Application of Internal Linings - Sample - PIP

8/3/2019 Application of Internal Linings - Sample - PIP

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TECHNICAL REVISIONAugust 2006

Process Industry PracticesCoatings

PIP CTSL1000Application of Internal Linings


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PURPOSE 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 information 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 orother 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, overlays, addenda, or modifications of any

kind are not permitted within any PIP Practice without the express written

authorization of PIP.

PRINTING HISTORY

August 2003 Issued August 2006 Technical Revision

Not printed with State funds


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TECHNICAL REVISIONAugust 2006

Process Industry Practices Page 1 of 13

Process Industry PracticesCoatings

PIP CTSL1000Application of Internal Linings

Table of Contents

1. Introduction.................................21.1 Purpose............................................ 21.2 Scope.................... ........................... 2

2. References ..................................22.1 Process Industry Practices .............. 22.2 Industry Codes and Standards ........ 22.3 Other References.............................3

3. Definitions...................................3

4. Requirements..............................34.1 Project Scope................................... 34.2 Selection Requirements and Internal

Lining Systems................................. 34.3 General ............................................ 3

4.4 Climatic Condition Control ............... 44.5 Surface Preparation......................... 64.6 Application ....................................... 64.7 Inspection....................................... 104.8 Documentation............................... 104.9 Shipping, Handling, and Storage... 10

Appendix A - Figures.....................12

Data Forms

CTSL1000-D1 DocumentationRequirements

The following data forms shall be part of

this practice only if indicated on the

purchaser's completed Documentation

Requirements Sheet.

CTSL1000-D2 Selection CriteriaSheet

CTSL1000-D3 Application ofInternal Linings

CTSL1000-F Daily InspectionReport

CTSL1000-T Inspection andTesting Requirements Sheet


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PIP CTSL1000 TECHNICAL REVISION Application of Internal Linings August 2006

Page 2 of 13 Process Industry Practices

1. Introduction

1.1 Purpose

This Practice provides requirements for contractors 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. Sheet linings and application to piping are not included.

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 tobe Lined

2.2 Industry Codes and Standards

American Society for Testing and Materials (ASTM)

ASTM D3359 Standard Test Methods for Measuring Adhesion by Tape Test

ASTM D4285 Standard Test Methods for Indicating Oil or Water inCompressed Air

ASTM D4417 Standard Test Methods for Field Measurement of Surface

Profile of Blast Cleaned Steel

ASTM D4541 Standard Test Methods for Pull-Off Strength of CoatingsUsing Portable Adhesion Testers

ASTM E337 Standard Test Method for Measuring Humidity with a

Psychrometer (the Measurement of Wet- and Dry-Bulb Temperatures)

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(StandardReference Photographs)

Deleted: covers

Deleted: PIP CTCL1000 Interna

Lining System Selection Criteria and Sy

Data Sheet

Deleted:


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TECHNICAL REVISION PIP CTSL1000 August 2006 Application of Internal Linings


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. DefinitionsCS: Carbon and low-alloy steel

SS: Austenitic stainless steel

contractor: The party responsible for furnishing and/or installing the lining system

nonferrous: Copper, aluminum, and nickel base alloys

owner: The principal end user

purchaser: The owner or the owners agent

inspector: The owner or the owners authorized agent

4. Requirements

4.1 Project Scope

4.1.1 Documents required to define the scope of the work are listed on Purchasers

Data SheetPIP CTSL1000-D1.

4.1.2 Systems requiring additional coating specifications beyond this practice and

referenced data sheets shall be covered by purchasers documentation.

4.2 Selection Requirements and Internal Lining Systems

4.2.1 Internal lining system selection criteria data sheet,PIP CTSL1000-D2, shallbe used for selecting the appropriate coating.

4.2.2 Internal lining system data sheet, CTSL1000-D3, 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 avessel that is to be lined.

4.3.1.2 The inspector shall verify that the vessel surfaces to be lined comply

with the requirements ofPIP VESV1003.

