 8 20
20 To 40 ¾ to 1½ 5 15 13 35
50 To 80 2 to 3 10 30 26 65
100 To 150 4 to 6 15 45 40 100
200 To 250 8 to 10 30 90 80 200
300 To 400 12 to 16 50 150 130 325
450 To 600 18 to 24 80 240 210 525
> 600 >24 100 300 260 650
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778
Appendix A
2.2 Application of the markings
2.2.1 Prior to the application of lettering and colour bands, a surface preparation is required. Coated
surfaces shall be free from any contamination (e.g. dust, oil, grease, salts). The surfaces should
be treated with abrasive paper to improve adhesion on the marking.
Surfaces of galvanised steel, alloy steel, aluminium and other non-ferrous metals shall be
slightly roughened with abrasive paper.
For the materials for markings, the technical specification with annexure 2 shall apply.
2.2.2 In case of plastic surfaces, self adhesive foils should be used for marking. Self adhesive foils
shall be applied on surface which shall be clean, smooth and free from grease.
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778
Rev 01 Page of
Annexure-1
Reference tkIS India Standards
UN 9257-91 - ERECTION – QUANTITY SURVEY OF PAINTING 04-2009
UN 9250-01 1 (M) ERECTION – WAREHOUSING 08-2008
UHDE STANDARD April 2009
UN
Erection
9257-91
Quantity survey of painting
Page 1 of 15
Montage; Aufmaß von Korrosionsschutzarbeiten Supersedes UN 9257-91 Part 1, 01-06
Contents
Page
1 Scope .................................................................................................................................................................... 1
2 Units, Abbreviated Terms ................................................................................................................................... 1
2.1 Units....................................................................................................................................................................... 1
2.2 Abbreviated Terms................................................................................................................................................. 2
3 Technical documents .......................................................................................................................................... 2
4 General notes to quantity surveying.................................................................................................................. 2
5 Quantity survey of steel structures.................................................................................................................... 2
6 Quantity survey of process equipment.............................................................................................................. 4
6.1 General notes ........................................................................................................................................................ 4
6.2 Round vessels ....................................................................................................................................................... 4
6.2.1 Circular surfaces .................................................................................................................................................... 5
6.2.2 Oval surfaces ......................................................................................................................................................... 5
6.2.3 Cylindrical shell surfaces ....................................................................................................................................... 5
6.2.4 Conical surfaces .................................................................................................................................................... 5
6.2.5 Spherical surfaces ................................................................................................................................................. 6
6.2.6 Composite surfaces ............................................................................................................................................... 7
6.3 Rectangular vessels............................................................................................................................................... 7
6.3.1 Rectangular surfaces ............................................................................................................................................. 7
6.3.2 Trapezoidal surfaces.............................................................................................................................................. 8
6.3.3 Pyramidal surfaces ................................................................................................................................................ 8
6.3.4 Composite surfaces ............................................................................................................................................... 9
6.4 Equipment.............................................................................................................................................................. 9
6.5 Machinery .............................................................................................................................................................. 9
6.6 Ducts, chutes ....................................................................................................................................................... 10
7 Quantity survey of piping.................................................................................................................................. 11
7.1 General notes ...................................................................................................................................................... 11
7.2 Straight pipes ....................................................................................................................................................... 11
7.3 Fittings ................................................................................................................................................................. 11
7.3.1 Elbows ................................................................................................................................................................. 11
7.3.2 Tees..................................................................................................................................................................... 12
7.3.3 Reducers ............................................................................................................................................................. 12
7.4 Flanges ................................................................................................................................................................ 12
7.5 Valves .................................................................................................................................................................. 12
7.6 Pipe supports ....................................................................................................................................................... 12
8 Quantity survey of materials............................................................................................................................. 13
9 Damages to pre-coated surfaces...................................................................................................................... 14
9.1 Examples for damages ........................................................................................................................................ 14
Reference standards ......................................................................................................................................................... 15
Amendments ...................................................................................................................................................................... 15
1 Scope
This Uhde Standard (UN) applies to the design and construction of industrial and chemical plants. It contains
statements for quantity surveying of areas protected by coatings.
2 Units, Abbreviated Terms

2.1 Units
Table 1. Units
General SI-units
Dimensions mm
UF 19 ST-F01 M01 D 06-04
Weights kg, t
Weight of sections kg/m
Surface calculation coefficient m²/t
14.05.09 Kuhnke 25.05.09 Jakob 19.05.09 Fellner 26.05.09 Dr. Lazaridis

Date Prepared Date Checked Date Standardization Date Approved
© 2009 Uhde GmbH

UN
Erection
9257-91
Page 2 of 15
2.2 Abbreviated Terms

A = surface
AS = surface of supporting structures
b, B = width
d, D = outside diameter
h, H = height
l, L = length
r, R = radius
s, S = side length of a cone
U = circumference
3 Technical documents
The technical documents provided (e.g. quantity take-offs, isometrics, parts lists, drawings, technical specifi-
cations) shall be binding for the quantity survey, on the precondition that the services were performed in con-
formance with these documents. If such documents contain no compilations of quantities they shall be com-
piled based on the technical documents. If no documents exist about the items in question the service con-
cerned shall be measured during or after execution. This also applies if the execution deviates from the tech-
nical documents.
Modifications made without the approval of the site management shall be excluded from the measurement.
4 General notes to quantity surveying

The services and their estimated scope are described in the bill of quantities. These descriptions shall always
be understood as complete services including the necessary auxiliary services. Auxiliary services
(e.g. storage of painting materials, provision of scaffolding, cleaning of the surfaces to be painted) shall only
be included in the quantity survey if they are listed as individual items in the bill of quantities.
The quantity survey shall be prepared for each plant unit. Side calculations shall be attached to the quantity
survey.
Surfaces of fasteners (e.g. bolts, nuts, rivets, washers) shall not be measured. The areas covered by the fas-
teners and the holes required for the fasteners are considered by the stipulations of sections 5 to 7.
5 Quantity survey of steel structures

Quantity survey of steel structures shall be performed according to parts lists or based on the weight installed.
According to parts lists the quantities shall be measured in terms of m² by using the values of Table 2 and
Table 3. They shall be adapted accordingly, if others than DIN sections are used.
Individual lengths shall be determined to an accuracy of 0.1 m. The quantity survey shall only include the pain-
ted surfaces of the sections.
UF 19 ST-F01 M01 D 06-04
Figure 1. Uncoated surfaces of steel sections

Raised pattern plates (e.g. checkered plates) shall be considered as plates with a flat surface.
UN
Erection
9257-91
Page 3 of 15
If the quantity survey bases on the weight installed, the individual weights shall be determined to an accuracy
of 0.01 t. The following values shall be used for computing the surfaces:
• 15 m²/t for heavy structures (weight of sections > 60 kg/m),
• 22 m²/t for medium-weight structures (weight of sections > 30 to 60 kg/m),
• 28 m²/t for light structures (weight of sections > 10 to 30 kg/m),
• 40 m²/t for very light structures (weight of sections ≤ 10 kg/m).
Anchoring elements, fasteners, shims and uncoated items shall not be measured.
Table 2. Surfaces of I-beams in m²/m
DIN 1025-1 DIN 1025-2 DIN 1025-3 DIN 1025-4 DIN 1025-5
Section symbol HE-B HE-A HE-M
I I PB I PBI I PBv I PE
80 0.304 0.328
100 0.370 0.567 0.561 0.619 0.400
120 0.439 0.686 0.677 0.738 0.475
140 0.502 0.805 0.794 0.857 0.551
160 0.575 0.918 0.906 0.970 0.623
180 0.640 1.04 1.02 1.09 0.698
200 0.709 1.15 1.14 1.20 0.768
220 0.775 1.27 1.26 1.32 0.848
240 0.844 1.38 1.37 1.46 0.922
260 0.906 1.50 1.48 1.57
270 1.04
280 0.966 1.62 1.60 1.69
300 1.03 1.73 1.72 1.83 1.16
320 1.09 1.77 1.76 1.87
320/305 1.78
330 1.25
340 1.15 1.81 1.79 1.90
360 1.21 1.85 1.83 1.93 1.35
380 1.27
400 1.33 1.93 1.91 2.00 1.47
450 1.48 2.03 2.01 2.10 1.61
500 1.63 2.12 2.11 2.18 1.74
550 1.80 2.22 2.21 2.28 1.88
600 2.32 2.31 2.37 2.01
650 2.42 2.41 2.47
700 2.52 2.50 2.56
800 2.71 2.70 2.75
900 2.91 2.90 2.93
1000 3.11 3.10 3.13
UF 19 ST-F01 M01 D 06-04
UN
Erection
9257-91
Page 4 of 15
Table 3. Surfaces of channels / Z-bars / T-bars and angles in m²/m

DIN 1026-1 DIN 1027 EN 10055 EN 10056-1
Section
symbol Section Equal Section Unequal
Channel Z-bar T-bar
symbol angle symbol angle
30 0.174 0.198 0.114 20 × 20 0.077
30 × 15 0.103 25 × 25 0.097
35 0.133 30 × 30 0.116 30 × 20 0.097
40 0.199 0.225 0.153 35 × 35 0.136
40 × 20 0.142 40 × 20 0.117
40 × 40 0.155
50 0.232 0.253 0.191 40 × 25 0.127
50 × 25 0.181 45 × 45 0.174 45 × 30 0.146
60 0.215 0.282 0.229 50 × 50 0.194 50 × 30 0.156
65 0.273 60 × 30 0.175
60 × 60 0.233
70 0.268 60 × 40 0.195
80 0.312 0.339 0.307 65 × 65 0.252 65 × 50 0.224
100 0.372 0.397 0.383 70 × 70 0.272 70 × 50 0.235
120 0.434 0.454 0.459 75 × 75 0.291 75 × 50 0.244
140 0.489 0.511 0.537 80 × 40 0.234
80 × 80 0.311
160 0.546 0.569 80 × 60 0.274
180 0.611 0.626 90 × 90 0.351
200 0.661 0.683 100 × 50 0.292
220 0.718 100 × 100 0.390 100 × 65 0.321
240 0.775 100 × 75 0.341
260 0.834 120 × 120 0.469 120 × 80 0.391
280 0.890 125 × 75 0.392
300 0.950 130 × 130 0.508
320 0.982 135 × 65 0.392
350 1.05 150 × 75 0.441
380 1.11 150 × 150 0.586 150 × 90 0.469
400 1.18 150 × 100 0.489
160 × 160 0.625
180 × 180 0.705
200 × 100 0.587
200 × 200 0.785
200 × 150 0.687
250 × 250 0.962
6 Quantity survey of process equipment

6.1 General notes
Painted surfaces of individual items of equipment and machinery shall be determined to an accuracy of
0.5 m². Cut-outs and openings of > 0.5 m² shall not be measured, i.e. they shall be regarded as non-coated
surfaces. Cut-outs and openings of ≤ 0.5 m² shall be disregarded for the quantity survey, i.e. they shall not be
deducted.
Painted insulation claddings shall be computed from the outer dimensions of the equipment or machinery,
increased by the insulation thickness.
Piping pertaining to equipment or machinery shall be measured according to section 7. Surfaces of supporting
structures, reinforcing members made of steel sections and the like shall be measured according to section 5.
For determining the surfaces, the formula given in sections 6.2 to 6.6 shall be used or adapted accordingly.
UF 19 ST-F01 M01 D 06-04
The abbreviations used in the formula are specified in section 2.2.
Surfaces of nozzles, manholes, vessel flanges and supporting brackets shall not be measured.
6.2 Round vessels

Quantities shall be measured in terms of m² with reference to the actual dimensions. The following formulae
are applicable to the various surfaces.
UN
Erection
9257-91
Page 5 of 15
6.2.1 Circular surfaces
A = 0.25 · π · D2
Figure 2. Circular surfaces

Conical heads and covers with angles of inclination ≤ 10° as well as dished heads shall also be considered as
circular surfaces.
As regards tanks and vessels on foundations, the bottom head surfaces shall only be included in the quantity
survey if they will be painted on site.
6.2.2 Oval surfaces
A=π·R·r
Figure 3. Oval surfaces

6.2.3 Cylindrical shell surfaces
A = π · D· H
Figure 4. Cylindrical shell surfaces

The height of conical heads and covers with angles of inclination ≤ 10° as well as of dished heads shall be
considered as cylindrical height.
6.2.4 Conical surfaces

Conical shell surfaces shall be considered as such whenever the angle of inclination is > 10°. The following
formulae apply to regular and irregular conical shell surfaces:
ratio D : d ≥ 10 Regular cone Irregular cone

A = 0.5 · π · D · S
S= 0.25 ⋅ D 2 + H2
UF 19 ST-F01 M01 D 06-04
ratio D : d < 10
A = 0.5 · π · (D + d) · S
0.25 ⋅ (D − d) + H2
2
S=
Figure 5. Conical surfaces

UN
Erection
9257-91
Page 6 of 15
Conical transitions of cylindrical shells with different diameters, where H ≤ 1 m and D : d ≤ 1.5 shall be consid-
ered as cylindrical shell surfaces.
Conical or pyramidal transitions from circular to angular cross sections, with D : b resp. D : l ≥ 10 and B : d
resp. L : d ≥ 10 shall be considered as a cone or a pyramid (see section 6.3.3). If the ratio is < 10, the quantity
survey shall be as for a truncated cone shell. The circumference of the rectangle shall be converted to a di-
ameter DT or dT.
A = 0.5 · π · S · (d + dT) dT = 0.64 · (b + l)
0.25 ⋅ (D − dT ) + H2
2
S=
A = 0.5 · π · S · (DT + d) DT = 0.64 · (B + L)
0.25 ⋅ (DT − d) + H2
2
S=
Figure 6. Transition surfaces
6.2.5 Spherical surfaces
A = π · D2
Figure 7. Spherical tank
The following applies to calottes (e.g. as tank roof):
A=2·π·R·H
H=R– R 2 − 0.25 ⋅ D 2
Figure 8. Tank roof with spherical surface

UF 19 ST-F01 M01 D 06-04
UN
Erection
9257-91
Page 7 of 15
6.2.6 Composite surfaces

For computing the total surface, use shall be made of the formula according to sections 6.2.1 through 6.2.5.
Verhältnis D : D ≤ 1.5
A = 0.25 · π · (D2 + d2) + π · D · H + π · d · h + 2 · π · D · L
Figure 9. Composite surfaces of cylindrical vessels (example)
Cut-outs in the skirt shall be taken into account as described in section 6.1.
A = 0.25 · π · D2 + π · D · H + 0,5 · π · D · S + AS
Figure 10. Composite surfaces of cylindrical vessels (example)
The cover surface A = 0.25 · π · D2 is omitted in the case of open vessels.
6.3 Rectangular vessels

Quantities shall be measured in terms of m² with reference to the actual dimensions. The following formulae
are applicable to the various surfaces.
6.3.1 Rectangular surfaces
A=L·B
Figure 11. Rectangular surfaces
Pyramidal covers with angles of inclination of ≤ 10° shall also be considered as rectangular surfaces.
UF 19 ST-F01 M01 D 06-04
As regards vessels on foundations, the bottom head surfaces shall be included in the quantity survey if they
will be painted on site. Cut-outs, openings, corners and the like of > 0.5 m² shall not be measured.
UN
Erection
9257-91
Page 8 of 15
6.3.2 Trapezoidal surfaces
A = 0.5 · H · (L + S)
Figure 12. Trapezoidal surfaces
6.3.3 Pyramidal surfaces

