Standard for Protective Coating

(Painting) System

Ref No – IP / G / Gen / IS_PAINT

Rev – 02

Issued by : INSPECTION SECTION

Issued Date : 7th October , 2016

Haldia Petrochemicals Limited

Haldia – W.B.

Revision by Checked by Approved by

Ramaprasad Baral 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
th
0 30 May’01 First time preparation Shamik Ch. D.D.C. S.R. Ghosh
th
1 10 Oct ‘06 Incorporation of ASME – 2004 Ananda Shamik Debjiban Ray
edition revision statements Sarkar Chowdhury
th
2 7 Oct ‘16 Revision for New Project R P Baral Manas Mandal Chayan Mondal
Construction

INDEX
Sec Para Description Page
No No No

S-1 Protective Coating - Selection and Application standard 1-6

S-2 Maintenance / New Construction Protective Coating System 1-3

S-3 Protective Coating System alternate Options – ( Maintenance and New 1-6
Construction)

S-4 Protective Coating Systems - HPL Specification 1 - 12

S-5 Surface Preparation Standards 1

S-6 Specification of Primer 1-2

S-7 Specification of Paint Coatings 1-3

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

Ramaprasad Baral 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 .
- Before deployment to job , Inspector’s knowledge and competence 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: 2

Protective Coating – Selection Ramaprasad Manas Chayan Issue no: 2
and Application Standard Baral Mandal Mondal
Date 7.10.16
Page no : 1 Inspection
Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-1
(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
- Hygrometer for recording relative humidity
- Contact type Thermometer
- Surface Profile gauge for measurement of Surface profile in – micron
- Surface profile comparator standard
- Cross hatch adhesion tester to check the bonding of Paint

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 mainteanace 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 .

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

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating – Selection Ramaprasad Manas Chayan Issue no: 2
and Application Standard Baral Mandal Mondal
Date 7.10.16
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 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-1
(Painting ) System

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 % Maxm . Same shall be measured by
Hygrometer
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
st
mentioned in the Coating specification .( as required by the Primer / 1 Coat )
- SA 2 ½ surface finish will be achieved by Shot Blasting / Grit Blasting . Unless specific approval is
accorded for special case , Sand Blasting will be not be allowed.
- Blasting shall always be conducted in a separately marked covered area .
- Grit / Shot size will be controlled by filtering through 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 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 .

Topic Name Prepared by Checked by Approved by Rev no: 2

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and Application Standard Baral Mandal Mondal
Date 7.10.16
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Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-1
(Painting ) System

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 Paint Manufacturer’s specification .
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
o Minimum Temp = 5 deg C or 3 deg C above Due Point temperature , whichever is
higher
o 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 )

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 .
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

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating – Selection Ramaprasad Manas Chayan Issue no: 2
and Application Standard Baral Mandal Mondal
Date 7.10.16
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 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-1
(Painting ) System

10 Inspection Method and Acceptance standard

Inspection check points before giving clearance for job execution

- Relative Humidity shall be within 85 % Maxm as measured by Hygrometer .
- Temperature of the Item as measured by a calibrated Contact Thermometer shall be within the
Range of
o Minimum Temp = 5 deg C or 3 deg C above Due Point temperature , whichever is
higher
o 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 Grit / Shot blasting
- Surface profile achieved on a test piece visa vis the a) Grit 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
o Grit size controlled thru Filtering thru Mesh
o Air Pressure
o Distance of Blasted surface from the Blast nozzle
o Air shall be dry
Inspection check points after completion of Surface preparation
- Profile shall be within specification as measured by Surface profile gauge .
- 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.

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 ( Primer ) DFT shall be measured to record existing coat DFT ( This
st
is not applicable if the 1 coat is applied over bare metal surface ) .
- 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 .

Topic Name Prepared by Checked by Approved by Rev no: 2

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and Application Standard Baral Mandal Mondal
Date 7.10.16
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Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-1
(Painting ) System

- For DFT measurement , one reading per 1 sq.m. shall be taken with minimum 5 readings .
- No reading shall be less than 70 % 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 .

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 .
In case the Paint fails in this Test , Paint performance will be declared as “ NON ACCEPTABLE “

11 Inspection Records

Records of measurement of all Inspection ( Quality ) Parameters as mentioned above in Para 9 will be
maintained.

Topic Name Prepared by Checked by Approved by Rev no: 2

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and Application Standard Baral Mandal Mondal
Date 7.10.16
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Section
 Document Name Document Ref No 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 .
Surf Primer Details Finish Coat Details
ace Coatin Minm No Minm
Shade Stan g Prim No of DFT per Coati DFT per
recoat of recoat
dard Primer specification er Coat Coat Coating specification ng Coat
System Code s (micro)
interv
Code
Coat
(micro)
interv
# al s al
Above Ground( AG ) Piping at Ambient Temp ( Upto 60 deg C ) : No Water immersion / Water Mist envelope No Chemical Exposure
ST2/3/
All shades SA2 ½
HCS-01 Modified Mastic Epoxy P-4 1 125-150 16 hrs HB Chlorinated Rubber C-2 2 30 8 hrs
ST2/3/
Dark Grey SA2 ½
HCS-02 Modified Mastic Epoxy P-4 1 125-150 16 hrs Modified Mastic Epoxy P-4 1 125-150 16 hrs
ST2/3/ Modified Coal Tar Epoxy
Smoke Grey HCS- 03 P-3 1 125-150 16 hrs Water based Acrylic Finish C-3 2 20-25 8 hrs
SA2 ½ Mastic
Structural / Hand Rail / Chequered Plate / Equipment shell & casing / Equipment Base / Cable Tray / Valves / Electrical Poles at Ambient Temp (Upto 60 deg C ) :
No Water immersion / Water Mist envelope or Chemical Exposure
ST2/3/
All shades SA2 ½
HCS-01 Modified Mastic Epoxy P-4 1 125-150 16 hrs HB Chlorinated Rubber C-2 2 30 8 hrs
ST2/3/
Dark Grey SA2 ½
HCS-02 Modified Mastic Epoxy P-4 1 125-150 16 hrs Modified Mastic Epoxy P-4 1 125-150 16 hrs
ST2/3/ Modified Coal Tar Epoxy
Opaline Green SA2 ½
HCS- 03 P-3 1 125-150 16 hrs Water based Acrylic Finish C-3 2 20-25 8 hrs
Mastic
ST2/3/ Modified Coal Tar Epoxy Modified Coal Tar Epoxy
Black HCS- 04 P-3 1 125-150 16 hrs P-3 1 125-150 16 hrs
SA2 ½ Mastic Mastic
Grating and Chequered Plates
ST2/3/ Modified Coal Tar Epoxy Modified Coal Tar Epoxy
Black SA2 ½
HCS- 04 P-3 1 125-150 16 hrs P-3 1 125-150 16 hrs
Mastic Mastic
Hand Rails
ST2/3/
Golden Yellow SA2 ½
HCS-01 Modified Mastic Epoxy P-4 1 125-150 16 hrs HB Chlorinated Rubber C-2 2 30 8 hrs
Electric Poles
ST2/3/ Zinc Phosphate Synthetic
Aluminum HCS-13 P-5 2 50 16 hrs Synthetic Enamel Finish C-4 2 20-25 16 hrs
SA2 ½ Base
Shade Surfac Coatin Primer Details Finish Coat Details