Formatted: Bullets and Numb

Formatted: Font: Italic


Formatted: PIP Head 1.1 gra

Indent: Left: 1", Hanging: 0.5



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4.3.2 Conflicts, Exceptions, and Deviations

4.3.2.1 All conflicts between the referenced documents and this Practice

shall be submitted 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 comply with all applicable federal, state, and

local codes and regulations on surface preparation, lining

application, storage, handling, safety, and environmental

requirements, including the recommendations ofSSPC-PA Guide 3.

4.3.3.2 The latest issue of the lining manufacturers 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 comply with SSPC-AB1 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 such as 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:

Deleted:


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a. Temperature of steel or lining material is below 50F (10C).

b. Air temperature is below 50F (10C) or above 120F (49C).

c. Surface temperature is expected to drop to 50F (10C) before

lining has cured if low temperature will 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 5F (3C) above the dew point.

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 eachworkday 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, at the location

where work is being performed.

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 10F

(6C) below 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 forregulation).

4.4.2.2 If the selected dehumidifier can reduce air dew point by more than

10F (6C), the air change rate can be reduced. If the dehumidifier

cannot reduce the dew point by at least 10F (6C), 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:

Deleted: 2

Deleted: b


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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 Precleaning

4.5.1.1 Before blasting, oil, tar, grease, salt, and other contaminants shall be

removed from the surfaces to be lined.

4.5.1.2 Hydrocarbon removal shall be accomplished by solvent cleaning

(SSPC SP1), power brush (SSPC SP2) high-pressure water, or steamcleaning using proper chemicals.

4.5.1.3 Cleaning shall be followed by a freshwater rinse to ensure complete

removal of soluble salts and cleaning chemicals.

4.5.1.4 If the entire tank is to be lined, all rafters, supports, and

superstructure shall be included in the cleaning process.

4.5.1.5 A black light shall be used to locate hydrocarbon contaminants.

4.5.1.6 If lining the bottom of a floating roof tank, before blasting begins,

the underside of the roof and 7-feet up the tank wall shall receive a

brush blast (SSPC-SP7/NACE No. 4) to remove contaminants andloose scale.

4.5.2 Abrasive Blast Cleaning

4.5.2.1 Compressed air supply used for blasting shall be free of water and

oil. Adequate separators and traps shall be provided and kept empty.

4.5.2.2 Abrasive shall be selected to produce a necessary profile or anchor

pattern for lining to be applied. Abrasive shall be free of

contaminants, such as water-soluble salts, dirt, clay, oil, and grease.

4.5.2.3 Silica or other abrasive substances containing more than 1 percent

crystalline silica shall not be used as an abrasive blasting material.

Refer toNIOSH Publication No. 92-102.

4.5.2.4 Blasting shall not be allowed if metal surfaces are less than 5F

(3C) above the dew point.

4.5.2.5 Abrasive blast cleaning shall be to a white metal finish and comply

with SSPC-SP5/NACE No. 1.

4.6 Application

4.6.1 General

4.6.1.1 Lining materials and thicknesses shall be as listed in

PIPCTSL1000-D3, Internal Lining System.

Deleted: 3

Deleted: 4

Deleted: CTCL1000


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4.6.1.2 Lining materials shall be furnished in the manufacturers unopened

containers, shall be clearly marked, and shall be kept covered, clean,

and protected.

4.6.1.3 Blasted surfaces shall be absolutely clean and dry before the

application of the first coat.

4.6.1.4 Spent blast media shall either be removed or adequately covered

before lining to prevent contamination of the surface to be lined.

4.6.1.5 Workers shall take precautions (changing or dusting shoes and

removing abrasive from pant cuffs) to ensure that cleanliness is

maintained throughout the entire lining operation.

4.6.1.6 If the prepared surface becomes dirty or rusty before the first prime

coat is applied, the surface shall be recleaned to a degree that was

initially specified.

4.6.1.7 When required, welds and edges shall be striped with primer by

brush application before the application of the first prime coat.

4.6.1.8 Before the application of any coat, damage to the previous coat shall

be repaired with a corresponding specified material.