Pyramidal shell surfaces shall be considered as such whenever the angle of inclination is > 10°. The following
applies to regular and irregular pyramidal shell surfaces:
Front view Side view

ratio L : l or B : b ≥ 10
A=B·S+L·s
S= 0.25 ⋅ L2 + H2
s= 0.25 ⋅ B 2 + H2
Figure 13. Pyramidal surfaces
ratio L : l or B : b < 10
A = S · (B + b) + s · (L + l)
S= 0.25 ⋅ (L − l)2 + H2
s= 0.25 ⋅ (B − b)2 + H2
Figure 14. Surfaces of truncated pyramids
In the case of irregular pyramids and truncated pyramids, for S and s a mean value shall be determined.
Pyramidal transitions of different rectangles, where H ≤ 1 m and L : I or B : b ≤ 1.5, shall be considered as

rectangular surfaces.
UF 19 ST-F01 M01 D 06-04
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6.3.4 Composite surfaces

For determining the total surface, use shall be made of the formula according to sections 6.3.1 through 6.3.3.
Front view Side view
A = L · B + 2 · H · (L + B) + B · S + L · s + AS
Figure 15. Composite surfaces of rectangular vessels
The cover surface A = L · B is omitted in the case of open vessels.
6.4 Equipment
Quantities shall be measured in terms of m² with reference to the actual dimensions.
For the quantity survey, the individual equipment shall be divided into individual surfaces. The formula given in
sections 6.2 and 6.3 shall be used accordingly.
A = sum of all individual surfaces + A S
6.5 Machinery
Quantities shall be measured in terms of m² with reference to the largest dimensions.
For determining the largest dimensions, installed piping, electrical items, and instruments shall not be taken
into account.
The following applies to machinery and motors, which are mounted on a common base plate:
A = 2.5 · L · B + 1.8 · H · B + 1.8 · H · L
Figure 16. Surfaces of pumps and blowers

UF 19 ST-F01 M01 D 06-04
Machinery, gears, motors and the like without a common base plate shall be measured individually. The fol-
lowing note applies to each item:
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A = 1.8 · L · B + 1.8 · H · B + 1.8 · H · L
Figure 17. Surfaces of compressors and turbines
Cranes shall be compartmentalised into their components. Crane girders and end carriages shall be meas-
ured according to section 5. Crabs shall be considered as machines according to section 6.5 (machines with-
out common base plate).
Figure 18. Surfaces of cranes
Belt conveyors shall be measured according to section 5. Other conveying facilities (e.g. bucket elevators,
feed screws) shall be measured according to sections 6.4 and 6.5.
6.6 Ducts, chutes

Quantities shall be measured in terms of m² with reference to the outer dimensions.
Circular or angular ducts, chutes and the like shall be divided such that the formula according to sections 6.2
and 6.3 can be used.
The length of corner pieces and bends is deemed to be the length of the centreline.
A = (2 · B + 2 · L) · (H1 + H2 + H3 + 0,5 · π · R + H4 + 1,2 m)

UF 19 ST-F01 M01 D 06-04
Figure 19. Surfaces of ducts (example)

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Page 11 of 15
The (sheet metal) flanges shall be considered as 0.15 m of straight duct or chute length. For internals
(e.g. gate valves, butterfly valves), their outer dimensions shall apply. Operating elements (e.g. levers) shall
not be measured.
In case of open channels or ducts the cover surface will be omitted. For the example above the first multiplica-
tion factor for the area calculation shall then be reduced to (B + 2 · L).
7 Quantity survey of piping

7.1 General notes
For the quantity survey, the values of Table 4 are binding. Parts not included in this table (e.g. caps, wel-
dolets) shall not be measured.
Classification of the piping into the corresponding nominal diameters shall be based on the outside pipe
diameter d.
Cut-outs and openings (e.g. for pipe nozzles) shall be included in the quantity survey.
Prefabricated piping (e.g. rubber-lined piping) shall be measured as field-fabricated piping.
Painted insulation claddings shall be computed from the outer pipe dimensions, increased by the insulation
thickness s. For simplifying the quantity survey, d + 2 · s may be replaced by the nearest larger (standard)
pipe outside diameter.
7.2 Straight pipes

Quantities shall be measured in terms of m with reference to the outside pipe diameter d.
Figure 20. Quantity survey of piping (example)
Straight pipe lengths shall be measured up to connecting welds of flanges, elbows, valves, reducers, tees, etc.
Referring to isometric drawings, the accuracy of the determination of lengths is given by the computer pro-
gramme.
If the quantity survey is performed on site, individual straight lengths shall be determined to an accuracy of 0.05 m.
7.3 Fittings
7.3.1 Elbows
Quantities shall be measured in terms of numbers with reference to the outside pipe diameter d, the standard
radius (based on the nominal size DN), and the elbow angle. For the surface per piece the values of Table 4
shall apply.
UF 19 ST-F01 M01 D 06-04
One-piece elbows with elbow angles differing from 90° shall be considered in case of:
• < 60° as ½ piece,
• ≥ 60° to 115° as 1 piece,
• > 115° to 160° as 1 ½ piece,
• > 160° as 2 pieces.
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7.3.2 Tees
Quantities shall be measured in terms of numbers with reference to the outside pipe diameter d. For the sur-
face per piece the values of Table 4 shall apply.
Only weld-in Tees shall be included in the quantity survey. Classification of the Tees shall be based on the
largest outside pipe diameter d.
7.3.3 Reducers
Quantities shall be measured in terms of numbers with reference to the outside pipe diameter d. For the sur-
face per piece the values of Table 4 shall apply.
Classification of the reducers shall be based on the larger outside pipe diameter d.
7.4 Flanges
Quantities shall be measured in terms of numbers with reference to the nominal diameter DN. For the surface
per piece the values of Table 4 shall apply.
The term “flanges” shall be deemed to include all types of flanges (e.g. welding neck flanges, lap joint flanges,
blind flanges) irrespective of their nominal pressure. The values of Table 4 are based on the maximum (stan-
dard) nominal pressure and include an extra charge for the shape of the flange.
7.5 Valves
Quantities shall be measured in terms of numbers with reference to the nominal diameter DN. For the surface
per piece the values of Table 4 shall apply.
The term "valves" shall be deemed to include all flanged components (e.g. check valves, gate valves, control
valves, sight glasses, strainers, level indicators), irrespective of their installed length and including their oper-
ating elements (hand wheels, levers).
Valves with DN > 500 shall be measured individually at site, because of their type-specific size of surface
areas. For computing the surface, the following formula (for a cuboid) shall be used:
A = 3 · L · D + 2 · L · H + 2 · D · H + D2
Figure 21. Quantity survey of a valve
Butterfly valves without flanges, valves with welding and with threaded ends shall be considered as
0.8 pieces.
7.6 Pipe supports

Quantities shall be measured according to section 5. If the quantity survey is based on weight, the value of
33 m²/t shall be used for computing the surfaces.
UF 19 ST-F01 M01 D 06-04
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Table 4. Surfaces of piping components
Nominal Outside Surfaces

size diameter Flanged Welded
Pipe 90° elbow Reducer Tee Flange
valve valve
DN D 1.5 DN 2.5 DN all PN all PN all PN
DIN ANSI DIN ANSI m²/m m²/St m²/St m²/St m²/St m²/St m²/St m²/St
8 ¼" 13.5 13.7 0.04 0.01 0.01 0.01 0.01 0.03 0.06 0.05
10 ⅜" 17.2 17.1 0.05 0.01 0.01 0.01 0.01 0.03 0.08 0.06
15 ½" 21.3 21.3 0.07 0.01 0.01 0.01 0.01 0.04 0.10 0.08
20 ¾" 26.9 26.7 0.08 0.01 0.01 0.01 0.01 0.05 0.12 0.10
25 1" 33.7 33.4 0.11 0.01 0.01 0.01 0.01 0.07 0.16 0.12
32 1¼" 42.4 42.2 0.13 0.01 0.02 0.01 0.01 0.08 0.20 0.15
40 1½" 48.3 48.3 0.15 0.02 0.03 0.01 0.02 0.10 0.23 0.18
50 2" 60.3 60.3 0.19 0.03 0.04 0.01 0.03 0.12 0.29 0.22
65 2½" 76.1 73 0.24 0.04 0.07 0.01 0.05 0.15 0.36 0.27
80 3" 88.9 88.9 0.28 0.06 0.10 0.02 0.06 0.18 0.45 0.34
90 3½" 101.6 101.6 0.32 0.08 0.13 0.03 0.08 0.20 0.52 0.39
100 4" 114.3 114.3 0.36 0.10 0.16 0.03 0.10 0.23 0.59 0.45
125 5" 139.7 141.3 0.44 0.14 0.24 0.05 0.15 0.28 0.76 0.56
150 6" 168.3 168.3 0.53 0.21 0.35 0.07 0.22 0.33 0.93 0.69
200 8" 219.1 219.1 0.69 0.36 0.59 0.12 0.38 0.43 1.28 0.94
250 10" 273 273 0.86 0.55 0.92 0.19 0.59 0.54 1.69 1.22
300 12" 323.9 323.8 1.02 0.78 1.29 0.26 0.82 0.64 2.11 1.51
350 14" 355.6 355.6 1.12 0.94 1.56 0.32 0.99 0.70 2.43 1.72
400 16" 406.4 406.4 1.28 1.22 2.04 0.42 1.30 0.80 2.91 2.04
450 18" 457 457 1.44 1.55 2.58 0.52 1.64 0.90 3.43 2.38
500 20" 508 508 1.60 1.91 3.18 0.65 2.03 1.01 3.98 2.74
600 24" 610 610 1.92 2.75 4.59 0.94 2.92 1.21
700 28" 711 711 2.23 3.74 6.24 1.27 3.97 1.41
750 30" 762 762 2.39 4.30 7.16 1.46 4.56 1.51
800 32" 813 813 2.55 4.89 8.15 1.66 5.19 1.61
900 36" 914 914 2.87 6.18 10.31 2.10 6.56 1.81
1000 40" 1016 1016 3.19 7.64 12.73 2.59 8.11 2.01
1100 44" 1118 1118 3.51 9.25 15.42 3.14 9.82 2.21
1200 48" 1219 1219 3.83 11.00 18.33 3.73 11.67 2.41
1300 52" 1321 1321 4.15 12.92 21.53 4.39 13.71 2.61
1400 56" 1422 1422 4.47 14.97 24.95 5.08 15.88 2.81
1500 60" 1524 1524 4.79 17.19 28.65 5.84 18.24 3.02
1600 64" 1626 1626 5.11 19.57 32.62 6.64 20.76 3.22
1700 1727 5.43 22.08 36.80 7.50 23.42 3.42
1800 72" 1829 1829 5.75 24.76 41.27 8.41 26.27 3.62
1900 1930 6.06 27.57 45.95 9.36 29.26 3.82
2000 80" 2032 2032 6.38 30.56 50.94 10.38 32.43 4.02
2100 2134 6.70 33.71 56.18 11.45 35.77 4.22
2200 2235 7.02 36.98 61.63 12.55 39.23 4.42
2300 2337 7.34 40.43 67.38 13.73 42.90 4.63
2400 2438 7.66 44.00 73.33 14.94 46.68 4.83
8 Quantity survey of materials

UF 19 ST-F01 M01 D 06-04
The yield of the painting material shall be decisive for the determination of the quantities (in kg or litres) con-
sumed. The actual yield shall be determined from the theoretical yield (in m²/l or m²/kg) specified by the paint-
ing material suppliers plus an extra charge for losses during application (e.g. surface irregularities, differing
peak-to-valley heights, subgrade unevenness, mixture losses due to limited pot life, application method, ex-
cessive layer thickness).
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The following extra charges on the theoretical yield are admissible for losses:
• 60 % for the first prime coat (directly after surface preparation),
• 80 % for inorganic zinc prime coats,
• 30 % for one-pack prime and top coats,
• 40 % for two-pack prime and top coats.
For the determination of the quantities of solvents applies:

• for painting material quantities ≤ 100 litres thinner: 10 % cleaner: 20 %
• for painting material quantities > 100 to 1000 litres thinner: 5% cleaner: 10 %
• for painting material quantities > 1000 litres thinner: 2% cleaner: 8%
9 Damages to pre-coated surfaces

Damages to pre-coated surfaces might be caused by others during shipment, loading and erection. the extent
of those damages shall be listed prior to commencement of the painting works.
If the ratio of damaged surfaces will be above 10% of the painted surface in total, the relevant component
shall completely be repainted. In that case the quantity survey shall be executed according to sections 5, 6 or 7.
In case the ratio of damaged surfaces will be beneath 10%, the touch-up works shall be brought to account in
the following manner:
For the evaluation of the touch-up area a line shall de drawn around each damage / scratch with an offset of
20 cm. The enveloping line depicts the touch-up area. The calculation of its surface area may be executed in
simplified terms by transforming it into equivalent rectangular areas. An area with the overlap of different
damages shall only once be included. The minimum size of a touch-up area will be 0.2 m².
In order to minimize time and effort the total number of the touch-up areas multiplied by the minimum size may
be brought to account as an alternative.
The validation for touch-up areas should be put into effect with the unit rate for touch-up work. In case no such
unit rate has been agreed upon, the unit rate for the relevant complete system will then also be valid for touch-
up work.
Areas for quantity survey shall be detected with an accuracy of 0.1 m².
9.1 Examples for damages
1.4 m × 0.4 m = 0.56 m²
rounded to 0,6 m²
Figure 22. Long scratches

UF 19 ST-F01 M01 D 06-04
0.4 m × 0.4 m = 0.16 m²
validation 0,2 m² (minimum size)
Figure 23. Spot-shaped scratches

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1.4 m × 0.4 m + 0.6 m × 0.4 m = 0.8 m²
Figure 24. Overlap of two scratches
Reference standards
DIN standards
DIN 1025-1 : 2009-04 Hot rolled I-beams; Narrow flange I-sections, I-serie; Dimensions, masses,
sectional properties
DIN 1025-2 : 1995-11 Hot rolled I-beams; Wide flange I-beams, IPB-serie; dimensions, masses,
sectional properties
DIN 1025-3 : 1994-03 Hot rolled I-beams; wide flange I-beams, light pattern, IPBl-serie; dimen-
sions, masses, sectional properties
DIN 1025-4 : 1994-03 Hot rolled I-beams; wide flange I-beams heavy pattern, IPBv-serie; dimen-
sions, masses, sectional properties
DIN 1025-5 : 1994-03 Hot rolled I-beams; medium flange I-beams, IPE-serie; dimensions,
masses, sectional properties
DIN 1026-1 : 2009-04 Hot rolled steel channels; Taper flange steel channels; Dimensions, masses
and sectional properties
DIN 1027 : 2004-04 Steel bars; Hot rolled round edge Zeds; Dimensions, weights, tolerances,
static values
EN standards
EN 10055 : 1995-12 Hot rolled steel equal flange tees with radiused root and toes; Dimensions and
tolerances on shape and dimensions
EN 10056-1 : 1998-10 Structural steel equal and unequal leg angles; Dimensions
Amendments
In comparison with UN 9257-91 Part 1 : 2001-06 edition, the following amendments have been made
− The tables 2 through 4 have been revised according to the new Standards, now being valid.
− Section 9 "Damages to pre-coated surfaces" has now been included.
UF 19 ST-F01 M01 D 06-04
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Part 1 (M)
WAREHOUSING
Page 1 of 8
[Modified: 29/08/2008]
Contents
Page
1 Scope ……………………………………………………………………………………. 1
2 Facilities …………………………………………………………………………………. 1
3 Receipt of material ……………………………………………………………………… 1
4 Storage of material ……………………………………………………………………… 4
5 Preservation …………………………………………………………………………….. 7
6 Issue and return of material …………………………………………………………… 8
1 Scope
This standard applies to the administration of the site warehouse and to the storage of equip-
ment. It contains generally applicable requirements which will be supplemented by special in-
structions, if necessary.
Deviations from this standard shall be agreed upon in writing.
2 Facilities
The warehouse usually comprises open-air storage facilities (with or without fencing, with roof)
and temporary storage rooms (e.g. lockable, heated, cool, dry).
The size of areas for the open-air storage facilities and storage rooms shall be determined on
the basis of the scope of supplies. If approved by the client, plant buildings (e.g. storage facili-
ties) may also be used for the storage of equipment. The type and quantity of warehouse
equipment (e.g. shelves, wire mesh boxes, fire-extinguishers, fork lifts, light cranes) shall be
determined sufficiently in advance of the commencement of site activities.
Depending on the prevailing weather conditions, the areas of the open-air storage facilities
shall be connected to a drainage system. The areas for the open-air storage facilities and stor-
age rooms shall be selected with a view to precluding flooding.
3 Receipt of material
Care shall be taken when unloading and transporting any packages and items of equipment.
The symbols for handling and storage marked on the packages and items of equipment shall
be observed at all events.
1, This side up 5. Use no hooks 9. Clamp here