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Baral Date 7.10.16
Page no : 1 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-2

e g
Minm No Minm
Stand System Prim No of DFT per Coati DFT per
# recoat of recoat
ard Primer specification er Coat Coat Coating specification ng Coat
interv Coat interv
Code s (micro) Code (micro)
al s al

Piping , Structural , Cable Tray : Continuous. / Intermit. Water Immersion or Continuous. Water Mist envelope near Cooling Tower

ST2/3/S Modified Coal Tar Epoxy Modified Coal Tar Epoxy

Black HCS- 04 P-3 1 125-150 16 hrs P-3 1 125-150 16 hrs
A2½ Mastic Mastic
Opaline ST2/3/S Modified Coal Tar Epoxy
HCS- 05 P-3 2 125-150 16 hrs Water based Acrylic Finish C-3 2 20-25 8 hrs
Green A2½ Mastic

CT Riser Pipe : Continuous. Water Mist envelope at Cooling Tower

ST2/3/S HB Black Bitumen -

Black A2 ½
HCS- 06 HB Black Bitumen - thinned P-9 1 75-100 16 hrs P-9 1 75-100 16 hrs
thinned

Sweating Line : On Sweat application : After ST 2 / ST 3 surface preparation : Coarse Water Wash . On sweat condition Paint application

ST2/3 Sweat Tolerant HB Epoxy 72-80 Sweat Tolerant HB Epoxy 72-80

HCS-14 C-8 1 100 C-8 1 100
Special Coat hrs Coat hrs

Pipe Line under Cold Insulation and Corrosion Protective Wrapping and Coating

Procedure and Primer as per the Item spec supplied by Insulation / Wrapping - Coating Material Vendor . In absence of same following :
ST2/3/S
A2½ Modified Coal Tar Epoxy
HCS-12 P-3 2 125-150 16 hrs
Mastic

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

Topic Name Prepared by Checked by Approved by Rev no: 2

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Baral Date 7.10.16
Page no : 2 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-2

Temp range Primer Details Finish Coat Details

From To Minm Minm
Surface No DFT No
( deg (deg Coating Prime recoa Coati DFT per recoa
Shade C) C) Standa Primer of per of
# System r t Coating specification ng Coat t
rd specification Coa Coat Coa
Code interv Code (micro) interv
ts (micro) ts
al al

Pipe Line / Equipment : High temperature

Dark ST2/3/SA Modified 125-

60 100 2½
HCS-02 P-4 1 16 hrs Modified Mastic Epoxy P-4 1 125-150 16 hrs
Grey Mastic Epoxy 150

Alumin ST2/3/SA
100 250 2½
HCS-08 Heat resistant Aluminum Paint C-5 2 15-20 16 hrs
um
Inorganic
Alumin
100 250 SA 2 ½ HCS-08.1 Zinc Silicate P-6 1 65-75 16 hrs Heat resistant Aluminum Paint C-5 2 15-20 16 hrs
um
primer
Alumin ST2/3/SA Heat resistant Silicon
250 400 HCS-09 C-6 2 20 - 25 16 hrs
um 2½ Aluminum Paint – 400 deg C
Inorganic
Alumin Heat resistant Silicon
250 400 SA 2 ½ HCS-10 Zinc Silicate P-6 1 65-75 16 hrs C-6 2 20 - 25 16 hrs
um Aluminum Paint – 400 deg C
primer
Inorganic
Smoke
250 400 SA 2 ½ HCS- 10.1 Zinc Silicate P-6 1 65-75 16 hrs
Grey
primer
Alumin Heat resistant Silicon
400 500 SA 2 ½ HCS-11 C-6 2 20 - 25 16 hrs
um Aluminum Paint – 500 deg C

Alumin Heat resistant Silicon

400 600 SA 2 ½ HCS-11 C-6 2 20 - 25 16 hrs
um Aluminum Paint – 600 deg C

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

Topic Name Prepared by Checked by Approved by Rev no: 2

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Baral Date 7.10.16
Page no : 3 Inspection Section
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Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-3

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 and New Construction .
Primer ( 1st Coat )_ details Intermediate Coat details Finish Coat details
Surfac
HC DFT No
e No DFT DFT per
S Primer per HPL of
Standa HPL No of Intermediate Coat HPL of per Coat
No specificati Coat Finish Coat specification Cod Co
rd Code Coats Specs Code Coa Coat (micron
on (micro e at
ts (micro) )
n) s
Above Ground Piping , Equipment , Structural - at Ambient Temp ( Upto 60 deg C ) : No Water immersion / Water Mist envelope No Chemical Exposure