4.6.1.9 Lined surfaces, including striping and repair, shall be thoroughly

dry and clean before the application of subsequent coats inaccordance with the manufacturers recommendation for recoat

time.

4.6.1.10 Unless otherwise specified, the allowable dry-film thickness range

shall be as specified by the lining manufacturer on the product data

sheet.

4.6.1.11 The recoat time between coats shall be that recommended by the

manufacturer for any given temperature.

4.6.1.12 Thinning shall not exceed the maximum allowable volatile organic

compound (VOC) level for the lining involved.

4.6.2 Preparation of Lining Materials

4.6.2.1 Lining materials shall be stirred or mechanically agitated to ensure

that pigments, vehicles, and activators are thoroughly mixed. Whenrequired by the manufacturer, linings shall be continuously stirred by

mechanical agitators.

4.6.2.2 Lining materials shall be thinned only with thinner that is

recommended by the manufacturer and in quantities that do not

exceed the manufacturers recommendation.

4.6.2.3 All mixing shall be done in clean containers that are free from traces

of grease, paints, and other contaminants. After mixing, the

containers shall be kept covered to prevent contamination.

4.6.2.4 The mixing of partial kits is not allowed.


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4.6.2.5 Inorganic zinc primers and all pigmented lining materials shall be

strained before the application in accordance with the lining

manufacturers written instructions.

4.6.2.6 Tinting for color contrast of the primer and midcoat is not allowed.

4.6.2.7 Pot life shall not exceed the limits specified by the manufacturer.

4.6.2.8 Materials that have exceeded the lining manufacturers

recommended shelf life shall not be used.

4.6.3 Thick Film Reinforced Systems

4.6.3.1 Putty/Caulking Application

1. Application may be by spray or putty knife and shall includechine, bottom plate seams, the bottom of sumps, and along the

column bases.

2. Putty used shall be compatible with the resin system asrecommended by the manufacturer.

3. Large projections and lap joints on welded plates to be linedshall be filled with putty to smooth out the surface and permit

complete contact with the laminate system. See Figure 1 and

Figure 5 in Appendix A.

4. Chine or bottom angle shall be filled with putty and covered to asmooth 3-inch (75-mm) radius to permit contact with the

laminate system. See Figure 3 in Appendix A.

5. Riveted seams, lap joints, and chine angle plates shall be filledwith putty and smoothed out to obtain complete contact with the

laminate system. See Figure 2 and Figure 4 in Appendix A.

4.6.3.2 Columns, Support Legs, Sumps, Etc.

1. For tanks on which the column base is not fixed or attached to

the bottom by welds, a striker plate and resin laminate patch

shall be placed under the column base as follows:

a. Plates shall be installed under fixed roof tanks one at a time.

No fixed roof support shall be raised while another is on the

jack.

b. Tack welds and/or guides shall be removed to free the

column base and to provide a smooth tank bottom.

c. The column base shall be jacked up in accordance with

instructions that are detailed in Figure 5, Figure 6, and

Figure 7 in Appendix A.

d. If a lining system is used without reinforcing, the lining

system shall be inserted into Step 6 instead of reinforced

laminate in Figure 5 in Appendix A.

2. Striker plate for support legs on floating roof tanks shall be

placed as follows:


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a. Tanks normally have a stationary striker plate with a

circumferential fillet weld as part of the original

construction. See Figure 5, Figure 6, and Figure 7 in

Appendix A. If this stationary plate is not a part of the

design, Step 5 and Step 6 shall be eliminated, and

reinforced laminate (or lining system) shall be applied

directly to the blasted and primed steel bottom, ensuring

that it extends 12 inches (300 mm) onto the floor. Stepsshown in Figure 7 in Appendix A shall then be continued.

b. The auxiliary striker plate shall be blasted, primed, and

placed into wet laminate. Support legs shall be lowered

onto the auxiliary striker plate when the resin starts to gel.

c. Hollow legs shall be wrapped with plastic, secured to

prevent dripping during the transfer to a temporary support,

and then raised.

d. Reinforced laminate (or lining system) shall extend at least

12 inches (300 mm) in all directions from the striker plate

such that there is a 3-inch (75-mm) overlap when the lay-up

operation is continued across the floor.