2. Fragile, handle with care 6. Centre of gravity 10. Do not use forklift truck here
3. Keep dry 7. Sling here
4. Keep away from heat 8. No hand truck here
Figure 1. Symbols for the handling of equipment
© 2008 UHDE INDIA Technical discipline: MQ

UHDE-STANDARD
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Part 1 (M)
WAREHOUSING
Page 2 of 8
Roofed storage Storage in closed rooms
Storage at ambient temperatures of > 0 °C Storage in air-conditioned rooms
Figure 2. Symbols for the storage of equipment
Lifting tackle (e.g. ropes, chains, shackles, cross-beams) shall be selected with due regard to
the centre of gravity and shape of the equipment to be lifted. The lifting tackle shall not be sub-
jected to loads exceeding their maximum permissible carrying capacity. The maximum permis-
sible carrying capacity is shown in the relevant load tables. In the case of multi-line lifting
tackle, only two lines shall be assumed to carry the load if it cannot be assured that the load is
distributed uniformly amongst all the lines. For asymmetrically arranged lifting tackle or loads
with an asymmetrical centre of gravity, the non-uniform load distribution shall be observed. The
angle subtended by the rope lines or chains shall not exceed 120°.
Ropes and chains shall only be fastened to the points (e.g. lifting clips, lifting lugs, trunnions,
eyebolts) provided for such purpose. If no sling points have been provided or marked, the at-
tachment method shall be agreed with the site management. Nozzles, shaft ends and other
protruding parts of the equipment shall not be used as sling points. Unprotected wire ropes or
steel chains shall not come into contact with bare steel surfaces and austenitic CrNi steel.
Cross-beams should be used for lifting vertical vessels of > 2 m diameter. Special care shall be
taken to prevent distortions when raising vessels delivered in a horizontal position. Synthetic
fibre belts of approx. 100 mm width should be used for lifting plastic vessels. Wire ropes shall
only be used for plastic vessels which are provided with lifting lugs or eyebolts.
Ropes and chains shall neither be knotted nor placed across sharp edges. The rope end at-
tachments and chain end links shall comply with the applicable standards. Wire ropes shall be
protected from moisture and shall be greased regularly. Synthetic fibre ropes shall be stored in
dry places with sufficient ventilation. Chains shall always be kept clean. Under adverse condi-
tions (e.g. impact loads, temperatures < 0 °C), the maximum carrying capacity of chains shall
be reduced accordingly. The chain manufacturer’s instructions shall be observed.
The lifting tackle shall be inspected regularly for damage. Wire ropes shall be deemed unserv-
iceable if any of the following defects are detected:
• Many visible wire fractures,

• A broken wire strand,
• Clustering,
• Loose external strands,
• Pinching, kinks and knots,
• Corrosion pits,
• Damage or extremely worn rope end attachments,
• Damage due to contact with items conducting electric current.
Chains shall be deemed unserviceable if any of the following defects are detected:
• Elongation of the chain or a chain link by > 5%,

• Decrease of nominal thickness of a chain link by > 10%,
• Deformation or fracture of a chain link,
• Cracks in a chain link,
• Damage due to contact with items conducting electric current.
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WAREHOUSING
Page 3 of 8
Natural or synthetic fibre ropes shall be deemed unserviceable if any of the following defects
are detected:
• Breakage of one strand,

• Mechanical damage, extreme wear or loose strands,
• Damage due to storage in moist places or exposure to corrosive media,
• Multiple yarn breakages,
• Loose splices.
Lifting hooks shall be deemed unserviceable if any of the following defects are detected:
• Cracks (particularly transverse cracks) in the shank, collar, thread or hook jaw,
• Wear of hook jaw by > 5%,
• Severe deformation of the hook jaw,
• Defective hook safety catch.
3.1 Inspection of incoming material
The receipt of material at the site shall be confirmed to the head office by a notification of re-
ceipt of material. If the client has to acknowledge the receipt of material, a “Erection: Ware-
housing; Material receiving report” (Uhde form UF 9250-21) shall be issued.
The equipment received shall be checked in accordance with the “Construction: Warehousing;
Requirements for material receiving inspection” (Uhde form UF 9250-22). The scope and time
of the checks shall be governed by the type and storage period of the equipment. The checks
shall be performed in sufficient time before erection of the equipment. The following checks
should be performed immediately upon receipt of the packages:
• Checking the packing lists against the number of packages received,

• Checking the outside packing for damage,
• Checking the inside packing (e.g. welded plastic sheets) for damage,
• Checking damaged packages for completeness and damage to the contents,
• Checking any protective inert-gas fillings.
Damage in transit shall be reported without delay to the insurance department at the head of-
fice, using special forms. In the event of severe damage, an average adjuster shall be con-
sulted.
The following checks may be performed at a later date, after the packages have been opened.
• Checking the contents for completeness,

• Checking the outer condition of the individual components (e.g. corrosion protection, preser-
vation),
• Checking the technical details.
The performance of the specified checks shall be recorded (e.g. in the warehouse file card-
index). Any defects detected shall be recorded in a “Construction: Warehousing; Deficiency
report” (Uhde form UF 9520-23).
Any missing items of equipment shall be replaced by re-ordering. In the case of defective
equipment, the site management shall decide whether the defects are still permissible or
whether repair can be performed on site. The site management shall make arrangements for
the return of any non-specification-grade items of equipment.
3.2 Warehouse file card-index
All movements of material (receipt, place of storage, issue, return) shall be recorded on appro-
priate warehouse file cards. On large sites, the warehouse file card-index can be computer-
ized.
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Part 1 (M)
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Page 4 of 8
4 Storage of material
4.1 General notes
The items of equipment shall be stored in accordance with the technical specification “Erection:
Storage of material and equipment” (Uhde form UF 9250-01) or in accordance with the manu-
facturer’s instructions either outdoors, indoors, in cooled or in dry rooms. Adequate protection
shall be ensured against pilfering, inclement conditions (e.g. moisture, rain, snow, sandstorm,
insects), soiling (e.g. by bird droppings, dust, tar), static and dynamic loads. In the event of
prolonged storage periods and extreme ambient conditions (high or low temperature, corrosive
atmosphere), special protective measures can be specified by the site management.
The storage temperatures depend on the type of storage facility. In open-air storage facilities
(open-air or roofed), the storage temperatures are governed by weather conditions. In closed
storage rooms without special requirements, a storage temperature between 5 °C and 35 °C
should be maintained. Special requirements as regards storage temperatures are indicated in
sections 4.2 to 4.8.
All items of equipment are marked with a TON (Technical Organization Number) or a part num-
ber. If necessary, this marking shall be touched up with weather-proof paint on receipt of the
material or during storage.
If tarpaulins are specified for covering the equipment in the open-air storage facilities, these
shall be of flame-resistant material (without PVC components). The tarpaulins shall be an-
chored carefully and arranged in such a manner as to permit proper drainage of surface water
and air circulation underneath the tarpaulins. For protecting equipment (e.g. with soft-rubber
lining) against UV radiation, tarpaulins impervious to light or plastic sheets of red or orange col-
our shall be used.
Equipment of austenitic CrNi steel shall be protected from direct contact with unalloyed steel or
low-alloy steel, detrimental influences (e.g. corrosive gas, sea air), metal dust (e.g. steel, tin,
zinc, copper) and from zinc-based coating materials. Items of austenitic CrNi steel shall only
be cleaned with demineralized water.
Protective coverings (e.g. covers, caps) shall not be removed from flanges and from machined,
rubber-lined or bare surfaces. Missing or damaged protective coverings shall be replaced.
Caps made of PVC should not be used.
Welding filler metals shall be stored at temperatures of ≥ 20 °C and a relative air humidity of ≤
60%.
Protective inert-gas fillings (e.g. of heat exchangers or transformers) shall be checked regularly
for pressure drop. The efficiency of the dessicant shall be checked regularly in the case of
equipment (e.g. instruments, electrical equipment) provided with bags of dessicant. The instruc-
tions on the bags containing the dessicant shall be observed.
The open storage areas and the storage rooms shall be selected such that they cannot be
flooded. The said areas shall be connected to a drainage system depending on the ambient
weather.
Storage rooms, in which combustible materials are stored, shall be provided with an adequate
number of fire extinguishers. The local fire regulations shall be observed.
Items of equipment which have to be checked and maintained regularly during storage shall be
provided with suitable record cards.
The site management shall be informed immediately if deficiencies or damage are detected
during storage. The site management will then decide about the measures required (repair, re-
ordering).
UHDE-STANDARD
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Part 1 (M)
WAREHOUSING
Page 5 of 8
4.2 Steel structures, vessels, and machinery
Steel structures, vessels, machinery and the like should be stored outdoors on timber blocks of
approximately 150 mm thickness. Placing the equipment on unprotected, bare or machined
surfaces as well as on flanges is not permitted. Care shall be taken not to damage nozzles,
shaft ends or other protruding parts.
Vessels, machinery and other equipment shall be stored in their “operating position” on a plane
surface and shall be supported by an adequate number of timber beams. Vertical vessels with
a height of > 5 m may be stored horizontally.
Rolled plates (e.g. for site-welded tanks) should be stored upright. For plates stored in horizon-
tal position, provision shall be made for adequate support. Care shall be taken not to damage
the machined plate edges.
If specified by the manufacturer, the shafts of machinery and electric motors shall be turned
regularly by several degrees.
Oil and grease shall be prevented from entering the equipment and machinery which will come
into contact with oxygen during operation.
4.3 Rubber-lined and plastic equipment
Rubber-lined equipment and plastic equipment shall be stored with special care. The equip-
ment shall be stored on a soft underlay to preclude any distortion. It shall be protected against
knocks, impacts and low temperatures. Impact-sensitive rubber linings and plastic equipment
shall be checked for cracks prior to erection.
Rubber-lined equipment, particularly with soft-rubber lining, shall be protected against exces-
sive heat (e.g. due to solar radiation or heating elements) and UV radiation (due to solar radia-
tion and artificial lighting). Plastic sheets of blue colour shall not be used for covering the rub-
ber-lined surfaces. The formation of ozone or high oxygen concentrations (e.g. due to fluores-
cent lighting) shall be prevented wherever rubber-lined equipment is stored.
Equipment with hard-rubber linings or brittle special material shall be protected from severe dif-
ferences in temperature. The temperature within rubber-lined equipment should not drop below
minus 10 °C if the hardness of the rubber lining is > 75 shore D and not below –20 °C if the
hardness of the rubber lining is ≤ 75 Shore D. At temperatures of < 0 °C, the equipment shall
be stored free of any stress.
At temperatures of < 0 °C, utmost care should be exercised when unloading and transporting
rubber-lined equipment.
Rubber lined items shall be checked for corrosion at the edges of the rubber lining.
4.4 Piping components
Pipes, spools, fittings, elbows flanges and valves should be stored outdoors on timber blocks of
approx. 150 mm thickness or on timber pallets. Flange faces shall not be damaged. Valves
shall be stored in the “closed” position. For the storage of piping components, section 4.1 shall
also apply analogously.
The piping components shall be stored separately by material groups. The marking of the pip-
ing components shall be checked on receipt of the material to avoid any mix-up at a later stage.
Pipes maybe stacked to a height of approx. 1.5 m if properly secured. In the case of pipes
≥ DN 500, only two pipes should be stacked one upon the other. The storage area should be
plane to ensure uniform support over the entire pipe length. A sufficient number of timber
planks shall be placed between the individual pipe layers.
Safety valves, control valves, bolts, nuts, washers, gaskets and other hardware shall be stored
indoors. Temporary storage of these items outside the storage rooms is not permitted.
UHDE-STANDARD
Erection
UN
9250-01
Part 1 (M)
WAREHOUSING
Page 6 of 8
4.5 Electrical equipment and instrumentation
Transformers for outdoor service, cable supports, cable drums and sectional steel for fixtures
may be stored outdoors. With the exception of cable drums, this equipment should be stored on
timber blocks of approx. 150 mm thickness or on timber pallets.
Other electrical, measuring and control equipment should be stored in dry and well ventilated
rooms on timber pallets or on shelves. The storage temperature should be ≥ 10 °C. If specified
by the manufacturer, equipment (e.g. switch boards, transformers) or parts thereof (e.g. termi-
nal boxes of high-voltage motors) shall be heated during storage.
A crane or a fork lift shall be used for un-loading the cable drums. Cable coils shall not be
thrown. Cable coils shall be stored lying flat. The sealing caps provided at the cable ends shall
be checked for proper condition and, if necessary, repaired.
Switch boards, distribution boards, control panel sections and the like shall be stored on level
surfaces and handled with such lifting and handling equipment that will not cause damage (e.g.
distortion). During storage and transportation, the surfaces of the equipment shall be protected
by plastic sheets against soiling and scratching.
Transformers with insulating fluid shall be checked for proper condition on receipt at the site. In
the case of transformers with complete filling and installed expansion vessel, the air dehumidi-
fier shall be checked for proper functioning. The nozzle on the expansion vessel of small trans-
formers shall be open. The moisture indicator shall be checked regularly. The colour change of
the indicator from blue to pink indicates that the relative humidity in the transformer housing has
risen unduly.
Storage batteries shall be stored in accordance with the manufacturer’s instructions. Batteries
filled with the electrolyte shall be recharged at least once in every 6 months.
Tubes for instrument process lines, pneumatic impulse lines and instrument-air lines as well as
the related hardware (e.g. unions, valves) shall be stored on shelves or on timber pallets, sepa-
rated by material groups. Transport of tube bundles shall be effected in such a way that the
bundles do not sag excessively, thus becoming distorted or bent. The tube bundles shall be not
pulled over the ground. Tube coils shall not be thrown and not stacked to a height of > 1 m. The
tube ends shall be protected from the ingress of foreign matter.
Instruments shall be stored on shelves. The original packing shall only be removed at the
place of installation. Caps, covers, plugs and the like on instruments and valves shall not be
removed until immediately prior to installation. Missing or damaged caps, covers and plugs
shall be replaced.
4.6 Insulation material
Insulation material and sheet-metal may be stored outdoors if soiling and ingress of moisture
can be prevented. Insulation material in unpacked state and hardware shall be stored indoors.
Shells and slabs shall be stored horizontally on a plane underlay. Sheet-metal reels and metal
plates shall be stored on timber pallets.
Insulation materials shall be stored as per instruction by manufacturer or as follows: PU foam