19 Epoxy HB Poly amide Finish C-1 1 100-125

HB MIO Epoxy -
21 Intermediate Coat - 100- Acrylic Poly Urethane C-7 2 30-35
C-12 1
Polyamide Cured 125 Epoxy Amine Adduct Cured –
20 C-9 2 30-35
Glossy CR Enamel
Inorganic
22 Zinc HB Chlorinated Rubber finish C-2 2 30
P-6 1 65-75
Silicate
19.1 Primer Epoxy HB Poly amide Finish C-1 2 100-125
Epoxy Zinc Phosphate
P-1 1 25-35
primer Epoxy Amine Adduct Cured –
20.1 C-9 2 30-35
SA 2 ½ Glossy CR Enamel
Super HB Aliphatic 150-
21.1 C-10 1 Acrylic Poly Urethane C-7 2 30-35
Amine Epoxy 200
19.2 Epoxy HB Poly amide Finish C-1 2 100-125

23 Epoxy HB Poly amide Finish C-1 1 100-125

HB MIO Epoxy -
25 Epoxy Acrylic Poly Urethane C-7 2 30-35
Intermediate Coat - 100-
Zinc C-12 1
P-1 2 25-35 Polyamide Cured 125 Epoxy Amine Adduct Cured –
24 Phosphate C-9 2 30-35
Glossy CR Enamel
primer
26 HB Chlorinated Rubber finish C-2 2 30
23.1 Epoxy HB Poly amide Finish C-1 2 100-125

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems Options Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
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 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-3

st
Primer ( 1 Coat )_ details Intermediate Coat details Finish Coat details
Surfac
HC No
e DFT per No DFT DFT per
S Primer No of HPL of
Standa HPL Coat Intermediate Coat HPL of per Coat
No specificat Coat Finish Coat specification Cod Co
rd # Code (micron Specs Code Coa Coat (micron
ion s e at
) ts (micro) )
s

Above Ground Piping , Equipment , Structural - at Ambient Temp ( Upto 60 deg C ) : No Water immersion / Water Mist envelope No Chemical Exposure
17 Epoxy HB Poly amide Finish C-1 2 100-125

Epoxy HB Poly amide 100-

18 C-1 1 Acrylic Poly Urethane C-7 2 30-35
Finish 125
HB MIO Epoxy -
100- Epoxy Amine Adduct Cured –
15 Intermediate- Polyamide C-12 1 C-9 2 30-35
125 Glossy CR Enamel
cured
Epoxy Amine Adduct Cured –
16 Modified C-9 2 30-35
Glossy CR Enamel
Mastic P-4 1 125-150
Epoxy HB MIO Chloro rubber
01.1 ST2/3/ C-13 1 50-75 HB Chlorinated Rubber finish C-2 2 30
SA2 ½ Intermediate Coat

01 HB Chlorinated Rubber finish C-2 2 30

Modified Coal Tar Epoxy 125-
03.1 P-3 1 Water based Acrylic Finish C-3 2 20-25
Mastic 150
Modified Coal Tar Epoxy 125-
03.2 P-3 1
Mastic 150
Modified
Coal Tar
03 P-3 1 125-150 Water based Acrylic Finish C-3 2 20-25
Epoxy
Mastic
#
N.B: The surface preparation standards in HPL are ST2 / ST3 for Maintenance Protective Coating only & SA 2 ½ for New Construction activity.

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems Options Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
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 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-3

st
Primer ( 1 Coat )_ details Intermediate Coat details Finish Coat details
Surfac
HCS e DFT DFT
No No
No Standa HPL DFT per HPL per HPL per
Primer No of Intermediate Coat of of
rd Cod Coat Cod Coat Finish Coat specification Cod Coat
specification Coats Specs Coa Co
e (micron) e (micr e (micro
ts ats
o) n)
Above Ground Piping , Equipment , Structural - at Ambient Temp ( Upto 60 deg C ) : :
Continuous. / Intermit. Water Immersion or Continuous. Water Mist envelope near Cooling Tower

28 150- Water based Acrylic Finish C-3 2 20-25

Coal Tar Epoxy HB P- 8 2
200
28.2
Inorganic
Zinc Silicate P-6 1 65-75 150-
29.2 Coal Tar Epoxy HB P- 8 2
Primer HB MIO Epoxy – 200
C- 100-
Intermediate - 1 P- 8 2 150-
12 125 Coal Tar Epoxy HB &
29 Polyamide Cured & & 200 &
Water based Acrylic Finish
C-3 2 20-25
SA 2 ½
30 150- Water based Acrylic Finish C-3 2 20-25
Coal Tar Epoxy HB P- 8 2
200
30.2
Epoxy Zinc
Phosphate P-1 1 25-35 150-
31.2 Coal Tar Epoxy HB P- 8 2
primer HB MIO Epoxy – 200
C- 100-
Intermediate - 1 P- 8 2 150-
12 125 Coal Tar Epoxy HB &
31 Polyamide Cured & & 200 &
Water based Acrylic Finish
C-3 2 20-25

CT Riser Pipe : Continuous. Water Mist envelope near Cooling Tower

Inorganic
SA 2 HB Black Bitumen - 75-
06 Zinc Silicate P-6 1 65-75 P-9 1 HB Black Bitumen - thinned P-9 1 75-100
½ thinned 100
Primer

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems Options Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
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 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-3

st
Primer ( 1 Coat )_ details Intermediate Coat details Finish Coat details
Surfac
HCS e DFT DFT
No No
No Standa HPL DFT per HPL per HPL per
# Primer No of Intermediate Coat of of
rd Cod Coat Cod Coat Finish Coat specification Cod Coat
specification Coats Specs Coa Co
e (micron) e (micr e (micro
ts ats
o) n)
Above Ground Piping , Equipment , Structural - at Ambient Temp ( Upto 60 deg C ) : :
Continuous. / Intermit. Water Immersion or Continuous. Water Mist envelope near Cooling Tower

