PIP CTSL1000 2010 Application of Internal Linings

REAFFIRMATION WITH EDITORIAL REVISION October 2010 Process Industry Practices Coatings CTSL1000 Application of Internal LiningsPURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on ination contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice. This Practice is subject to revision at any time. © Process Industry Practices PIP, Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane R4500, Austin, Texas 78759. PIP member companies and subscribers may copy this Practice for their internal use. Changes or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or exceptions to specific sections of PIP Practices. Authorized Users may provide their clients, suppliers and contractors with copies of the Practice solely for Authorized Users’ purposes. These purposes include but are not limited to the procurement process e.g., as attachments to requests for quotation/ purchase orders or requests for proposals/contracts and preparation and issue of design engineering deliverables for use on a specific project by Authorized User’s client. PIP’s copyright notices must be clearly indicated and unequivocally incorporated in documents where an Authorized User desires to provide any third party with copies of the Practice. PRINTING HISTORY August 2003 Issued June 2007 Editorial Revision August 2006 Technical Revision October 2010 Reaffirmation with Editorial Revision Not printed with State funds REAFFIRMATION WITH EDITORIAL REVISION October 2010 Process Industry Practices Page 1 of 11 Process Industry Practices Coatings PIP CTSL1000 Application of Internal Linings Table of Contents 1. Introduction ................................. 2 1.1 Purpose ............................................ 2 1.2 Scope ............................................... 2 2. References .................................. 2 2.1 Process Industry Practices .............. 2 2.2 Industry Codes and Standards ........ 2 2.3 Other References ............................. 3 3. Definitions ................................... 3 4. Requirements .............................. 4 4.1 Project Scope ................................... 4 4.2 Selection Requirements and Internal Lining Systems ................................. 4 4.3 General ............................................ 4 4.4 Climatic Condition Control ............... 5 4.5 Surface Preparation ......................... 6 4.6 Application ....................................... 7 4.7 Inspection ....................................... 10 4.8 Documentation ............................... 11 4.9 Shipping, Handling, and Storage ... 11 Appendix A - Figures Data s CTSL1000-D1 – Documentation Requirements Sheet The following data s shall be part of this practice only if indicated on the purchaser s completed Documentation Requirements Sheet. CTSL1000-D2 – Lining Selection Criteria – User Defined CTSL1000-D3 –Internal Lining System Data Sheet CTSL1000-F – Daily Inspection Report CTSL1000-T – Inspection and Testing Requirements Sheet PIP CTSL1000 REAFFIRMATION WITH EDITORIAL REVISION Application of Internal Linings October 2010 Page 2 of 11 Process Industry Practices 1. Introduction 1.1 Purpose This Practice provides requirements for installing industrial linings. 1.2 Scope This Practice describes the general requirements for surface preparation, environmental control, and the installation and inspection of liquid-applied internal linings to metal substrates. This Practice does not cover sheet linings and application of linings to piping. 2. References Applicable parts of the following Practices, industry codes and standards, and references shall be considered an integral part of this Practice. The edition in effect on the date of contract awards shall be used, except as otherwise noted. Short titles are used herein where appropriate. 