components shall be stored at temperatures between 10 °C and 15 °C. The foaming agent
shall be stored at a temperature of < 22 °C. The individual components shall be stored sepa-
rately from one another.
4.7 Coating materials
Coating materials shall be stored at temperatures between 5 °C and 30 °C in dry and well venti-
lated rooms. The instructions of the manufacturers shall be observed. Any rise in temperature
(e.g. by solar radiation) of the coating material shall be prevented.
The statutory regulations governing the storage of inflammable coating materials and auxiliary
materials shall be observed.
UHDE-STANDARD
Erection
UN
9250-01
Part 1 (M)
WAREHOUSING
Page 7 of 8
4.8 Other materials
Bricks (for refractory linings), packing materials, catalysts and the like should be stored accord-
ing to the manufacturer’s instructions.
Polyester resins (e.g. for glass-fibre-reinforced plastic pipes) shall be stored at temperatures
between 15 °C and 20 °C in well ventilated rooms. Glass fibre mats shall be kept in a dry place
and protected from moisture. Accelerators and catalysts shall be stored separately from one
another and from resins. Any explosion hazards shall be taken into account when storing ac-
celerators and catalysts.
Rubber lining material shall be stored at temperatures between 6 °C and 10 °C. The rubber
reels shall be jacked up at both ends of the mandrel to preclude contact with the ground. Any
missing or damaged mandrels shall be replaced. Rubber reels shall not be stacked.
Rubber lining material shall be protected against direct solar radiation and UV radiation accord-
ing to section 4.3. The formation of ozone or high oxygen concentrations (e.g. due to fluores-
cent lighting) shall be prevented in the storage room. Plastic sheets of blue colour shall not be
used for covering the rubber reels.
Baled conveyor belts, which are to be stored for a prolonged period, shall be jacked up and
turned from time to time to prevent the belt plies from becoming distorted as a result of the
dead weight of the belt bale.
Solvents, fuels, lubricants and corrosive chemicals shall not be stored close to rubber-lined
equipment, rubber sheets and the like and shall not come in contact with rubber.
Lubricants (oil and grease), insulating fluids for transformers and insulating oils shall be stored
indoors in the original containers. Oils and insulating fluids shall be protected against moisture
and water. Oil drums shall be stored with the bungs down.
Special measures are usually required for the storage of chemicals. Particular attention shall
be paid to :
• Statutory regulations,
• Maximum shelf life,
• Flammability,
• Chemical reactivity,
• Explosion hazard,
• Formation of toxic vapours,
• Maximum storage temperatures.
5 Preservation
The preservation of items of equipment shall be checked at regular intervals and touched-up, if
necessary. The manufacturer’s instructions for the application of preservation agents shall be
observed. Unless otherwise specified, the preservation agents may be selected according to
table 1. The branded products indicated in table 1 may be substituted by equivalent products
of other manufacturers.
UHDE-STANDARD
Erection
UN
9250-01
Part 1 (M)
WAREHOUSING
Page 8 of 8
Table 1. Preservation agents
Preservation agents Application

1)
Tectyl 506 Valves, gliding surfaces, bearings, guide pins, keys,
Covering with oiled paper Outside surfaces of gears, are metal parts
1)
Tectyl 846 Compressors, rotors, unalloyed steel piping
1) 1)
Tectyl 511 M , Tectyl 506 Inside surfaces of crank cases, oil tanks, oil filters, oil
lubricated bearings and gears
Covering with oiled paper Casings, bearings caps, valve bodies
Anti-corrosion oil (e.g. Shell Eusin Instruments, electrical appliances
2) 1)
I OW , 20 W Valvoline )
Collordal molybdenum disulphide, Spindles, spindle bushings, couplings, bearings
vaseline
Dessicants (e.g. silica gel) Interior of compressors, casings.
1) Branded product of Valvoline Oel GmbH & Co., Hamburg, Germany
2) Branded product of Shell AG, Hamburg, Germany.
6 Issue and return of material
Material shall be issued against store issue forms which are to be signed by the area superin-
tendent in charge.
If fairly large quantities are required at a time (e.g. material for complete pipelines), advance
notice shall be given to permit the necessary preparations for the issue of this material to be
made, thus avoiding waiting periods.
In cooperation with the area superintendents in charge, the warehouse superintendent shall
regularly check whether material bottlenecks are likely to occur. Material bottlenecks shall be
reported to the head office immediately so that the problem can be solved by priority expediting
or procurement of supplementary material. In the case of large sites, material planning (e.g. for
piping) can be performed with the aid of a site computer.
When the stocks of bulk material (e.g. pipes, fittings, valves, bolts, cables) have decreased to a
certain level (e.g. 5%), a check shall be made to determine whether the stock in hand will be
sufficient for the remaining work.
If the quantity of material taken from the warehouse proves to be larger than required, the ma-
terial in excess shall either be returned to the warehouse or set off against the next issue of
material. The returned material shall be recorded as incoming material in the warehouse file
card-index. Cutting spoil (e.g. from pipes, cables) remains the property of the Orderer. The site
management will decide whether cutting spoil can still be used or is to be considered as scrap.
Cutting spoil shall be stored separately by material type in an area designated by the site man-
agement.
Reference standards
Uhde standards:
UF 9250-01 Erection: Storage of material and equipment

UF 9250-21 Erection: Warehousing; Material receiving report
UF 9250-22 Construction: Warehousing; Requirements for material receiving inspection
UF 9250-23 Construction: Warehousing; Deficiency report
HPL Contract No.
4010464

6778-EQS-G0000-EB-0007 66-6778
Rev 01 Page of
Annexure-2
Reference Painting specification
standards
IP/ G/ Gen / 2nd June,

Standard for Protective Coating (Painting) System
IS_PAINT Rev-03 2021
HPL/IMS/MECH/S
MP/7.5.1/10/ANN S-1 Annexure -I : Material Specification
EX-I-R-1
IP/ G/Gen/
S-1 FRP Coating specification 10/6/2023
IS_FRP COATING
Standard for Protective Coating
(Painting) System
Ref No IP / G / Gen / IS_PAINT

Rev 03
Issued by : INSPECTION SECTION
Issued Date : 2nd June, 2021
Haldia Petrochemicals Limited

Haldia W.B.
Revision by Checked by Approved by

S Seth/ Md Amanullah Manas Mandal Chayan Mondal
Document Name Document Ref No
Standard of Protective Coating (Painting ) IP/G/GEN/IS_PAINT
System
List of Revisions
Rev Issue date Reason of Revision Revision by Checked by Approved by
0 30th First time preparation Shamik Ch. D.D.C. S.R. Ghosh
1 10th Incorporation of ASME 2004 Ananda Shamik Debjiban Ray
edition revision statements Sarkar Chowdhury
2 7th Revision for New Project R P Baral Manas Mandal Chayan Mondal
Construction
3 2nd Ju Removal of Cl based system S Seth/ Manas Mandal Chayan Mondal
Md Amanullah
INDEX
Sec Para Description Page
No No No
S-1 Protective Coating - Selection and Application standard 1-7
S-2 Maintenance Protective Coating System 1-3
S-3 Protective Coating System alternate Options ( Maintenance and New 1-4
Construction)
S-4 Protective Coating Systems - HPL Specification 1 - 12
S-5 Surface Preparation Standards 1
S-6 Specification of Primer 1
S-7 Specification of Paint Coatings 1
S-8 Protective Coating : General Specifications 1 - 10
S-9 Color Coding of Plant Pipe Line 1- 6
S-10 Color Coding of Plant Equipment 1
S-11 Color Coding of Plant Structure 1-3
Revision by Checked by Approved by

S Seth/ Md Amanullah Manas Mandal Chayan Mondal
Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-1
(Painting ) System
1 Purpose
Purpose of this document is document is to define the Standard applicable for the Protective Coating
Systems at HPL both for Maintenance Protective Coating Systems and also for new Construction.
2 Reference Documents
- Surface Preparation standards
- Coating specifications by EIL and TOYO for HPL construction project
- Data sheet of Paints of reputed brands
- IS 2379 ; 1990 - Pipelines - Identification - Color Code ( First Revision )
- IS : 5 ; 1978 - Colors for Ready Mixed Paints and Enamels ( Third Revision )
3 Personnel Qualification
Painter :
- He shall have at least 3 years experience of Industrial paint on Steel structure, Piping or
Equipment.
- He shall be responsible for mixing and application of Paint.
- He shall have knowledge of the Mixing and Application of Paint. He shall have knowledge about
the safety norms and hazards associated with this job.
- Knowledge status of the Painter should be verified before deployment to job .In absence of above
required knowledge, Painter shall not be deployed for the job .
Paint Inspector / Supervisor
- He shall have at least 3 years experience as Paint Inspector / Supervisor for Industrial paint
application on Steel structure, Piping or Equipment.
- He shall be responsible for advising and supervising on a) Surface Preparation Methods, b) Paint
Mixing and application methods. He shall be responsible for Inspecting a) Surface Preparation
w.r.t. required specs, b) DFT measurement after each coat, c) Final Visual Inspection and d)
Recording of results and measurement.
- He shall have knowledge on Paint Type and its specification as mentioned in the data sheet. He
shall have knowledge on Paint suitability and compatibility to different service, temperature , water
, humidity and chemical exposure condition .
- He shall have knowledge of the Surface preparation standard requirements and method to
achieve required surface profile. He shall have knowledge on Surface preparation and Coating
Inspection techniques.
- ce level will be verified by HPL
Inspection Dept . Only after approval by HPL Inspection Dept, specific person can be deployed in
the capacity of Paint Inspector / Supervisor.
Topic Name Prepared by Checked by Approved by Rev no: 3

Protective Coating Selection S Seth/ Md Manas Chayan Issue no: 1
and Application Standard Amanullah Mandal Mondal
Date 02.06.21
Page no : 1 Inspection
Section
(Painting ) System
4 Personnel Certification
Paint Supervisor / Inspector deployed for each Gang shall be certified by HPL Inspection Department .
For this matter , before deployment at field , concerned person has to undergo competency verification
by HPL Inspection . On satisfactory completion of the evaluation process , a Card will be issued to
them which must be carried by the concerned supervisor / inspector .
The concerned Supervisor / Inspector shall be ready to submit for verification by any HPL Employee
in-charge of the Plant Coating activity .
The Painter engaged by the Contractor shall bear the minimum professional experience and
knowledge as mentioned in Para 3 . The same is subjected to random verification by HPL Inspection
Department .
5 Inspection Instrument
- Digital Elcometer for checking DFT with calibration block / strip (at least 2 nos. instrument)
- Hygrometer for recording relative humidity
- Contact type Thermometer
- Surface Profile gauge for measurement of Surface profile in micron
- Dial Micrometer with testex (Press-O-film)
- Surface profile comparator standard
- Cross hatch adhesion tester to check the bonding of Paint
- Psychometer
- Bresle patch test kits
- MEK test kit
N.B.: All instruments shall be in proper working condition with NABL approve Certificate.
6 HPL Protective Coating Systems

General Maintenance/new construction Protective Coating systems will be adopted as per Section S-
2 of this document ,
Normally Maintenance Protective Coating of Pipe Line and Structural are selected with ST2 / ST3
surface preparation standard & SA 2 ½ for New Construction activity. For maintenance painting
whenever ST2/ST3 grade surface preparation are carried out, the prepared surface is always to be
primer painted/ coated by Surface ( Rust ) Tolerant Epoxy Mastic Coating with Finish Coat of the
required shade .

Date 02.06.21
Section
(Painting ) System
The alternate specification for new construction and special application will however be chosen from
the options as mentioned in the Section S-3 of this document . Selection criteria will be derived from
the allowable expenses for the specific case vis a vis the performance and durability expected from
the systems selected.
Specification for any Protective Coating System will be as per Section S-4 of this document
7 Surface Preparation
Surface standard will be as per Section S-5 of this document .
Applicable standards in HPL are ST2 / ST3 for Maintenance Protective Coating & SA 2 ½ for New
Construction activity .
Relative Humidity during surface preparation shall be within 85 % Max. Same shall be measured by
whirling/Aspirated Hygrometer or Psychrometer.
Minimum Temperature shall be 5 deg C or 3 deg C above Due Point temperature , whichever is higher
The interval between the completion of surface preparation and application of Primer shall not exceed
4 hours.
For ST2 and ST3 surface finish
- Surface shall be free of a) Loose Rust, b) Loose Paint. Surface shall be Dry and Existing sound
coat shall be roughened.
- ST-2 will be achieved by Manual cleaning by mechanical striking tools, chipping hammers. After
removal of dust, surface should have a Faint Metallic Shine representative.
- ST-3 will be achieved by Power tool cleaning by rotating abrasive wheel like Grinding, Buffing.
After cleaning surface should have a Pronounced Metallic Shine
For SA 2 ½ surface finish
- Surface finish shall be Near white ( 95% white ) metallic finish with the required surface profile as
mentioned in the Coating specification .( as required by the Primer / 1 st Coat )
- SA 2 ½ surface finish will be achieved by abrasive (Copper Slag/Shot Blasting/Grit Blasting/Shot-
Grit mix blasting). Unless specific approval is accorded for special case, Sand Blasting will be not
be allowed.
- All blasting abrasives (copper slag for CS and Aluminum oxide for SS) shall be tested and
qualified in accordance with the procedures described in SSPC-AB1 Type II, Class-B, and
Grade-3.
- Abrasive shall not be re-usable. Reconciliation documents of abrasive must be submitted after
completion of surface preparation.
- Abrasive shall be checked at field as per SSPC AB1 i.e. Water soluble salt, Oil content and Size.
- Blasting shall always be conducted in a separately marked covered area.

Date 02.06.21
Section
(Painting ) System
- Vacuum cleaning shall be required after surface profile preparation.

- Abrasive (Grit / Shot) size will be controlled by filtering through Mesh (Abrasive shall be used after
sieving through 20 & 40 mesh). Air shall be Dry.
- Before staring the job, it shall be demonstrated by the party that required Surface finish and
Surface profile is achieved by the applied Abrasive size and blasting pressure. Accordingly
Abrasive size and blasting pressure (Air Pressure and distance of Blasting) will be established and
certified.
- Surface profile will be measured by profile gauge and recorded. Same has to be within the
specified range (between Max. and Min.).
ST-1/SSPC SP-1 will be applied in case Surface is contaminated by Grease, Alkali.

Water washing will be applied, if required.
8 Application of Primer and Protective Coats

Primer and Paint Selection will be as per Protective Coating specification mentioned in S-2 , S-3 and
S-4 .
Paint application will be strictly as per the Pai
Unless mentioned otherwise by the Manufacturer for the specific paint following general guidelines will
however be adopted
- The interval between the completion of surface preparation and application of Primer shall not
exceed 4 hours.
- During Coating application process , including Surface preparation , temperature of the
component shall be within the Range of
Minimum Temp = 5 deg C or 3 deg C above Due Point temperature , whichever is
higher
Maximum Temp = 60 deg C
- Relative Humidity during Coating application process, including Surface preparation shall be within
85 % Maxm. Same shall be measured by Hygrometer.
- Paint shall not be applied in extremely windy or sandy condition.
- No Painting job (including Surface preparation) shall be conducted during rain or water fall
(drizzling or heavy) as well as in evening/ night.
Note: Water misting or steaming must be carried out over IZS if Relative Humidity (RH%) drops below
50% before hard dry i.e. just after touch dry. ply IZS paint when temperature above 40 degree
C and Relative Humidity (RH%) drops below 50%.