04 Modified Coal
Tar Epoxy P-3 2 125-150
05 Mastic Water based Acrylic Finish C-3 2 20-25
ST2/3/
SA2 ½ Modified Modified Coal Tar 125-
03.4 P-4 1 125-150 P-3 2 Water based Acrylic Finish C-3 2 20-25
Mastic Epoxy Epoxy Mastic 150
Modified Modified Coal Tar 125-
03.3 P-4 1 125-150 P-3 2
Mastic Epoxy Epoxy Mastic 150

CT Riser Pipe : Continuous. Water Mist envelope near Cooling Tower

HB Black
ST2/3/ HB Black Bitumen - 75-
06 Bitumen - P-9 1 75-100 P-9 1
SA2 ½ thinned 100
thinned

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

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems Options Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
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 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-3

Temp range Primer Details Finish Coat Details

From To Minm Minm
Surface Pri No No
HCS ( deg (deg DFT per recoa Coati DFT per recoa
Shade Standar Primer mer of of
No C) C) # Coat t Coating specification ng Coat t
d specification Cod Co Coa
(micro) interv Code (micro) interv
e ats ts
al al

Pipe Line / Equipment : High temperature

Dark ST2/3/S Modified Mastic

02 60 100 P-4 1 125-150 16 hrs Modified Mastic Epoxy P-4 1 125-150 16 hrs
Grey A2 ½ Epoxy

Alumin ST2/3/S Heat resistant Aluminum

08 100 250 C-5 2 15-20 16 hrs
um A2 ½ Paint

Alumin Inorganic Zinc Heat resistant Aluminum

08.1 100 250 SA 2 ½ P-6 1 65-75 16 hrs C-5 2 15-20 16 hrs
um Silicate primer Paint

Alumin Heat resistant Silicon

09 250 400 ST2/3 C-6 2 20 - 25 16 hrs
um Aluminum Paint – 400 deg C

Alumin Inorganic Zinc Heat resistant Silicon

10 250 400 SA 2 ½ P-6 1 65-75 16 hrs C-6 2 20 - 25 16 hrs
um Silicate primer Aluminum Paint – 400 deg C

Smoke Inorganic Zinc

10.1 250 400 SA 2 ½ P-6 1 65-75 16 hrs
Grey Silicate primer

Alumin Heat resistant Silicon

11 400 500 SA 2 ½ C-6 2 20 - 25 16 hrs
um Aluminum Paint – 500 deg C

Alumin Heat resistant Silicon

12 400 600 SA 2 ½ C-6 2 20 - 25 16 hrs
um Aluminum Paint – 600 deg C

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

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems Options Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
(Maintenance and New Construction) Baral Date 7.10.16
Page no : 5 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-3

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

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems Options Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
(Maintenance and New Construction) Baral Date 7.10.16
Page no : 6 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

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

Primer Modified Mastic Epoxy P-4 1 125-150 16 hrs

No Rust/Loose Paint , Dry, HB MIO Chloro 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

Primer Modified Mastic Epoxy P-4 1 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS-02 ST2/3/SA2 ½
Existing sound coat roughened
Finish Modified Mastic Epoxy P-4 1 125-150 16 hrs

Primer Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS-03 ST2/3/SA2 ½
Existing sound coat roughened
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Modified Mastic Epoxy P-4 1 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS-03.1 ST2/3/SA2 ½ Inter Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs
Existing sound coat roughened
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 1 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

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-03.2 ST2/3/SA2 ½
Existing sound coat roughened Finish Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs

Primer Modified Mastic Epoxy P-4 1 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS-03.3 ST2/3/SA2 ½
Existing sound coat roughened
Finish Modified Coal Tar Epoxy Mastic P-3 2 125-150 16 hrs

Primer Modified Mastic Epoxy P-4 1 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS-03.4 ST2/3/SA2 ½ Inter Modified Coal Tar Epoxy Mastic P-3 2 125-150 16 hrs
Existing sound coat roughened
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

No Rust/Loose Paint , Dry,

HCS-04 ST2/3/SA2 ½ Primer Modified Coal Tar Epoxy Mastic P-3 2 125-150 16 hrs
Existing sound coat roughened
No Rust/Loose Paint , Dry,
HCS-04.1 ST2/3/SA2 ½ Primer Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs
Existing sound coat roughened

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

Primer Modified Mastic Epoxy P-4 2 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS-05.1 ST2/3/SA2 ½ Inter Modified Coal Tar Epoxy Mastic P-3 1 125-150 16 hrs
Existing sound coat roughened
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 2 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

SurfacePre Minimum
Coating paration Coatin No of DFT/Coat
Surface Condition Coats Coating specification recoat
Systems # g Code Coats (micron)
standard interval
Primer HB Black Bitumen - thinned P-9 1 765-100 16 hrs
No Rust/Loose Paint , Dry,
HCS-06 ST2/3/SA2 ½
Existing sound coat roughened
Finish HB Black Bitumen - thinned P-9 1 75-100 16 hrs

Primer Modified Mastic Epoxy P-4 2 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS-07 ST2/3/SA2 ½
Existing sound coat roughened
Finish Acrylic Aliphatic Poly Urethane C-7 2 30 - 35 16 hrs

Primer
No Rust/Loose Paint , Dry,
HCS-08 ST2/3/SA2 ½
Existing sound coat roughened
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
No Rust/Loose Paint , Dry,
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

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
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
95 % white metal finish .
HCS-10.1 SA 2 1/2 Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs
Surface profile =55 – 65 micron

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 3 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

SurfacePre Minimum
Coating paration Coatin No of DFT/Coat
Surface Condition Coats Coating specification recoat
Systems # g Code Coats (micron)
standard interval
Primer
95 % white metal finish .
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
Existing sound coat roughened
Modified Coal Tar Epoxy Mastic P-3 2 125-150 16 hrs