2.1 Process Industry Practices PIP – PIP VESV1003 – Fabrication Requirements for Welded Vessels and Tanks to be Lined 2.2 Industry Codes and Standards American Society for Testing and Materials ASTM – ASTM D3359 – Standard Test s for Measuring Adhesion by Tape Test – ASTM D4285 – Standard Test s for Indicating Oil or Water in Compressed Air – ASTM D4417 – Standard Test s for Field Measurement of Surface Profile of Blast Cleaned Steel – ASTM D4541 – Standard Test s for Pull-Off Strength of Coatings Using Portable Adhesion Testers – ASTM E337 – Standard Test for Measuring Humidity with a Psychrometer the Measurement of Wet- and Dry-Bulb Temperatures International Organization for Standardization ISO – ISO 2178 – Non-magnetic coatings on magnetic substrates - Measurement of coating thickness - Magnetic – ISO 2360 – Non-conductive coatings on non-magnetic electrically conductive basis materials - Measurement of coating thickness - Amplitude-sensitive eddy current – ISO 2409 – Paints and varnishes - Cross-cut test – ISO 4624 – Paints and varnishes Pull-off test for adhesion – ISO 4677-2 – Atmospheres for conditioning and testing - Determination of relative humidity - Part 2 Whirling psychrometer REAFFIRMATION WITH EDITORIAL REVISION PIP CTSL1000 October 2010 Application of Internal Linings Process Industry Practices Page 3 of 11 – ISO 8501-1 – Preparation of Steel Substrates Before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 1 Rust Grades and Preparation Grades of Uncoated Steel Substrates and of Steel Substrates After Overall Removal of Previous Coatings – ISO 8503-5 – Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Roughness Characteristics of Blast-Cleaned Steel Substrates - Part 5 Replica tape for the determination of the surface profile – ISO 8504-2 – Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Preparation s - Part 2 Abrasive Blast-Cleaning-second edition – ISO 8504-3 – Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Preparation s - Part 3 Hand- and Power-Tool Cleaning First Edition – ISO 8573 – Compressed air – ISO 11126 – Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Preparation s 10 Parts – ISO 12944-4 – Paints and Varnishes - Corrosion Protection of Steel Structures by Protective Paint Systems - Part 4 Types of Surface and Surface Preparation Steel Structures Painting Council SSPC – SSPC-AB1 – Mineral and Slag Abrasives – SSPC-PA2 – Measurement of Dry Paint Thickness with Magnetic Gages Measurement of Dry Coating Thickness with Magnetic Gages – SSPC-PA Guide 3 – A Guide to Safety in Paint Application – SSPC-SP1 – Solvent Cleaning – SSPC-SP2 – Hand Tool Cleaning – SSPC-SP5/NACE No. 1 – White Metal Blast Cleaning – SSPC-SP7/NACE No. 4 – Brush-Off Blast Cleaning – SSPC-VIS 1-89 – Visual Standard for Abrasive Blast Cleaned Steel Standard Reference Photographs 2.3 Other References National Institute of Occupational Safety and Health NIOSH – NIOSH Publication No. 92-102 – NIOSH Alert Request for Assistance in Preventing Silicosis and Deaths from Sandblasting 3. Definitions CS Carbon and low-alloy steel SS Austenitic stainless steel nonferrous Copper, aluminum, and nickel base alloys PIP CTSL1000 REAFFIRMATION WITH EDITORIAL REVISION Application of Internal Linings October 2010 Page 4 of 11 Process Industry Practices owner The party who owns the facility wherein the lining will be used purchaser The party who awards the contract to the supplier. The purchaser may be the owner or the owner’s authorized agent inspector The purchaser’s authorized representative with authority to act in the interest of, and on behalf of, the purchaser in quality assurance matters. supplier The party responsible for providing and/or installing the lining system 4. Requirements 4.1 Project Scope 4.1.1 Documents required to define the scope of the work are listed on purchaser’s PIP CTSL1000-D1 Documentation Requirements Sheet. 4.1.2 Systems requiring additional coating specifications beyond this Practice and referenced data sheets shall be in accordance with purchaser’s contract documents. 4.2 Selection Requirements and Internal Lining Systems 4.2.1 PIP CTSL1000-D2 Lining Criteria Selection Sheet shall be used for selecting the appropriate coating. 4.2.2 PIP CTSL1000-D3 Internal Lining Systems Data Sheet shall be used to define specific requirements for each lining system. 4.3 General 4.3.1 Condition of Surfaces to be Lined 4.3.1.1 PIP VESV1003 defines the details to be followed in fabricating a vessel that is to be lined. 4.3.1.2 The inspector shall verify that the vessel surfaces to be lined are in accordance with the requirements of PIP VESV1003. 4.3.2 Conflicts, Exceptions, and Deviations 4.3.2.1 All conflicts between the referenced documents and this Practice shall be ted in writing to the purchaser for clarification and resolution before proceeding with the lining application. 