3. Sumps shall receive a reinforcement layer across the bottom, upsides, and 6 inches (150 mm) to 12 inches (300 mm) onto the

floor.

4. Additional layers of laminate shall be installed onto the tank

bottom as follows:

a. Under the gage hatch (4-foot by 4-foot [1.2-M by 1.2-M]

area).

b. Fill line outlet (4-foot by 4-foot [1.2-M by 1.2-M] area).

c. Swing the line arresting chain of floating roof tanks (3-foot

by 12-foot [1-M by 4-M] area).

4.6.4 Repair of Linings

4.4.4.1 If, after inspection, the lining thickness is deemed to be insufficient,

necessary additional lining to achieve the required film thicknessshall be applied. If the lining is too thick and detrimental to the

integrity of the system, the excess lining shall be sanded off to the

required film thickness.

4.6.4.2 If abrasive or other contaminants have contaminated the lining, the

lining shall be repaired in accordance with the lining manufacturers

written recommendation.

4.6.4.3 If improperly mixed linings (e.g., wrong catalyst or no catalyst) are

applied, the lining shall be removed and the surface restored to the

originally specified condition.

4.6.4.4 Holidays shall be repaired in accordance with the lining

manufacturers recommended procedure.


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4.7 Inspection

4.7.1 General

4.7.1.1 Inspections and tests shall be performed in accordance with

purchasers Inspection and Testing Requirements Sheet,

PIPCTSL000-T, to ensure that the surface preparation and liningapplication comply with the requirements of this Practice.

4.7.1.2 The lining shall be holiday free unless otherwise specified on

purchasers Inspection and Testing Requirements Sheet,

PIPCTSL1000-T.

4.7.2 Inspection Hold Points

4.7.2.1 Hold Point (H)

1. A hold point (H) is the notification that a shop process is ready

for purchasers inspection and to hold any furtherapplication

until inspection has occurred.

2. Hold points shall be provided in accordance with purchasersInspection and Testing Requirements Sheet,PIPCTSL1000-T.

4.7.2.2. Witness Point (W)

1. A witness point (W) is an observation by purchasersinspector(s) of the actual test as it is being performed.

Application may proceed if purchasers inspector(s) is not

present and was given proper notification.

2. Witness points shall be provided in accordance with purchasers

Inspection and Testing Requirements Sheet,PIPCTSL1000-T.

4.8 Documentation

4.8.1 A Daily Inspection Report,PIPCTSL1000-F, shall be completed for eachwork shift.

4.8.2 The contractors forms may be used with prior approval from the purchaser.

4.8.3 A log shall be maintained of all reports, inspections, and tests (including

date, time, and results of instrument calibrations).

4.9 Shipping, Handling, and Storage

4.9.1 Lined items shall not be handled or moved until all linings have been

properly dried or cured as required in the lining manufacturers instructions.

4.9.2 Lined items shall be handled with equipment such as wide belt slings, web

belts, and wide padded skids that are selected to prevent damage to the

lining. Handling equipment that is likely to cause damage to the lining shall

not be used. Items such as chains, cables, hooks, tongs, metal bars, and

narrow skids shall not be permitted to come in contact with the lining.

4.9.3 Lined items shall be loaded, padded, and secured for transport in a manner

such that the lining will not be damaged in transit.

Deleted: CTSL1001

Deleted: CTSL1001

Deleted: fabrication

Deleted: CTSL1001

Deleted: Fabrication

Deleted: CTSL1001

Deleted: CTSL1002

Deleted: Dragging or skidding of line

shall not be permitted.


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4.9.4 HDPE flange protectors shall be used to protect lined flange faces. The

protectors shall be attached by bolts.


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Appendix A - Figures


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STEERING TEAM BALLOT TECHNICAL REVISION PIP CTSL1000 August 2006 Application of Internal Linings