Primer Zinc Phosphate Synthetic Base P-5 2 50 16 hrs

No Rust/Loose Paint , Dry,
HCS - 13 ST2/3/SA2 ½
Existing sound coat roughened
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

Primer Modified Mastic Epoxy P-4 1 125-150 16 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

Primer Modified Mastic Epoxy P-4 1 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS - 16 ST2/3/SA2 ½
Existing sound coat roughened Epoxy Amine adduct cured
Finish C-9 2 30 –35 16 hrs
Glossy CR Enamel

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 4 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

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 - 17 ST2/3/SA2 ½
Existing sound coat roughened
Finish Epoxy HB Poly amide Finish C-1 2 100-125 16 hrs

Primer Modified Mastic Epoxy P-4 1 125-150 16 hrs

No Rust/Loose Paint , Dry,
HCS - 18 ST2/3/SA2 ½ Interm. Epoxy HB Poly amide Finish C-1 1 100-125 16 hrs
Existing sound coat roughened
Finish Aliphatic Acrylic Poly Urethane C-11 2 30 –35 16 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 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
Finish Epoxy HB Poly amide Finish C-1 2 100-125 16 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS-19.1 SA 2 1/2 Interm. Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs
Surface profile =55 – 65 micron
Finish Epoxy HB Poly amide Finish C-1 2 100-125 16 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS-19.2 SA 2 1/2
Surface profile =55 – 65 micron
Finish Epoxy HB Poly amide Finish C-1 2 100-125 16 hrs
#
N.B: The surface preparation standards in HPL are ST2 / ST3 for Maintenance Protective Coating only & SA 2 ½ for New Construction activity.

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 5 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

Surface Minimum
Coating Coatin No of DFT/Coat
Preparatio Surface Condition Coats Coating specification recoat
Systems g Code Coats (micron)
n standard interval
Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs
95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 20 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Epoxy Amine adduct cured
Finish C-9 2 30 –35 16 hrs
Glossy CR Enamel

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS-20.1 SA 2 1/2 Interm. Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs
Surface profile =55 – 65 micron
Epoxy Amine adduct cured
Finish C-9 2 30 –35 16 hrs
Glossy CR Enamel

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 21 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Finish Aliphatic Acrylic Poly Urethane C-11 2 30 –35 16 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS-21.1 SA 2 1/2 Inter Super HB Aliphatic Amine Epoxy C-10 1 150-200 16 hrs
Surface profile =55 – 65 micron
Finish Aliphatic Acrylic Poly Urethane C-11 2 30 –35 16 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 6 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

Surface Minimum
Coating Coatin No of DFT/Coat
Preparatio Surface Condition Coats Coating specification recoat
Systems g Code Coats (micron)
n standard interval
Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs
95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 22 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Finish HB Chlorinated Rubber finish C-2 2 30 8 hrs

Primer Epoxy Zinc Phosphate primer P-1 2 25-35 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 23 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Finish Epoxy HB Poly amide Finish C-1 2 100-125 16 hrs

Primer Epoxy Zinc Phosphate primer P-1 2 25-35 16 hrs

95 % white metal finish .
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

Primer Epoxy Zinc Phosphate primer P-1 2 25-35 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 24 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Epoxy Amine adduct cured
Finish C-9 2 30 –35 16 hrs
Glossy CR Enamel

Primer Epoxy Zinc Phosphate primer P-1 2 25-35 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 25 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Finish Aliphatic Acrylic Poly Urethane C-11 2 30 –35 16 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 7 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

Surface Minimum
Coating Coatin No of DFT/Coat
Preparatio Surface Condition Coats Coating specification recoat
Systems g Code Coats (micron)
n standard interval
Primer Epoxy Zinc Phosphate primer P-1 2 25-35 16 hrs
95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 26 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Finish HB Chlorinated Rubber finish C-2 2 30 8 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS - 27 SA 2 1/2 Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Epoxy Amine adduct cured
Finish C-9 2 30 –35 16 hrs
Glossy CR Enamel

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS - 28 SA 2 ½ Inter Coal Tar Epoxy HB P- 8 2 150-200 24 hrs
Surface profile =55 – 65 micron
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS-28.1 SA 2 ½ Inter Coal Tar Epoxy HB P- 8 1 150-200 24 hrs
Surface profile =55 – 65 micron
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS-28.2 SA 2 ½
Surface profile =55 – 65 micron
Finish Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 8 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

Surface Minimum
Coating Coatin No of DFT/Coat
Preparatio Surface Condition Coats Coating specification recoat
Systems g Code Coats (micron)
n standard interval
Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs
95 % white metal finish .
HCS-28.3 SA 2 ½
Surface profile =55 – 65 micron
Finish Coal Tar Epoxy HB P- 8 1 150-200 24 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

HB MIO Epoxy - Intermediate-

Inter C-12 1 100-125 16 hrs
95 % white metal finish . Polyamide Cured
HCS-29 SA 2 ½
Surface profile =55 – 65 micron
Inter Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

HB MIO Epoxy - Intermediate-
Inter C-12 1 100-125 16 hrs
95 % white metal finish . Polyamide Cured
HCS-29.1 SA 2 ½
Surface profile =55 – 65 micron
Inter Coal Tar Epoxy HB P- 8 1 150-200 24 hrs

Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-

HCS-29.2 SA 2 ½ Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured

Finish Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 9 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

Surface Minimum
Coating Coatin No of DFT/Coat
Preparatio Surface Condition Coats Coating specification recoat
Systems g Code Coats (micron)
n standard interval
Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-

HCS-29.3 SA 2 ½ Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured

Finish Coal Tar Epoxy HB P- 8 1 150-200 24 hrs

Primer Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs

95 % white metal finish .
HCS - 30 SA 2 ½ Inter Coal Tar Epoxy HB P- 8 2 150-200 24 hrs
Surface profile =55 – 65 micron
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs

95 % white metal finish .
HCS-30.1 SA 2 ½ Inter Coal Tar Epoxy HB P- 8 1 150-200 24 hrs
Surface profile =55 – 65 micron
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs

95 % white metal finish .
HCS-30.2 SA 2 ½
Surface profile =55 – 65 micron
Finish Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

Primer Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs

95 % white metal finish .
HCS-30.3 SA 2 ½
Surface profile =55 – 65 micron
Finish Coal Tar Epoxy HB P- 8 1 150-200 24 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 10 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

Surface Minimum
Coating Coatin No of DFT/Coat
Preparatio Surface Condition Coats Coating specification recoat
Systems g Code Coats (micron)
n standard interval
Primer Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs
HB MIO Epoxy - Intermediate-
Inter C-12 1 100-125 16 hrs
95 % white metal finish . Polyamide Cured
HCS-31 SA 2 ½
Surface profile =55 – 65 micron
Inter Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs

HB MIO Epoxy - Intermediate-
95 % white metal finish . Inter C-12 1 100-125 16 hrs
HCS-31.1 SA 2 ½ Polyamide Cured
Surface profile =55 – 65 micron
Inter Coal Tar Epoxy HB P- 8 1 150-200 24 hrs
Finish Water based Acrylic Finish C-3 2 20-25 8 hrs

Primer Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS-31.2 SA 2 ½ Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Finish Coal Tar Epoxy HB P- 8 2 150-200 24 hrs

Primer Epoxy Zinc Phosphate primer P-1 1 25-35 16 hrs

95 % white metal finish . HB MIO Epoxy - Intermediate-
HCS-31.3 SA 2 ½ Inter C-12 1 100-125 16 hrs
Surface profile =55 – 65 micron Polyamide Cured
Finish Coal Tar Epoxy HB P- 8 1 150-200 24 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 11 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-4

Surface Minimum
Coating Coatin No of DFT/Coat
Preparatio Surface Condition Coats Coating specification recoat
Systems g Code Coats (micron)
n standard interval
Primer Amine adduct HB Epoxy tank Liner C-11 1 100-125 16 hrs
95 % white metal finish .
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

Primer Inorganic Zinc Silicate primer P-6 1 65-75 16 hrs

95 % white metal finish .
HCS - 33 SA 2 1/2
Surface profile =55 – 65 micron
Finish Amine adduct HB Epoxy tank Liner C-11 2 100-125 16 hrs

Primer Epoxy Zinc Phosphate primer P-1 2 25-35 16 hrs

95 % white metal finish .
HCS - 34 SA 2 1/2
Surface profile =25-30 micron
Finish Amine adduct HB Epoxy tank Liner C-11 2 100-125 16 hrs

Topic Name Prepared by Checked by Approved by Rev no: 2

Protective Coating Systems - Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
HPL Specification Baral Date 7.10.16
Page no : 12 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-5

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 .

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Surface Preparation Standards Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
Baral Date 7.10.16
Page no : 1 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-6

1. Scope

Scope of this section is to define the specifications of Protective PRIMERS applicable for HPL Maint. Protective Coating ( Painting ) System .

DFT per
Volum
Coat
HPL e
Primer Type (Micron BERGER PAINT GODLAS NEROLAC SHALIMAR PAINT P C CHANDA ASIAN PAINT
Code Solid
/ coat)
in %
minm
NEROPOXY Zn EDELPOXY APCODUR Epoxy Zn
Epilux 610
Phosphate Primer ZPPR 103 Phosphate Primer
Epoxy Zinc
P-1 35 40 EPIGARD 4 APCODUR HB Epoxy
Phosphate Primer
EPILUX 610 HB NEROPOXY HB Zn EDELPOXY Zn Phosphate Primer
Primer R.O. Phosphate Primer PR 101
APCODUR CP 689

NEROLAC HB Chloro ASIOCHLOR HB Zn

HB Zinc Phosphate LINSOL HB ZN EDELCHLOR Phosphate Primer
P-2 50 35-40 Rubber Zn Phosphate CHLOROKOTE HB
Rubber Base Primer Phosphate Primer
Primer
ZPPR 201
ASIOCHLOR CP 620

Modified Coal Tar PROTECTEROS NEROSEAL EPOXY BIPIGARD ST CTE EDELPOXY

P-3 125-150 65-80 RUST – O - SEAL
Epoxy Mastic Primer – CTE MASTIC TAR ( Surface Tolerant) Black CTE FN 169

Modified Mastic PROTECTOMAS EDELPOXY

P-4 125-150 65-80 NEROMASTIC 400 EPIPLUS - 556 RUST – O - CAP
Epoxy Primer TIC ST FN 161

Zinc Phosphate
BISON HB ZN NEROMIN HB Zn TUFFKOTE ZN EDELBRITE APCOMIN HB ZN
P-5 Synthetic Base 35-50 40-4 5
Phosphate Primer Phosphate Primer PHOSPHATE ZPPR 402 PHSPHATE
Primer

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Specification of Primer Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
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Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-6

DFT per
Volum
Coat
HPL e
Primer Type (Micron BERGER PAINT GODLAS NEROLAC SHALIMAR PAINT P C CHANDA ASIAN PAINT
Code Solid
/ coat)
in %
minm

Inorganic Zinc ZINC ANODE TUFFKOTE APCOSIL 601

P-6 65-75 60 NEROSIL 118
Silicate primer 304 ZISILICATE APCOSIL 605

Etch Primer/Wash BISON Wash EDELETCH

P-7 8-10 7-8 NEROLAC Etch Primer TUFFKOTE ETCH APCONYL WP 636
Primer: Primer PR 106

Coal Tar BIPIGARD CTE

100-125 65 NEROPOXY Coal Tar APCODUR 651
Epoxy HB- BLACK
Coal Amine EPILUX 555 CTE NEROPOXY HB Coal BIPIGARD 580 HB
Tar adduct 150-200 80 EDELPOXY
P-8 HB Tar CTE BLACK
Epoxy CTE PR 168
Coal Tar NEROLAC Epoxy Coal
HB Epoxy HB – Tar BIPIGARD CTEXL
100-120 80 EPLILUX 64 CTE APCODUR CF 655
Polyamide BLACK
adduct

NEROLAC HB Asian Bitumenous

75 47
Bitumenous Black Coating
HB Bitumen Black
P-9
Thinned
BISON HB TUFFCOTE HB BITU Asian Super Service
75-100 56
BLACK Black HB

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Specification of Primer Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
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 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-7

1. Scope

Scope of this section is to define the specifications of PROTECTIVE COATS applicable for HPL Maint. Protective Coating ( Painting ) System.