Date 02.06.21
Section
(Painting ) System
9 Paint Specification
Brands of Primers, Intermediate Coats and Finish Paints will always be of repute. Same will be as per
Section S-6 and S-7 of this Document.
Primer, Intermediate Coat and Finish Paint combination for any application shall always be from same
brand. Two different brand products shall not be applied one over another.
Before applying Paint, the Paint batch certificate will be submitted. Same shall contain Paint Batch No,
Date of Manufacturer , data sheet and Paint type and specification . Only after verification of the same
vis a vis the actual Paint Material approval will be accorded for application of same. For blast cleaning,
abrasive batch test certificate of NABL approved laboratory is to be submitted for approval &
acceptance.
Vendor shall arrange its storage space so as to clearly demarcate
a) Paint Material pending Inspection by Inspector ,
b) Paint Material Inspected and Approved by Inspector
c) Paint Material Inspected and Rejected by Inspector

Date 02.06.21
Section
(Painting ) System
Inspection Method and Acceptance standard
Inspection check points before giving clearance for job execution

- Relative Humidity shall be within 85 % Max as measured by whirling/Aspirated Hygrometer or
Psychrometer.
- Temperature of the Item as measured by a calibrated Contact Thermometer shall be within the
Range of
Minimum Temp = 5 deg C or 3 deg C above Due Point temperature , whichever is
higher
Maximum Temp = 60 deg C
- No Strong wind blowing / sandy condition.
- No rain or water fall ( drizzling or heavy ) on the Item
Inspection check points before forwarding clearance for Abrasive (Copper, Grit / Shot blasting)
- Surface profile achieved on a test piece visa vis the a) Abrasive size, b) Air Pressure, c) Distance
of Blasted surface from the Blast nozzle. After establishment of the parameters as required to
achieve the required surface standard following will be the Inspection check points
Abrasive size controlled thru Filtering thru Mesh (Mesh 20 & 40)
Air Pressure
Distance of Blasted surface from the Blast nozzle
Air shall be dry
Inspection check points after completion of Surface preparation
- Profile shall be within specification as measured by Surface profile gauge as per ISO 8503-2, 4, 5
or ASTM D4417 method A, B and C (10%).
- Surface appearance shall match with that of Surface Profile comparator as per specs.
- Surface condition as revealed by Visual Inspection shall be as per the specification SSPC VIS-1.
- Surface condition shall be checked for dissolve salt as per ISO 8502-9
Stage wise inspection check points during Paint Coating application

- Time lag between Primer application and Surface preparation completion: Same shall not exceed
4 hours .
- Before application of first coat (Prime ) DFT shall be measured to record existing coat DFT (This is
not applicable if the 1st coat is applied over bare metal surface).
- Stripe- coating is to be followed strictly, during each layer of painting.

Date 02.06.21
Section
(Painting ) System
- Recoat interval : Same shall be always within the minimum and maximum range specified by the
Paint manufacturer .
- After each coat DFT will be measured. DFT value will match with that of specs.
- After final coat total DFT will be measured as per SSPC PA2.
- For DFT measurement, one reading per 1 sq.m. shall be taken with minimum 5 readings .
- No reading shall be less than 80 % of the specified DFT per coat.
- Average Film thickness shall be within 90 % of the DFT per coat specified, while total DFT shall
not be less than 90 % of the total DFT or SSPC PA2 level IV.
Inspection Check Point for testing of Paint performance short term

For checking the Paint performance short term , Cross hatch adhesion Testing will be performed by
HPL Inspection .
Same shall be performed randomly or selectively ,as adjudged by HPL .
This Test will be performed within a period of 2 - 3 months from the application of Paint .
10 Inspection Records
Records of measurement of all Inspection (Quality) Parameters as mentioned above in Para 9 will be
maintained.

Date 02.06.21
Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-2
1 Scope
Scope of this section is to define the Coating System that is generally adopted for HPL Maintenance Protective Coating ( Painting ) System .

Maintenance Protective Coating Systems S Seth/ Md Manas Mandal Chayan Mondal Issue no: 1
Amanullah Date 02.06.21
Page no : 1 Inspection Section

N.B: The surface preparation standards in HPL are ST2 / ST3 for Maintenance Protective Coating only & SA 2 ½ for New Construction activity.

1. Scope
Scope of this section is to define the Coating System Options that will be evaluated while selecting Coating specification at HPL during
Maintenance (wherever possible) and New Construction .

Protective Coating Systems Options S Seth/ Md Manas Mandal Chayan Mondal Issue no: 1
(Maintenance and New Construction) Amanullah Date 02.06.21


T. - Hydrocarbon Storage Tank Protective Coating System

Surface Standard ST 2 or ST 3 or better Surface Standard SA 2 ½ or better
S
Component Shade
No Avg Cost & Perfor --- High Cost & Perfor. Avg Cost & Perfor ---- High Cost & Perfor.
Spec - 1 Spec - 2 Spec - 3 Spec - 4 Spec - 5 Spec - 6
Shell External along 1 ft from the HCS - 03.3 , HCS 28.2 , HCS 29 , 29.2 ; 31
T.1 Black HCS - 04 HCS - 05 HCS 28 , 30
Annular plate projection . 03.4 30.2 , 31.2
- Shell External Rest complete ,
- Roof Top ; HCS 19.2 ,
T.2 White HCS - 16 HCS - 15 HCS 17 , 18 HCS 20 ; 20.1 HCS 21 ; 21.1
- Wind Guarder & Other external 19 ; 19.1 ;
accessories
HCS 28.3 , HCS 28.2 , HCS - 29.2 , 29.3 ,
T.3 - Pontoon Box , Black HCS - 04.1 HCS 03.2 HCS 04 or 03.3
30.3 30.2 31.2. , 31.3
HCS - 03.3 , HCS 28.2 , HCS 29 , 29.2 ; 31
T.4 - Rolling Ladder Black HCS - 04 HCS - 05 HCS 28 , 30
03.4 30.2 , 31.2
Opaline
HCS - 03 HCS - 01 HCS 28.1 ,
T.5 Tank external - Steel Structure & Platform Green HCS 22 , 23 HCS 28 , 30
30.1
Dark Grey HCS - 02 HCS - 01
Golden
T.6 Handrail HCS - 01
Yellow
HCS 28.2 , HCS 29.2 ,
T.7 Grating / Chequered Plate Black HCS - 04 HCS 03.3
30.2 31.2
HCS 19.2 ,
T.8 Tank Roof structure Internal HCS - 16 HCS - 15 HCS 17 HCS 20 ; 20.1 HCS 21 ; 21.1
19 ; 19.1 ;
HCS 28.2 , HCS 29.2 ,
T.9 Tank Bottom & Annular Plate Soil side Black HCS - 04 HCS 03.3 HCS - 06
30.2 31.2
Tank internal ( Product side )
T. - Bottom Plate Top ,
HCS - 32 HCS - 33 HCS - 34
10 - Shell Internal ,
- Bottom Deck Bottom

1. Scope
Scope of this section is to define the Coating System Specification that will be availed while selecting Coating specification at HPL during
Maintenance and New Construction .
SurfacePre Minimum
Coating paration Coatin No of DFT/Coat
Surface Condition Coats Coating specification recoat
Systems g Code Coats (micron)
standard # interval
Primer Modified Mastic Epoxy P-4 1 125-150 16 hrs
No Rust/Loose Paint , Dry,
HCS-01 ST2/3/SA2 ½
Existing sound coat roughened
Finish HB Chlorinated Rubber C-2 2 30 8 hrs

No Rust/Loose Paint , Dry, HB MIO Chlorinated rubber
HCS-01.1 ST2/3/SA2 ½ Inter C-13 1 50-75 16 hrs
Existing sound coat roughened Intermediate Coat
Finish HB Chlorinated Rubber C-2 2 30 8 hrs

HCS-02 ST2/3/SA2 ½
Finish Modified Mastic Epoxy P-4 1 125-150 16 hrs
Primer Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs

HCS-03 ST2/3/SA2 ½
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

HCS-03.1 ST2/3/SA2 ½ Inter Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs

Protective Coating Systems - S Seth/ Md Amanullah Manas Mandal Chayan Mondal Issue no: 1
HPL Specification Date 02.06.21
SurfacePre Minimum
standard # interval
HCS-03.2 ST2/3/SA2 ½
Existing sound coat roughened Finish Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs

HCS-03.3 ST2/3/SA2 ½
Finish Modified Coal Tar Epoxy Mastic P-3 2 125-150 16 hrs


HCS-04 ST2/3/SA2 ½ Primer Modified Coal Tar Epoxy Mastic P-3 2 125-150 16 hrs
HCS-04.1 ST2/3/SA2 ½ Primer Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs
No Rust/Loose Paint , Dry, Primer Modified Coal Tar Epoxy Mastic P-3 2 125-150 16 hrs
HCS-05 ST2/3/SA2 ½
Existing sound coat roughened Finish Water based Acrylic Finish C-3 2 20-25 8 hrs


SurfacePre Minimum
standard# interval
Primer HB Black Bitumen - thinned P-9 1 765-100 16 hrs
HCS-06 ST2/3/SA2 ½
Finish HB Black Bitumen - thinned P-9 1 75-100 16 hrs

HCS-07 ST2/3/SA2 ½
Finish Acrylic Aliphatic Poly Urethane C-7 2 30 - 35 16 hrs
Primer
HCS-08 ST2/3/SA2 ½
Finish Heat resistant Aluminum Paint C-5 2 15-20 16 hrs
Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS-08.1 SA 2 1/2
Surface profile =55 65 micron
Finish Heat resistant Aluminum Paint C-5 2 15-20 16 hrs
Primer
HCS-09 ST2/3/SA2 ½
Existing sound coat roughened Heat resistant Silicon Aluminum
Finish C-6 2 20 - 25 16 hrs
Paint 400 deg C

HCS-10 SA 2 1/2
Surface profile =55 65 micron Heat resistant Silicon Aluminum
Finish C-6 2 20 - 25 16 hrs
Paint 400 deg C
HCS-10.1 SA 2 1/2 Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

SurfacePre Minimum
standard # interval
Primer
HCS-11 SA 2 1/2
Surface profile =25-30 micron Heat resistant Silicon Aluminum
Finish C-6 2 20 - 25 16 hrs
Paint 500 deg C
Primer supplied by Insulation / Wrapping - Coating Material Vendor or in
No Rust/Loose Paint , Dry, absence of same
HCS-12 ST2/3/SA2 ½ Primer
Modified Coal Tar Epoxy Mastic P-3 2 125-150 16 hrs
Primer Zinc Phosphate Synthetic Base P-5 2 50 16 hrs

HCS - 13 ST2/3/SA2 ½
Finish Synthetic Enamel Finish C-4 2 20-25 16 hrs
No Rust/Loose Paint, Existing Primer Sweat Tolerant HB Epoxy Coat C-8 1 100 72-80 hrs
sound coat roughened
HCS - 14 ST2/3/SA2 ½
Coarse Water Wash. On sweat
condition Paint application Finish Sweat Tolerant HB Epoxy Coat C-8 1 100 72-80 hrs

No Rust/Loose Paint , Dry, HB MIO Epoxy - Intermediate-
HCS - 15 ST2/3/SA2 ½ Inter C-12 1 100-125 16 hrs
Existing sound coat roughened Polyamide Cured
Epoxy Amine adduct cured
Finish C-9 2 30 35 16 hrs
Glossy CR Enamel

HCS - 16 ST2/3/SA2 ½
Existing sound coat roughened Epoxy Amine adduct cured
Glossy CR Enamel

SurfacePre Minimum
standard # interval
HCS - 17 ST2/3/SA2 ½
Finish Epoxy HB Poly amide Finish C-1 2 100-125 16 hrs

HCS - 18 ST2/3/SA2 ½ Interm. Epoxy HB Poly amide Finish C-1 1 100-125 16 hrs
Finish Aliphatic Acrylic Poly Urethane C-11 2 30 35 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 19 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 65 micron Polyamide Cured

HCS-19.1 SA 2 1/2 Interm. Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs

HCS-19.2 SA 2 1/2
#
N.B: The surface preparation standards in HPL are ST2 / ST3 for Maintenance Protective Coating only & SA 2 ½ for New Construction activity.

Surface Minimum
Coating Coatin No of DFT/Coat
Preparatio Surface Condition Coats Coating specification recoat
n standard interval
HCS - 20 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Glossy CR Enamel

HCS-20.1 SA 2 1/2 Interm. Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs
Glossy CR Enamel

HCS - 21 SA 2 1/2 Inter C-12 1 100-125 16 hrs

HCS-21.1 SA 2 1/2 Inter Super HB Aliphatic Amine Epoxy C-10 1 150-200 16 hrs

Surface Minimum
n standard interval
HCS - 22 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Finish HB Chlorinated Rubber finish C-2 2 30 8 hrs
Primer Epoxy Zinc Phosphate primer P-1 2 25-35 16 hrs

HCS - 23 SA 2 1/2 Inter C-12 1 100-125 16 hrs

HCS-23.1 SA 2 1/2
Surface profile =55 65 micron Finish Epoxy HB Poly amide Finish C-1 2 100-125 16 hrs

HCS - 24 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Glossy CR Enamel

HCS - 25 SA 2 1/2 Inter C-12 1 100-125 16 hrs

Surface Minimum
n standard interval
HCS - 26 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Finish HB Chlorinated Rubber finish C-2 2 30 8 hrs

HCS - 27 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Glossy CR Enamel

HCS - 28 SA 2 ½ Inter Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

HCS-28.1 SA 2 ½ Inter Coal Tar Epoxy HB P- 8 1 150-200 24 hrs

HCS-28.2 SA 2 ½
Finish Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

Surface Minimum
n standard interval
HCS-28.3 SA 2 ½
HB MIO Epoxy - Intermediate-

Inter C-12 1 100-125 16 hrs
95 % white metal finish . Polyamide Cured
HCS-29 SA 2 ½
Inter Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

Inter C-12 1 100-125 16 hrs
HCS-29.1 SA 2 ½

HCS-29.2 SA 2 ½ Inter C-12 1 100-125 16 hrs

Surface Minimum
n standard interval

HCS-29.3 SA 2 ½ Inter C-12 1 100-125 16 hrs

HCS - 30 SA 2 ½ Inter Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

HCS-30.1 SA 2 ½ Inter Coal Tar Epoxy HB P- 8 1 150-200 24 hrs

HCS-30.2 SA 2 ½

HCS-30.3 SA 2 ½

Surface Minimum
n standard interval
Inter C-12 1 100-125 16 hrs
HCS-31 SA 2 ½

95 % white metal finish . Inter C-12 1 100-125 16 hrs
HCS-31.1 SA 2 ½ Polyamide Cured

HCS-31.2 SA 2 ½ Inter C-12 1 100-125 16 hrs

HCS-31.3 SA 2 ½ Inter C-12 1 100-125 16 hrs

Surface Minimum
n standard interval
Primer Amine adduct HB Epoxy tank Liner C-11 1 100-125 16 hrs
HCS - 32 SA 2 1/2
Surface profile =100-125 micron
Finish Amine adduct HB Epoxy tank Liner C-11 1 100-125 16 hrs

HCS - 33 SA 2 1/2

HCS - 34 SA 2 1/2
Surface profile =25-30 micron

1. Scope
Scope of this section is to define the specifications of Surface Preparation standards applicable for HPL Maint. Protective Coating ( Painting) System
Code Specification summary Details of Specification

SURFACE PREPARATION BY Removal of loose rust, loose mill scale and loose/old paint. Manual cleaning shall be done by
ST-2 HANDTOOL AND MANUAL mechanical striking tools, chipping hammers. After removal of dust, surface should have a Faint
CLEANING-[ST-2]: Metallic Shine representative to ST-2.
Removal of loose rust, loose mill scale and entire old paint. Power tool cleaning shall be done by
SURFACE PREPARATION BY
ST-3 mechanical striking tools, chipping hammers & by rotating abrasive wheel like Grinding, Buffing. After
POWER TOOL CLEANING-[ST-3]:
cleaning surface should have a Pronounced Metallic Shine to ST-3.
SURFACE PREPARATION BY
Near 95 % White Metal cleaning to the Standard SA-2 1/2 by means of blast cleaning by using grit,
SA 2 ½ BLAST CLEANING-[SA-2.5]:
shot to remove mill scale, old paint, foreign matter, rust etc.
Chemically contaminated surface, heavily pitted surface, grease, acid, alkali spillage etc. surface
SURFACE PREPARATION BY needs to be chemically cleaned by organic solvent/cleaner/suitable hydrocarbon and the cleaned
ST-1
CHEMICAL CLEANING-[ST-1]: surface should be free from any residues by proper checking. Necessary Chemical with proper MSDS
has to be brought by Vendor.
For ST2 and T3 surface finish Surface shall be free of a) Loose Rust , b) Loose Paint . Surface shall be Dry and Existing sound coat shall be roughened .
SA 2 ½ surface finish will be achieved by Shot Blasting / Grit Blasting . Grit size will be controlled by filtering through Mesh . Air shall be Dry .
Before staring the job , it will be demonstrated by the party that required Surface finish and Surface profile is achieved by the applied Grit size and blasting
pressure . Accordingly Grit size and Blasting pressure ( Air Pressure and distance of Blasting ) will be established and certified .
Surface profile will be measured by profile gauge and recorded . Same has to be within the specified range ( between Maxm and Minm )
ST-1 will be applied in case Surface is contaminated by Grease , Alkali . Water washing will be applied , if required .