4.3.2.2 All exceptions, deviations, and substitutions to the requirements specified herein and in referenced documents shall be approved by the purchaser. 4.3.3 Regulations and Material Safety Data Sheets 4.3.3.1 Protective linings shall be in accordance with all applicable federal, state, and local codes and regulations on surface preparation, lining application, storage, handling, safety, and environmental requirements, including the recommendations of SSPC-PA Guide 3. REAFFIRMATION WITH EDITORIAL REVISION PIP CTSL1000 October 2010 Application of Internal Linings Process Industry Practices Page 5 of 11 4.3.3.2 The latest issue of the lining manufacturer’s product data sheets, application instructions, and Material Safety Data Sheets MSDSs shall be available at the lining site and complied with during lining operations. 4.3.4 Surfaces not Lined 4.3.4.1 The following surfaces shall not be lined, unless otherwise specified a. Nonferrous metals b. Galvanized or metallized surfaces c. Nonmetallic 4.3.4.2 The following surfaces shall not be lined and shall be protected from surface preparation and lining activity in the area a. Sacrificial anodes b. Resilient seal materials 4.3.5 Precautions for Stainless Steel and Nonferrous Metals 4.3.5.1 All SS and nonferrous metals shall be protected from blasting, overspray, and linings intended for CS, especially linings that contain zinc. 4.3.5.2 Abrasives for use on SS shall be in accordance with SSPC-AB1 [ISO 11126, natural abrasives except silica sand, coal furnace slag, and fused aluminum oxide] and shall be free of metals. 4.3.5.3 Linings and solvents for use on SS and nonferrous metals shall be free of substances e.g., chlorides, sulfur, halogens, or metallic pigments that can harmfully affect SS or nonferrous metals. 4.4 Climatic Condition Control 4.4.1 Factors Affecting Application 4.4.1.1 Temperature Unless otherwise specified by the lining manufacturer, linings shall not be applied if a. Temperature of steel or lining material is less than 10°C 50°F. b. Air temperature is less than 10°C 50°F or greater than 49°C 120°F. c. Surface temperature is expected to drop to 10°C 50°F or less before lining has cured if low temperature can be detrimental to the lining. 4.4.1.2 Moisture a. Linings shall not be applied in rain, snow, fog, or mist. b. Linings shall not be applied if steel surface temperature is less than 3°C 5°F greater than the dew point. PIP CTSL1000 REAFFIRMATION WITH EDITORIAL REVISION Application of Internal Linings October 2010 Page 6 of 11 Process Industry Practices c. Linings shall not be applied to surfaces that show visible traces of moisture as condensation or precipitation. 4.4.1.3 Humidity The manufacturer s instructions shall be followed regarding acceptable humidity range for application and curing of moisture-cured linings. 4.4.1.4 Measure of Ambient Conditions a. Measurements of temperature, humidity, and dew point shall be taken inside the equipment to be lined at the beginning of each workday and every 4 hours thereafter or sooner if weather conditions appear to be changing. b. Dew point temperature shall be determined by sling psychrometer in accordance with ASTM E337 or ISO 4677-2, at the location where work is being pered. c. A record of these measurements shall be kept, indicating the wet- and dry-bulb temperature, relative humidity, dew point, and surface temperature of the metal of items lined. 4.4.2 Dehumidification 4.4.2.1 Dehumidification equipment shall, as a minimum, have the capacity to a. Depress the air dew point in the equipment being lined to 6 C 10 F less than ambient temperature within 20 minutes. b. Affect an air change rate of three times per hour, unless particle loading is unusually high. See SSPC-PA Guide 3 for regulation. 4.4.2.2 If the selected dehumidifier can reduce air dew point by greater than 6 C 10 F, the air change rate can be reduced. If the dehumidifier cannot reduce the dew point by a minimum of 6 C 10 F, more air shall be used. 4.4.2.3 The following critical measurements shall be taken on a regular basis at a frequency to be determined by the purchaser a. Ambient dew point air entering the dehumidifier b. Dew point of air leaving the humidifier c. Dew point of air inside the tank near metal surface d. Surface temperature of the substrate 4.5 Surface Preparation 4.5.1