DFT per
Volum
Coat
HPL e GODLAS
Coating Type (Micron BERGER PAINT SHALIMAR PAINT P C CHANDA ASIAN PAINT
Code Solid NEROLAC
/ coat)
in %
minm
ASIAN EPOXY
EPLIUX 4 HB Finish NEROPOXY HB
Epoxy HB Poly EPIGARD XL HB EDELPOXY HB HB COAT
C-1 100-125 60-65 Coating 6061
amide Finish 533 Finish FN 132
EPLIUX 89 HB Finish APCODUR 693

LINOSOL Chloro rubber NEROCHLORO

Finish Rubber Enamel ASIAN Chloro
HB Chlorinated CHLOROKOTE HB EDELCHLOR
C-2 30 30 Rubber HB
Rubber finish Finish FN 222
LINOSOL - HB Chloro NEROCHLORO COAT
rubber Finish HB Rubber Enamel

Water based Acrylic PROTECTEROS- Acrylic Suraksha Acrylic TUFFCOTE WB ASIACRYL WB

C-3 20-25 35 WALTONE
Finish Finish Emulsion Acrylic 531

NEROLAC X
TUFFKOTE APCOMIN
Synthetic Enamel TORPEDO Synthetic synthetic Enamel EDELBRITE
C-4 20-25 30-40 Chemical Resisting Synthetic
Finish Paint Enamel NEROMIN SYFN 436
Enamel ENAMEL
Synthetic Enamel

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Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-7

DFT
per Maxm
Volu
Coat temp
HPL me GODLAS
Coating Type (Micro resistan BERGER PAINT SHALIMAR PAINT P C CHANDA ASIAN PAINT
Code Solid NEROLAC
n/ ce (deg
in %
coat) C)
minm
FERROTOL HR
Heat resistant Aluminum NEROTHERM - HR LUSTROL EDEL ALU 250 ASIAN HR
C-5 15-20 20-25 250
Aluminum Paint 250 ALUMINIUM HR 601 ALUMINIUM
CORROHEAT
Alluminum
APCOTHERM HR
EDELSIL HR 603
300
( upto 350 deg C)
( upto 300 deg C)
NEROTHERM LUSTROTHERM
LUMEROS HR 47 APCOTHERM HR
400 Sl HT 400 SI – AL
( 250 – 400 deg C ) Finish ( 250-400)
(Upto 400 degC) ( 250 – 400 deg C )

Heat resistant LUMEROS HR 123 APCOTHERM HR

C-6 Silicon Aluminum 20 20-25 > 250 (250-500 deg C ) 500 ( 250-500)
Paint NEROTHERM
HR Silicone
HR Silicone Alluminum 538
Alluminum
(250-500 deg C ) (upto 538 deg
(250-500 deg C )
C)

LUSTROTHERM EDELSIL 600 HR APCOTHERM HR

LUMEROS HR 143
HT 600 SI – AL 602 (250-600 deg 600
(400-600 deg C )
(400-600 deg C ) C) (400-600 deg C )

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Specification of Paint Coatings Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
Baral Date 7.10.16
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 Document Name Document Ref No Section
Standard of Protective Coating (Painting ) System IP/G/GEN/IS_PAINT S-7

DFT
per Volu
HPL Coat me GODLAS
Coating Type BERGER PAINT SHALIMAR PAINT P C CHANDA ASIAN PAINT
Code (Micron Solid NEROLAC
/ coat) in %
minm

Acrylic Aliphatic BERGERTHANE SHALITHANE EDELTHANE FN APCOTHANE CF

C-7 30-35 45
Poly Urethane FINISH FINSIH 311 674 or 675

Sweat Tolerant HB
C-8 AMERLOC 400
Epoxy Coat

Epoxy Amine EPILUX 84 High

NEROPOXY
C-9 adduct cured 30-35 45 Gloss Chemical
Enamel 40 FA
EPIGARD 4 FINISH APCODUR CF 691
Glossy CR Enamel Resistant Enamel

Super HB Aliphatic EPILUX 950

C-10 200
Amine Epoxy SUPER HB

Amine adduct HB NEROPOXY 62 TL EPIGARD TL HB

C-11 100-150 60 EPILUX 78 HTBL APCODUR CF 699
Epoxy tank Liner HB Coat 533 Finish

HB MIO Epoxy -
NEROPOXY 266 EDELPOXY HB MIO APCODUR EPOXY
C-12 Intermediate- 75-100 50 EPILUX HB MIO
HB MIO Coat
EPIGARD HB MIO
116 MIO Paint
Polyamide Cured
HB MIO Chloro
NEROCHLOR HB CHLOROKOTE HB EDELCHLOR HB ASIACHLOR HB
C-13 rubber Intermediate 50-75 45 LINOSOL HB MIO
MIO MIO MIO 211 MIO
Coat

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Specification of Paint Coatings Ramaprasad Manas Mandal Chayan Mondal Issue no: 2
Baral Date 7.10.16
Page no : 3 Inspection Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-8
(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

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Standard of Protective Coating IP/G/GEN/IS_PAINT S-8
(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 st
1 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
nd
Near 95 % white metal cleanliness by 2 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 ( 1.5 –
75/100 micron
2mm grain size)

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Standard of Protective Coating IP/G/GEN/IS_PAINT S-8
(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 .

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Standard of Protective Coating IP/G/GEN/IS_PAINT S-8
(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 .