Surface Preparation Standards S Seth/ Md Amanullah Manas Mandal Chayan Mondal Issue no: 1
Date 02.06.21
1. Scope
Scope of this section is to define approved manufacturers of Protective PRIMERS applicable for HPL Maint. Protective Coating ( Painting ) System
BERGER PAINT
AKZO NOBEL
JOTUN
CARBOLINE
Grauer & Weil India ltd (Bombay Paint)
HEMPEL
SHALIMAR PAINT
ASIAN PAINT
GODLAS NEROLAC
CHANDA PAINTS
N.B.: Paint brands against different specification will be approved time to time based on review of Datasheet & MSDS copy.

Specification of Primer S Seth/ Md Amanullah Manas Mandal Chayan Mondal Issue no: 1
Date 02.06.21
1. Scope
Scope of this section is to define approved manufacturers of PROTECTIVE COATS applicable for HPL Maint. Protective Coating ( Painting ) System
BERGER PAINT
AKZO NOBEL
JOTUN
CARBOLINE
Grauer & Weil India ltd (Bombay Paint)
HEMPEL
SHALIMAR PAINT
ASIAN PAINT
GODLAS NEROLAC
CHANDA PAINTS
N.B.: Paint brands against different specification will be approved time to time based on review of Datasheet & MSDS copy.

Specification of Paint Coatings S Seth/ Md Amanullah Manas Mandal Chayan Mondal Issue no: 1
Date 02.06.21
(Painting) System
1. Scope
Scope of this section is to outline the general specifications applicable to the Protective Coating
System . The same includes :
1.1 Calculation of Volume Solid , Film Thickness and Coverage
1.2 Coating evaluation techniques
1.3 Surface Preparation Standards
1.4 Protective Coating type : their advantage and limitations . Dry Heat resistance
1.5 Coating compatibility
2 Calculation of Volume Solid , Film Thickness and Coverage
- % Volume Solid = { Measured DFT X 100 } / Measured WFT
- Dry Film thickness DFT = { WFT X % Volume Solid } / 100
- Wet Film thickness WFT = { Desired DFT X 100 } / % Volume Solid }
- Theoretical Spreading Rate ( TSR ) ( sq meter/lit ) = { Volume Solid % X 10 /} /

DFT (micron )
- Practical Coverage Rate ( PSR ) = TSR less Loss ( Apparent & Actual )
3 Coating evaluation & Performance parameter test
Volume Volatile Content Volume Solid ( Non volatile content )

Hiding Powder test
Test test
Pigment test Viscosity test Sprayability Test
Hardness Test Adhesion Test ( by tape test ) : Test involves scribbling a cross hatch
patters of closely spaced parallel lines and then applying a pressure
sensitive tape.
Abrasion resistance Test Chemical resistance test : Can range from tap water immersion test to
NaOH spill test
Flexibility Test Impact resistance test
Humidity resistance test Salt spray resistance test Accelerated weathering test
Permeability Test Gloss Test : Matt / Egg shell / satin / Semi Gloss / Glossy
Protective Coating S Seth/ Md Manas Chayan Issue no: 1

General specification Amanullah Mandal Mondal Date 02.06.21
Section
(Painting) System
4 Surface Preparation Standards ( SSPC )
Swedis Japan
Surface Preparation Standard SSPC-SP NACE BS 4232
h Std SPSS
Cleaning by wrapping with cloth or rag ,
solvent spray , Vapour degreasing , SP-1-82
emulsion etc
Manual Hand Tool cleaning by hand
chiseling / scrapping / wire brushing to ST-2 SP-2-95
give faint metallic shine
Mechanical / Power Tool cleaning to
ST-3 SP-3-95
give pronounced metallic shine
Blast Cleaning by Air or Water to provide
white metal cleanliness . Removal of all
1st JA Sh3 or
metallic scale / paint and foreign matter Sa 3 SP-5-94 NACE-1
Quality JA Sd 3
by sand / grit / shot blast cleaning :
Thorough Clean Metal
Near 95 % white metal cleanliness by 2nd JA Sh2 or
Sa 2 ½ SP-10-94 NACE-2
sand / grit / shot blast cleaning Quality JA Sd 2
3rd JA Sh1 or
Commercial Blast Cleaning Sa 2 SP-6-94 NACE-3
Quality JA Sd 1
Brush off blast Cleaning : Virtually Clean
Sa 1 SP-7-94 NACE-4
Metal
Pickling SP-8-91
Light Blast Cleaning Sa 4
Surface roughness profile should be approx 1/3 rd of coating thickness upto a coating thickness of 0.3 mm.
Too low a profile may not provide sufficient bonding of Coating , while too high a profile may result in
uneven coverage of sharp peals leading to premature coating failure , particularly for thin coatings such as
blast primers . Profile obtained during blasting depend on the abrasive used , the air pressure and the
technique of blasting . Typical roughness profile obtained using various types of abrasives are as follows :
Mesh Maxm profile Maxm profile

Abrasive used Abrasive used Mesh size
size height height
Very Fine Sand 80 37 micron Coarse Sand 12 70 micron
Iron Shot S 230 18 75 micron Iron Shot S 390 14 90 micron
Iron Grit G 50 25 83 micron Iron Grit G 16 12 200 micron
Copper Slag (0.42
20-40 51/89 micron
0.84mm size)

Section
(Painting) System
Pre Treatment Specification ( SSPC )
PT-1 Wetting Oil Treatment

PT-2 Cold phosphate surface treatment
PT-3 Basic Zinc Chromate Vinyl Butyral Wash Coat
PT-4 Hot phosphate surface treatment
NACE Standard
RP 0172 - 72 Surface preparation of steel by water blast cleaning

RP 0675 - 88 Control of external corrosion on off-shore steel pipe lines
RP 0181 - 81 Liquid applied internal protection linings and coatings for oil field production equipment
RP 0281 - 86 Method for conducting coating evaluation testing in atmospheric exposure
RP 0184 - 94 Repair of lining system
RP 0188 - 90 Holiday testing of protective coating
TM 170 - 70 Visual standards for new steel blast cleaned with sand abrasives
TM 0174 - 91 Laboratory method for evaluation of protective coatings and linings in immersion service
Accelerated test procedure for screening atmosphere service coating for offshore platform and
TM 0184 - 88
equipment.

Section
(Painting) System
5 Coating Types : Their advantage and Limitations
Thermoplastic Resin
This is characterized by softening at elevated temp . here molecular structure is not cross linked into rigid
molecules . On vapor of solvents the resin deposits as barrier protection . Because no chemicals change
takes place on drying , applied coating therefore gets re-dissolved if it is exposed to same solvent that it
was originally dissolved under formulation .
Thermosetting Resin
Low molecular weight resin when mixed with curing agent ( Polyamide / amine ) reacts with moisture /
atmosphere gets cured and thereby forms cross linked , 3 dimensional large molecular structure . This
provides very strong , tough , chemically resistant protective barrier .
Advantages Limitation Comments

Alkyds
Good resistance to atmospheric Not resistant to chemicals (splash Long oil alkyds make excellent primer
weathering and moderate spillage ) for rusted and pitted steel and wooden
chemicals forms. Not suitable for applying over surface .
Long oil alkyds have good alkaline surface such as fresh Corrosion resistance is adequate for
penetration but are slow drying. concrete or water immersion . mild chemicals fume.
Short Oil alkyds are fast drying. Used as interior and exterior industrial
Temperature resistant upto 105 and marine finishes.
deg C.
Epoxy Easters
Good weather resistance . Generally least resistant epoxy A high quality oil base coating with
Chemical resistance is better than resin . good compatibility with most other
alkyds and usually sufficient to Not resistant to strong chemical coating type .
resist normal atmospheric fumes , splash or spillage . Easy to apply .
corrosive attack . Not suitable for immersion service Used widely for atmospheric
Temperature resistance = 105 deg resistance to chemical environment on
C in dry atmosphere . structural steel , tank interior .
Vinyl : Thermoplastic resin

Insoluble in oil , grease , aliphatic Strong polar solvents re-dissolve Tough and flexible .
hydrocarbon and alcohol. Vinyl . Low toxicity , tasteless , colourless ,
Resistant to water and solution . Initial adhesion is poor . fire resistant .
Not attacked at room temp. by Sometimes will not adhere to bare Used in potable water tanks and
inorganic acids / alkalis. steel without primer . sanitary equipment .
Fire resistant : Good abrasion Pin holes in dried film are more May not comply with VOC regulation .
resistance . prevalent than any other coating .

Section
(Painting) System

Chloro Rubber Thermo plastic
Low moisture permeability and Re-dissolved in strong solvents. Fire resistant , colorless , tasteless ,
excellent resistance to water. Degraded by heat ( 95 deg C dry , non toxic .
Resistance to strong acid , alkalis , 65 deg C wet ) & UV light . Quick drying & excellent adhesive to
bleaches , soaps and detergents , May be difficult to spray , especially concrete and steel.
mineral oils . in hot weather Used in concrete and masonry paints ,
Good abrasion resistance . swimming pool coatings , industrial
coating , marine finish .
Coal Tar Pitch
Excellent water resistance : Better Unless cross linked with another Used as moisture resistance coating in
than all other types . resin , is thermoplastic and will flow immersion / underground service .
Good resistance to alkalis , acids , at 40 deg C or less . Relatively inexpensive .
mineral / animal / vegetable oil . Hardness and embrittles in cold Widely used as pipeline exterior and
weather . interior coating below grade .
Black color only .
Will alligator and crack upon on
prolonged sunlight exposure ,
although still protective .
Asphalt Pitch
Good water and UV resistance. Black color only .Poor resistance to Often used as inexpensive coating in
hydrocarbon solvent , oil , fats and atmospheric service.
some organic solvent . Relatively inexpensive .
Non toxic and suitable for
exposure for food products . Do not have moisture resistant of Mostly used as pavement sealer / roof
coal tar . coating .
Resistant to mineral salts / alkalis
upto 30 % solution . Can embrittle after prolonged
exposure in dry environment or
temp above 150 deg C .
Acrylycs
Excellent light and UV stability , Thermoplastic and water emulsion Used predominantly where light
gloss and colour retention . acrylic not suitable for any stability , gloss and colour retention is
Good chemical resistance . immersion service or any primary requirement .
substantial acid / alkali spillage . With cross linking , greater chemical
Excellent atmospheric / weathering
resistance . Most acrylic coatings are used as resistance can be achieved .
top coat in atmospheric service . Cross linked acrylics are the most
Resistance to chemical fume and
occasional mild chemical splash , Acrylic emulsion has limitation common automotive finish paint .
spillage . similar to water emulsion latex. Emulsion acrylics are often used as
Minimal chalking . primer on concrete / masonry .
Little, if any darkening after

prolonged exposure to UV light.

Section
(Painting) System

Water emulsion latex
Reduced level of VOC . Must be stored above freezing Ease of application and clean up .
Easy to apply , top coat and repair. temp. No toxic solvents .
Easy to dry for recoating . Does not penetrate chalking Successfully used to coat wood and
Excellent flexibility .Resistant to surface. masonry structure.
water , mild chemical fume and Exterior weather and chemical Relatively porous nature of structure
weathering . resistance not as good as solvent or allows passage of water vapor .
Good alkali resistance . oil base coating . Poor chemical
resistance.
Compatibility with most generic
coating types , either as undercoat Not suitable for immersion service
or top coat . Limited durability .
Low cost . Best cure above 50 deg C .
Organic Zinc rich
Galvanic protection by Zn content Generally have lower service Organic binder can be closely tailored
with chemical and moisture performance (Galvanic protection ) to top coats ( eg. Epoxy top coats over
resistance similar to organic than inorganic Zn rich coating . Epoxy Zn rich coating ) .for a more
binder. But ease of application and surface compatible system .
Should be top coated in chemical preparation tolerance make it Organic Zn rich coatings are often
environment with ph outside range increasingly popular . used to repair galvanized or inorganic
5-10. Zn rich coating ,.
More tolerant of surface
preparation and top coating than
inorganic Zn rich primary coating .
In organic Zinc rich

Provides excellent long term Inorganic nature necessitates Ethyl silicate and Zn rich coating
protection against pitting in thorough blast cleaning surface requires atmospheric moisture to
neutral and near neutral preparation and results in cure and are most common type .
atmosphere and same difficulty with organic top coat . Widely used as primer on bridge ,
immersion service . Zn dust us reactive outside ph off shore structure and steel .
Abrasion resistance is range 5 10 and top coating is
excellent. Dry heat resistance > must in chemical fume
370 deg C . environment .
Water base inorganic silicate
are available for confined
space VOC compliance .
Pre-Treatment wash primer
Used to promote adhesion to Steel Have Very high VOC . They are 2 compound product : Poly
and Al. and provides temporary vinyl butyral in alcohol with Zn
corrosion protection before top chromate and a solution of Phosphoric
coat is applied . acid .