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Standard of Protective Coating IP/G/GEN/IS_PAINT S-8
(Painting) System

Advantages Limitation Comments

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
Won’t crack / degrade in sunlight . 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.

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Standard of Protective Coating IP/G/GEN/IS_PAINT S-8
(Painting) System

Advantages Limitation Comments

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 .

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(Painting) System

Advantages Limitation Comments

Polyamide cured epoxy
Superior to amine cured epoxy for Cross linking doesn’t occur below 5 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 .
Won’t cure below 5 deg C .
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 .

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(Painting) System

Advantages Limitation Comments

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 . Applied in large thickness ( 500  to 5
performance corrosion resistant Need blast surface when used as a mm )
lining for Steel and Concrete . primer .
Limited Pot life .

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(Painting) System

Advantages Limitation Comments

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
2 Over coating within 72 hrs
Coat ( 404 gm / m / 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

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Standard of Protective Coating IP/G/GEN/IS_PAINT S-8
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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

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Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-9
(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 procedure is not applicable for any Underground Pipelines or it’s section and
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.

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Standard of Protective Coating IP/G/GEN/IS_PAINT S-9
(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 .

TABLE 1 follows….

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 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-9
(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 Fire Red- IS:5 No. 536 ----
Condensate Water Sea Green- IS:5 No. 217 Light Brown-IS:5 No. 410 ----
Fire Red- IS:5
Drinking Water Sea Green- IS:5 No. 217 Sky Blue- - IS:5 No. 101
No. 536
Fire Red- IS:5
Waste Water Sea Green- IS:5 No. 217 Golden Yellow- IS:5 No. 356
No. 536
Fire Red- IS:5
Quench Water Sea Green- IS:5 No. 217 Dark Adm. Grey- IS:5 No. 632
No. 536
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 Fire Red - IS:5 No. 536 ---- ---
Untreated River Water Fire Red - IS:5 No. 536 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 Fire Red- IS:5 No. 536 ----
Kg/ cm2
Vacuum Sky Blue- - IS:5 No. 101 Black ----
STEAM
Very High Pressure
Aluminum to IS : 2339 Fire Red- IS:5 No. 536 ----
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

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 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-9
(Painting) System

2nd Color
Pipeline Service Finish Color 1st Color Band
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 Fire Red- IS:5 No. 536
No. 101
Hydrogen Sulphide Canary Yellow-IS:5No. 309 Fire Red- IS:5 No. 536 ----
Oxygen Canary Yellow-IS:5No. 309 White ----
Nitrogen Deep Orange - IS:5No. 591 Black ----
Chlorine Canary Yellow-IS:5No. 309 Fire Red- IS:5 No. 536 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 Fire Red- IS:5 No. 536
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 Fire Red- IS:5 No. 536 White
CanaryYellow-
Waste/ Spent Caustic Dark Violet- - IS:5No. 796 White
IS5No.309

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 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-9
(Painting) System

2nd Color
Pipeline Service Finish Color 1st Color Band
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
Fire Red- IS:5
Ethylene Glycol (LIQ.) Dark Grey- IS:5No. 632 Sea Green-IS:5 No. 217
No. 536
Ethylene Dichloride
Dark Grey- IS:5No. 632 Fire Red- IS:5 No. 536 ----
(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
Fire Red- IS:5
Methanol (LIQ.) Dark Grey- IS:5No. 632 White
No. 536
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 Fire Red- IS:5 No. 536 White
Dark Violet- -
LPG ( LIQ.) Dark Grey- IS:5No. 632 Sea Green-IS:5 No. 217
IS:5No. 796
DMDS (LIQ.) Black Fire Red- IS:5 No. 536 ----
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
Fire Red- IS:5
Cyclopentane (LIQ.) Dark Grey- IS:5No. 632 Sky Blue- IS:5 No. 101
No. 536
CBFS (LIQ.) Dark Grey- IS:5No. 632 Smoke Grey-IS:5No. 692 ----

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Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-9
(Painting) System

2nd Color
Pipeline Service Finish Color 1st Color Band
Band
HYDROCARBON ( GASEOUS )
Fire Red- IS:5
Ethylene Canary Yellow-IS:5No. 309 GoldenYellow-IS:5 No.356
No. 536
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 Fire Red- IS:5 No. 536
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 Fire Red- IS:5 No. 536
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 Fire Red- IS:5 No. 536
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:5No. 309
For Flare Line OSBL and OFFSITE : Smoke Grey-IS:5No. 692
For SS MOC Flare Line : No Finish Color

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Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-10
(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.
1.3 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.
1.4 This procedure is not in strict compliance with applicable referencing Codes but with
certain Plant Specific modifications, the approval note of which has to be with Inspection.

2 Applicable References :

2.1 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 )

Equipment Finish Color

TANKS
Tank Farm Area Tanks White
Naphtha Tanks White
All other Tanks at AU, IOP and other areas 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:5No. 632
metal skin

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Equipment Baral Mandal Mondal Date 7.10.16
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Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-11
(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 .
1.6 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.
1.7 This procedure is not in strict compliance with applicable referencing Codes but with
certain Plant Specific modifications, the approval note of which has to be with Inspection.
1.8 This procedure is not applicable for any Underground Pipelines Support Structures or it’s
section thereof.

2 Applicable References :

2.2 IS : 5 ; 1978 - Colors for Ready Mixed Paints and Enamels ( Third Revision )

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:5No. 632

WALK WAYS

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 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-11
(Painting) System

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:5No. 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:5No. 632

Cathodic Protection System Box Dark Grey- IS:5No. 632

INSTRUMENTATION STRUCTURALS

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Section
 Document Name Document Ref No Section
Standard of Protective Coating IP/G/GEN/IS_PAINT S-11
(Painting) System

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 Fire Red – IS : 5 , No. 536 Matt Finish

Hose Box and its stands Fire Red – IS : 5 , No. 536 Matt Finish

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Section