Section
(Painting) System

Polyamide cured epoxy
Superior to amine cured epoxy for Easier to apply and top coat .
water resistance . deg C . More flexible and better moisture
Excellent adhesion , gloss , Maxm resistance generally requires resistance than amine cured epoxy .
hardness , impact and abrasion 7 day cure at 20 degC ( slow Excellent adhesion over steel and
resistance . curing) . concrete .
More flexible and tougher than Slightly lower chemical resistance A widely used industrial and marine
amine cured epoxy . than amine cured epoxy. maintenance coating .
Temperature resistance = 105 deg Same formulation can be applied to
C dry & 65 deg C wet. wet / under water service .
Long Pot life .
Aliphatic Amine cured Epoxy

Excellent resistance to alkali , most Short pot life . Good chemical and weather resistance
organic and inorganic acids , water Harder and less flexible than other .
and aqueous salt solution . epoxies . Best chemical resistance of epoxy
Solvent resistance and resistance Intolerant of moisture during family .
to oxidizing agent are good as long application . Excellent adhesion to Steel and
as cont continuously wetted . Concrete .
Will chalk in UV light .
Amine adducts have slightly less Widely used in maintenance coating
chemical and moisture resistance . Stray solvents may lift coatings .
and tank lining .
Temperature resistance is 105 deg
C wet & 95 deg C dry .
Should be top coated within 72 hr to

avoid inter coat de -lamination .
Maxm properties require curing time
of 7 days .
Phenolic epoxy
Phenolic epoxy coatings are especially formulated to produce hard , dense , chemically resistance films . They
have best combination of chemical , solvent and heat resistance .

Section
(Painting) System

Coal Tar epoxy
Excellent resistance to salt water Embrittles upon exposure to cold or It is a blend of epoxy and coal tar
and fresh water immersion . UV light and can cause loss in compound .
Very good acid and alkali adhesion ( Top coat is a problem ) . Good water resistance .
resistance . Cold weather abrasion resistance is Thickness to 0.25 mm per coat .
Solvent resistance is good , poor .
Can be applied on bare steel or
although immersion in strong Should be top coated within 48 hour concrete without primer .
solvent may leach out coal tar . to avoid intercoat adhesion problem
. Low cost per coverage .
Low in VOC .
Good film buildup . Good abrasion Black or dark colour only .
resistance . Temp resistance :105 deg C dry &
65 deg C wet. .
Toxic . Limited Pot life .
Polyeurathane ( Aromatic / Aliphatic )
Aliphatic PUs have excellent glow , Because of versatility of isocyanate Usually two pack system : Isocyanate
colour and UV light resistance . reaction , wide diversity exists in + Polycol .
Generally chemical and moisture specific coating properties : Hard , Aliphatic Urethane are widely used as
resistance are similar to Polyamide Brittle or Elastomeric glossy light fast top coat on many
cured epoxy . CO2 is released upon exposure to exterior structure in corrosion
Abrasion resistance is excellent . humidity , which may result in environment .
gassing or bubbling of coating in Relatively expensive , but extremely
Aliphatics has excellent weathering humid condition .
properties . durable .
Toxicity ( because of Isocyanate ) is The isocyanates can be combined with
Aromatic has better chemical; of concern .
resistance in immersion , but chalk other generic material to enhance
in sunlight . Because of Iso cyanate , PU are chemical / moisture , low temp and
sensitive to moisture and water . abrasion resistance .
Poly easter and Vinyl Easter Coating

Thermosetting resin . Used as high More expensive than epoxies . Solvent free, about 98% solid, Applied
performance corrosion resistant Need blast surface when used as a in large thickness ( 500 to 5 mm )
lining for Steel and Concrete and primer .
also used for internal lining. Limited Pot life .

Section
(Painting) System

Glass flaked filled coating and lining
Provides tortuous path and Needs surface preparation on minm
therefore moisture vapor SA 2 ½ finish of SSPC SP 10
transmission rate ( MVTR ) is very and a surface profile of 50-75
low ( 8 gm / m2 / 24 hrs) as trough to peak .
compared to Unfilled Epoxy Resin
Over coating within 72 hrs
Coat ( 404 gm / m2 / 24 hrs).
maximum .
High build thickness per coat ( 300
Low pot life ( 45 mins )
per coat minm ) . Lining
thickness can vary from 500 to Needs top coat of PU
3000 .
Have excellent chemical , solvent
and immersion temp resistance .
Used for high corrosive immersion
services on off shore platform ,
splash zone , helideck and Sour
crude oil tank bottom .
Dry Heat resistance : Occasional maximum dry temp that is permissible
Bitumen : 50 deg C Chloro Rubber : 60 deg C

Tar Epoxy : 80 deg C Stoving enamel : 100 deg C
Alkyd Aluminum : 150 deg C Epoxy Aluminum : 160 deg C
Silicone : 450 deg C Silicone Aluminum : 500 deg C
Vinyl : 70 deg C Alkyd : 80 deg C
Polyurethane : 125 deg C Epoxy : 150 deg C
Silicone Acrylic : 200 deg C Silicone : 450 deg C
Zinc Silicate : 500 deg C

Section
(Painting) System
6 Coating compatibility
R = Recommended NR = Not Recommended TP = Trial Patch
Case 1 : Internal Dry / Wet exposure : not so aggressive .

Rural exposure : Exterior exposure UV , rain , SO 2 < 10 mg
Alkyd , Acrylic dispersion , Epoxy , Poly urethane , Chloro rubber , Epoxy dispersions are recommended .
Condition External / Internal : Dry External / Internal : Wet

Old Coat Alkyd CR Acrylic Epoxy PU Alkyd CR Acrylic Epoxy PU EPD
Alkyd R TP R TP TP R TP R TP TP R
CR NR R R TP TP NR R R TP TP R
Existing
Coat
Acrylic R R R TP TP R R R TP TP R
Epoxy R R R R R R R R R R R
PU R R R R R R R R R R R
Case 2 : Industrial Polluted Exposure

Epoxy , Poly urethane , Chloro rubber , Poly silicones and Epoxy dispersions are recommended
Condition External / Internal : Dry External / Internal : Wet

Old Coat Alkyd CR Acrylic Epoxy PU CR Acrylic Epoxy PU EPD PSX
Alkyd R TP R TP TP TP R TP TP R R
CR NR R R TP TP R R TP TP R R
Existing
Coat
Acrylic R R R TP TP R R TP TP R R
Epoxy R R R R R R R R R R R
PU R R R R R R R R R R R
Case 3 : High temperature exposure : Boiler furnace , chimney

Alkyd Aluminum , Silicone Acrylic , Silicone , Epoxy , Silicate coatings are recommended .
Old Coat Alkyd Al. Epoxy Silicone Acrylic Silicone Silicate

Alkyd Al R NR NR NR NR
Epoxy TP R TP NR NR
Existing
Coat
Silicone Acrylic NR NR TP TP NR
Silicone NR NR TP R NR
Silicate NR TP R R R
Case 4 : Water immersion : maximum temp = 100 deg C

Epoxy Coal Epoxy - High Epoxy Epoxy -
Old Coat Cr
tar build sold Solvent free Phenolic
Maxm temp ( deg C ) 50 60 80 90 100
CR R TP NR NR NR
Epoxy Coal Tar TP R TP NR NR
Existing
Coat
Epoxy - High build sold R R R TP NR

Epoxy Solvent free R R R R NR
Epoxy - Phenolic R R R R R

Section
(Painting) System
1. Scope
1.1 This procedure defines the Finish Color Coding identification of different service fluid
Pipelines as in HPL .
1.2 For the purpose of this Procedure , Piping system will metallic pipes of any kind and in
addition corresponding fittings, valves and pipe coverings.
1.3 Structural and Supports are specifically excluded from the scope of this procedure.
1.4 This procedure can be modified and amended to on very specific cases with due
approval from Management , the approval note of which has to be with Inspection.
1.5 This procedure is not in strict compliance with applicable referencing Codes but with
certain Plant Specific modifications .
1.6 This proced
Electrical Services.
1.7 This procedure is equally applicable for both Un-insulated and Insulated Pipelines for
Ground Finish Color.
2 Applicable References :
2.1 IS 2379 ; 1990 - Pipelines - Identification - Color Code ( First Revision )

2.2 IS : 5 ; 1978 - Colors for Ready Mixed Paints and Enamels ( Third Revision )
3. Definitions
3.1 Ground Colors
3.1.1 This is the final finish color of the pipelines ( TABLE 1 )

3.1.2 This finish color is meant to identify the basic nature of fluid it handles and to
distinguishes one fluid from another
3.1.3 Ground Colors shall be applied throughout the entire length of Un-insulated and
insulated pipelines but in no case it will be less than 300 mm.
3.1.4 Due to extreme emergencies or due to any other Plant reasons if full length
Ground Coloring is not possible for the entire length , it shall be applied near
Valves, On & Near weld joints, at Bend Junctions , Bulkheads.
Color Coding of Plant S Seth/ Md Manas Chayan Issue no: 1

Piping Amanullah Mandal Mondal Date 02.06.21
Section
(Painting) System
3.2 Color Bands
3.2.1 Color Bands are multicolor Ribbon Strips to be applied over the finish Ground
Pipeline color to identify of one type of fluid from another of same and different
category .
3.2.2 Color bands should be superimposed on ground color at least at the following
locations :
3.2.2.1 At Battery Limits Points
3.2.2.2 Branch connection and change of direction vicinity in piping ways.
3.2.2.3 Near Valves, On either side of pipe culverts ( entry and exit visible
portion) , At midway random,
3.2.2.4 For long pipe stretch at 50 M intervals and at start and end points .
The color band sequence follows the direction of flow.
3.2.2.5 The relative proportional widths of the first color band : second color
band shall be 4 : 1
3.2.2.6 The minimum width of the color band shall confirm the following Table
Nominal Pipe Size (NPS) Width (mm)
80 NB and below 25
Over 100 NB upto 150 NB incl. 50
Over 200 NB upto 300 NB incl. 75
Over 350 NB . 100
3.2.3 All Un-insulated Pipes having temperature above 100 deg. C ( HR Al Painted)
need not to be identified with Color Bands.
3.2.4 Valves shall be painted with the same color that of pipelines.
3.2.5 Color Bands are not in strict compliance with IS : 2379 but with certain custom
design changes to facilitate Job Progress w.r.t. standard stock of Paint Colors.
This will not create any problem so far as Pipeline identifications are concerned in
HPL .

Section
(Painting) System
2nd Color
Pipeline Service Finish Color 1st Color Band
Band
WATER
Cooling Water Sea Green- IS:5 No. 217 Sky Blue- - IS:5 No. 101 ----
BFW Sea Green- IS:5 No. 217 P.O. Red- IS:5 No. 538 ----
Condensate Water Sea Green- IS:5 No. 217 Light Brown-IS:5 No. 410 ----
P.O. Red- IS:5
Drinking Water Sea Green- IS:5 No. 217 Sky Blue- - IS:5 No. 101
No. 538
P.O. Red- IS:5
Waste Water Sea Green- IS:5 No. 217 Golden Yellow- IS:5 No. 356
No. 538
P.O. Red- IS:5
Quench Water Sea Green- IS:5 No. 217 Dark Adm. Grey- IS:5 No. 632
No. 538
Treated DM Water Sea Green- IS:5 No. 217 Deep Orange - IS:5No. 591 ----
Process Water Sea Green- IS:5 No. 217 Dark Adm. Grey- IS:5 No. 632 ----
Wash Water Sea Green- IS:5 No. 217 Canary Yellow- IS:5 No. 309 ----
Fire Water P.O. Red- IS:5 No. 538 ---- ---
Untreated River Water P.O. Red- IS:5 No. 538 White ----
Polished Water Sea Green - IS:5 No. 217 Black ----
Industrial Water Sea Green- IS:5 No. 217
SHP Blow down Water Sea Green- IS:5 No. 217 Black White
AIR
Plant Service Air Sky Blue- - IS:5 No. 101 Dark Adm. Grey- IS:5 No. 632 ----
Instrument Air Sky Blue- - IS:5 No. 101 Golden Yellow- IS:5 No. 356
Dry Out Air Sky Blue- - IS:5 No. 101
Compressed Air upto &
Sky Blue- - IS:5 No. 101 ---- ----
incl. 15 Kg/ cm2
Compressed Air over 15
Sky Blue- - IS:5 No. 101 P.O. Red- IS:5 No. 538 ----
Kg/ cm2
Vacuum Sky Blue- - IS:5 No. 101 Black ----
STEAM
Very High Pressure
Aluminum to IS : 2339 P.O. Red- IS:5 No. 538 ----
Steam
High Pressure Steam Aluminum to IS : 2339 Sky Blue- - IS:5 No. 101 ----
Medium Pressure Steam Aluminum to IS : 2339 Deep Orange - IS:5No. 591 ----
Low Pressure Steam Aluminum to IS : 2339 Canary Yellow- IS:5 No. 309 ----
Dilution Steam / Purge Canary Yellow-
Aluminum to IS : 2339 Dark Adm.Grey-IS:5No.632
IS : 5 No . 309
Steam

Section
(Painting) System
2nd Color
Band
OIL
Quench Oil Light Brown -IS:5No. 101 Canary Yellow- IS:5 No. 309 ----
Furnace Fuel Oil Light Brown -IS:5No. 101 Sky Blue- - IS:5 No. 101 ----
Wash Oil Light Brown -IS:5No. 101 White ----
Lub. Oil Light Brown -IS:5No. 101 Dark Adm.Grey-IS:5No.632 ----
Transformer Oil Light Brown -IS:5No. 101 Black ----
Any other types of Oil, as
Light Brown -IS:5No. 101 ---- ----
applicable
GASES
Sky Blue- - IS:5
Hydrogen Canary Yellow-IS:5No. 309 P.O. Red- IS:5 No. 538
No. 101
Hydrogen Sulphide Canary Yellow-IS:5No. 309 P.O. Red- IS:5 No. 538 ----
Oxygen Canary Yellow-IS:5No. 309 White ----
Nitrogen Deep Orange - IS:5No. 591 Black ----
Chlorine Canary Yellow-IS:5No. 309 P.O. Red- IS:5 No. 538 Black
Carbon Dioxide Canary Yellow-IS:5No. 309 Dark Adm.Grey-IS:5No.632 ----
ACIDS
Deep Orange-
Sulphuric Acid Dark Violet- - IS:5No. 796 Sea Green- IS:5 No. 217
IS:5No. 591
Deep Orange-
Nitric Acid Dark Violet- - IS:5No. 796 Sky Blue- - IS:5 No. 101
IS:5No. 591
Deep Orange-
Hydrochloric Acid Dark Violet- - IS:5No. 796 P.O. Red- IS:5 No. 538
IS:5No. 591
Acetic Acid Dark Violet- - IS:5No. 796 White ----
Phosphoric Acid Dark Violet- - IS:5No. 796 ---- ----
CAUSTICS/ ALKALIES
Sodium Hydroxide Smoke Grey - IS:5No. 692 Deep Orange-IS:5No. 591 ----
Strong Caustic Smoke Grey - IS:5No. 692 Sky Blue- - IS:5 No. 101 White
Recovered Caustic Smoke Grey - IS:5No. 692 P.O. Red- IS:5 No. 538 White
CanaryYellow-
Waste/ Spent Caustic Dark Violet- - IS:5No. 796 White
IS5No.309

Section
(Painting) System
2nd Color
Band
HYDROCARBON ( LIQUID)
Naphtha (LIQ.) Dark Grey- IS:5No. 632 ---- ----
Propylene F.P. (LIQ.) Dark Grey- IS:5No. 632 Sea Green-IS:5 No. 217 ----
Smoke Grey-
Propylene C.G (LIQ.) Dark Grey- IS:5No. 632 Sea Green-IS:5 No. 217
IS:5No. 692
P.O. Red- IS:5
Ethylene Glycol (LIQ.) Dark Grey- IS:5No. 632 Sea Green-IS:5 No. 217
No. 538
Ethylene Dichloride
Dark Grey- IS:5No. 632 P.O. Red- IS:5 No. 538 ----
(LIQ.)
Benzene (LIQ.) Dark Grey- IS:5No. 632 Canary Yellow- No309 ----
Butadiene (LIQ.) Dark Grey- IS:5No. 632 Black ----
Ethylene (LIQ.) Dark Grey- IS:5No. 632 White Black
Sky Blue- IS:5
Ethane (LIQ.) Dark Grey- IS:5No. 632 White
No. 101
Propane (LIQ.) Dark Grey- IS:5No. 632
P.O. Red- IS:5
Methanol (LIQ.) Dark Grey- IS:5No. 632 White
No. 538
GoldenYellow-
Acetone (LIQ.) Dark Grey- IS:5No. 632 Black
IS:5 No.356
Canary Yellow-
Aromatic Gasoline (LIQ.) Dark Grey- IS:5No. 632 Sea Green-IS:5 No. 217
No309
RawPyrolysis
Dark Grey- IS:5No. 632 Sea Green-IS:5 No. 217 Black
Gasoline(RPG)
Hydro treated PG Dark Grey- IS:5No. 632
Mixed C4 (LIQ.) Dark Grey- IS:5No. 632 P.O. Red- IS:5 No. 538 White
Dark Violet- -
LPG ( LIQ.) Dark Grey- IS:5No. 632 Sea Green-IS:5 No. 217
IS:5No. 796
DMDS (LIQ.) Black P.O. Red- IS:5 No. 538 ----
NMP (LIQ.) Black White ----
Hexane (LIQ.) Dark Grey- IS:5No. 632 GoldenYellow-IS:5 No.356 ----
Hexane I (LIQ.) Dark Grey- IS:5No. 632 Dark Violet- - IS:5No. 796 White
GoldenYellow-
C6 Raffinate (LIQ.) Dark Grey- IS:5No. 632 Smoke Grey-IS:5No. 692
IS:5 No.356
C5-C6 Cut (LIQ.) Dark Grey- IS:5No. 632 GoldenYellow-IS:5 No.356 Black
P.O. Red- IS:5
Cyclopentane (LIQ.) Dark Grey- IS:5No. 632 Sky Blue- IS:5 No. 101
No. 538
CBFS (LIQ.) Dark Grey- IS:5No. 632 Smoke Grey-IS:5No. 692 ----

Section
(Painting) System
2nd Color
Band
HYDROCARBON ( GASEOUS )
P.O. Red- IS:5
Ethylene Canary Yellow-IS:5No. 309 GoldenYellow-IS:5 No.356
No. 538
Propylene Canary Yellow-IS:5No. 309 Sea Green-IS:5 No. 217 Black
Sky Blue- IS:5
Ethane Canary Yellow-IS:5No. 309 Dark Grey- IS:5No. 632
No. 101
Dark Grey-
Propane Canary Yellow-IS:5No. 309 P.O. Red- IS:5 No. 538
IS:5No. 632
Light Brown -
Methane Canary Yellow-IS:5No. 309 Sea Green-IS:5 No. 217
IS:5No. 101
Ethane + Propane Canary Yellow-IS:5No. 309 Light Brown -IS:5No. 101 Black
Fuel Gas Canary Yellow-IS:5No. 309 Light Brown -IS:5No. 101 White
Flare Gas Pl. see the Footnote 1

Smoke Grey-
Charge Gas Canary Yellow-IS:5No. 309 P.O. Red- IS:5 No. 538
IS:5No. 692
Dark Violet- -
Regeneration Off. Gas Canary Yellow-IS:5No. 309 White
IS:5No. 796
Dark Violet- -
Butane Canary Yellow-IS:5No. 309 P.O. Red- IS:5 No. 538
IS:5No. 796
Acetylene Canary Yellow-IS:5No. 309 Light Brown -IS:5No. 101 ----
LPG Canary Yellow-IS:5No. 309 Sea Green-IS:5 No. 217 White
Charge Gas Canary Yellow-IS:5No. 309 Sea Green
CHEMICALS
Brine Black White ----
GoldenYellow-
Sodium Sulphide Black Sea Green-IS:5 No. 217
IS:5 No.356
Phosphates Black --- ----
Other Chemicals Black ---- ----

ALL LIQUIDS WHICH
DO NOT NEED
INDIVIDUAL ---- ----
Black
IDENTIFICATIONS
Footnote 1 : For Flare Line ISBL all Plant : Canary Yellow-IS: 5 No. 309
For Flare Line OSBL and OFFSITE : Smoke Grey-IS: 5 No. 692
For SS MOC Flare Line : No Finish Color
*New finish color is introduced, for Ash conveying line in Power plant: Dark Brown- IS: 5 No. 412

Section
(Painting) System
1. Scope
1.1 This procedure defines the Finish Color Coding identification of different Equipment as in
HPL..
1.2 Equipment herein refers to outside metal body surface of Vessels, Tanks, Exchangers,
Columns , Furnace etc. applicable for Uninsulated Equipment.
certain Plant Specific modifications, the approval note of which has to be with Inspection.
3. Definitions
3.1 Ground Colors
3.1.1 This is the final finish color of the pipelines ( TABLE 1 )
Equipment Finish Color

STORAGE TANKS
Tank Farm Area Tanks Milky White
Naphtha Tanks Milky White
All other Tanks at AU, IOP and other areas Milky White
FURNACES
NCU Heater Body Aluminum Color
AU Furnace Body Aluminum Color
EXCHANGERS & PRESSURE VESSEL

Ambient Temp. to upto 80 deg. C MAWT outside Dark Adm. Grey- IS:5 No. 632
metal skin

Equipment Amanullah Mandal Mondal Date 02.06.21
Section
(Painting) System
1. Scope
1.5 This procedure defines the Finish Color Coding identification of different Structures,
Supports, Beams , Casings , Electrical & Instrumentation Structures and other associates
as in HPL .
certain Plant Specific modifications, the approval note of which has to be with Inspection.
1.8
section thereof.
3. Definitions
3.2 Ground Colors
3.2.1 This is the final finish color of the structures ( TABLE 1 )
Structural Finish Color

PLANT BUILDING STRUCTURAL STEEL
Beams, Brackets, Bracings , Vertical Column Opaline Green -IS:5 No. 275 or Dark Grey-
Channels and all support structures IS:5No. 632 as applicable as-is where-is basis.
Opaline Green -IS:5 No. 275 or Dark Grey-

Pipe Rack Structures and Supports
IS:5No. 632 as applicable as-is where-is basis.
As applicable in HPL Polymer Plants ( LLDPE, HDPE, PP ) in general will be DARK GRAY Finish
Shade and Non Polymer Plants ( NCU, AU ) in general will be OPALINE GREEN Finish Shade by
default except any specific cases
Building Roof Cover
Flare Line Trestles & Supports Opaline Green -IS:5 No. 275
GANTRY
Gantry Handrail System Golden Yellow IS : 5 No. 356
Gantry Structural and Supports Dark Grey- IS: 5 No. 632

Structure Amanullah Mandal Mondal Date 02.06.21
Section
(Painting) System
WALK WAYS
Gratings ( Galvanized ) Normal Galvanizing Color
Chequered Plates Black

Underneath & Side Support Plate Structures to
Black
Gratings
HANDRAILING SYSTEMS
Hand Rails Golden Yellow IS : 5 No. 356
Middle Rails Golden Yellow IS : 5 No. 356
Vertical Post Rails Golden Yellow IS : 5 No. 356
Toe Plates Golden Yellow IS : 5 No. 356
PUMP CASINGS
Plant wise in general Opaline Green -IS:5 No. 275
PUMP BASE FRAME
Base Frame remains generally Dry Opaline Green -IS:5 No. 275
Base Frame- remains generally Wet by WATER
Black
only
Base Frame remains intermittently/
continuously wet by spillage of Chemicals/ White
Solvents
ELECTRICAL ITEMS
Opaline Green -IS:5 No. 275
Electrical Cable Trays - Plant wise in general Or Dark Grey- IS:5 No. 632 as per previous
shade
Electrical Cable Trays - near Cooling Tower
Black
area
Electrical Towers Aluminum to IS : 2339
Electrical Light Poles Aluminum to IS : 2339
Plant Announcing Speaker Structural Stands Dark Grey- IS:5 No. 632
Cathodic Protection System Box Dark Grey- IS:5 No. 632

Section
(Painting) System
INSTRUMENTATION STRUCTURALS
Hot LG structure Frame Admiralty Grey
Cold and Subzero LG structure frame Admiralty Grey ( Anti rust coat )
Canopy Structure Sea Green -IS:5 No. 217
Control Valves Red/Green as per existing
Actuator Body Fire Red or Sea Green as per previous shade
G.C. Shelter Floor Base Frame (inside/ outside) Black
FIRE FIGHTING SYSTEMS

On Concrete Support Structures to Hydrant,
Black or White Wrapping Coatings
Monitors
Hydrant, Monitor Isolation Valves and Flanges Silver
Wheel of Isolation Valves of Hydrant, Monitors Black
Fire Water Line and On-Line Isolation Valves P.O. Red- IS:5 No. 538 Matt Finish
Hose Box and its stands P.O. Red- IS:5 No. 538 Matt Finish

Section
FRP Coating specification IP/G/GEN/IS_FRP COATING S-1
1.1. General
1.1.1 The applications method, given in this standard is general in nature. The contractor is
responsible for applying an FRP coating/Lining that will give a satisfactory operational performance
and the requirements given herein shall be regarded as the acceptable minimum. The contractor shall
carryout the work in accordance with applicable standard.
The contractor shall only FRP coat those sections of the plant that has been specifically released
for such work by the engineer in charge. If FRP Lining is installed before pressure test, then all
welds and flanged joints in the pipe shall be left uncovered till successful competition of pressure test.
Then FRP Coating shall be completed.
1.1.2 Insulated surface shall be thoroughly cleaned, dried, and made free from lose scale, oil, or
grease. It shall be the contractor responsibility to remove loosely adhering scale and dirt before
applying insulation.
1.1.3 Corrosion Prevention
1.1.3.1 The desire surface to be lined properly clean & is free from water grease foreign
deposition etc. with SSPC SP1 specification, and surface preparation standard for FRP Coating (in
case of maintenance based old, erected pipeline / equipment) shall be of grade ST2 (manual
mechanical tool cleaning with help of wire brush, chipping hammer, mechanical striking tool etc.) or
ST3 (power tool cleaning by rotating abrasive wheel like grinding, buffing etc.) or Sa 2½ (abrasive
blasting) for new installation.
2.1. References standard
BS EN 13121 Latest edition

ASME RTP Latest edition
ASME NM Latest edition
ISO 14692 Latest edition.
3.1. Coating material requirement
Material: Composite material consists of epoxy/vinyl ester resin mixed with suitable hardener/catalyst
and ECR Woven roving fabric.
Epoxy Resin and Hardener - Epoxy resin and Curing agent/Hardener (Aromatic Amine) shall be
confirm to ASTM D 2517 or Epoxy value 5.2-5.4 Eq/kg, Tensile strength 60 N/mm2,
Tensile Modulus 3000 N/mm2, Flexural strength 100 N/mm2, Flexural Modulus 3100
N/mm2, Barcol hardness 45 BHU, Heat distortion temperature - 800C, Water absorption at
250C 50mg, Fracture Elongation 2.5., chemical resistance in sea water 700C and
Curing temperature 30 to 400C.

FRP Coating Issue no Date: 1
Specification
Date: 10/6/2023
Inspection
Section
FRP Coating specification IP/G/GEN/IS_FRP COATING S-1
Bisphenol A vinyl ester Tensile strength 60 N/mm2, Tensile Modulus 3000 N/mm2, Flexural
strength 100 N/mm2, Flexural Modulus 3100 N/mm2, Barcol hardness 40 BHU, Heat
distortion temperature - 700C, Water absorption at 250C 80mg, Fracture Elongation 2.5.
Reinforcing material (Type ECR glass Na2O <1%)) shall be made of textile yarn or roving. The
density of yarn/ , ratio of mass of warp and weft, bi or unidirectional. Mass per unit
area shall be 600g/m2 to 1200g/m2. Fabric shall be in accordance with ISO 2113 and roving
of filament winding as per ISO 2797.
Surface Veil- exotic veil such that carbon fiber veil will be applied as final layer followed with resin
coat about 300 microns.
Pigments are permissible only on the outer resin surface and shall be applied after visual inspection
has been carried out.
Thickness - laminate thickness with corrosion barrier shall not be less than 3mm.
Note: - Combined Chopped Strand Mat (CSM)/Woven fabric or multi axial fabrics may be used

FRP Coating Issue no Date: 1
Specification
Date: 10/6/2023
Inspection
Section

6778 EQS G0000 EB 0007 - Painting

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HPL Contract No.

Plant Client Contract Code Document ID

PROJECT Haldia HPL tkIS Contract No.

GENERAL ENGINEERING SPECIFICATION

PROJECT Haldia HPL tkIS Contract No.

GENERAL ENGINEERING SPECIFICATION

Appendix A Colour coding and lettering of Equipment and piping

PROJECT Haldia HPL tkIS Contract No.

GENERAL ENGINEERING SPECIFICATION

For under insulation painting refer :Annexure -2

For FRP coating specification refer : Annexure – 2

Quantity survey for painting shall be as per UN 9257-91.

Scope of painting for various equipment shall be as below:

PROJECT Haldia HPL tkIS Contract No.

GENERAL ENGINEERING SPECIFICATION

3 Approved Paint manufacturers

4 Painting of Stainless steel surfaces

PROJECT Haldia HPL tkIS Contract No.

GENERAL ENGINEERING SPECIFICATION

5 Painting of steel surfaces under fireproofing

PROJECT Haldia HPL tkIS Contract No.

GENERAL ENGINEERING SPECIFICATION

Annexure-1 : Reference tkIS India Standards

Standard No. Part Title Issue Dt

UN 9257-91 - ERECTION – QUANTITY SURVEY OF PAINTING 04-2009

UN 9250-01 1 (M) ERECTION – WAREHOUSING 08-2008

Annexure-2 : Reference Painting specification standards

Standard No. Part Title Issue Dt

IP/ G/ Gen / 2nd June,

PROJECT Haldia HPL tkIS Contract No.

PROJECT Haldia HPL tkIS Contract No.

PROJECT Haldia HPL tkIS Contract No.

1 Procedure of Colour Coding of Pipelines

2 Marking by Lettering & Symbols

Table 1 Colours for Lettering and Symbols

Surface Lettering / Symbol

PROJECT Haldia HPL tkIS Contract No.

Nominal Size Dimensions of Arrow in mm

PROJECT Haldia HPL tkIS Contract No.

2.2 Application of the markings

PROJECT Haldia HPL tkIS Contract No.

UN 9257-91 - ERECTION – QUANTITY SURVEY OF PAINTING 04-2009

UN 9250-01 1 (M) ERECTION – WAREHOUSING 08-2008

2 Units, Abbreviated Terms

14.05.09 Kuhnke 25.05.09 Jakob 19.05.09 Fellner 26.05.09 Dr. Lazaridis

© 2009 Uhde GmbH

2.2 Abbreviated Terms

4 General notes to quantity surveying

5 Quantity survey of steel structures

Figure 1. Uncoated surfaces of steel sections

Table 2. Surfaces of I-beams in m²/m

Table 3. Surfaces of channels / Z-bars / T-bars and angles in m²/m

6 Quantity survey of process equipment

The abbreviations used in the formula are specified in section 2.2.

6.2 Round vessels

6.2.1 Circular surfaces

Figure 2. Circular surfaces

6.2.2 Oval surfaces

Figure 3. Oval surfaces