coating work flow

Corrosion Mapping andSurvey Guideline for

Ferrous Metal and Alloy

ContentsContents....................................................2

1. Introduction.............................................3

2. Objective................................................3

3. Work Location............................................3

4. Standard References......................................3

5. Methodology..............................................5

6. Scope of Work............................................6

6.1. Measure and Document The Environmental condition........6

6.2. Determine and Document The Corrosion Form and

Categorization..............................................6

6.3. Determine The Damaged Area..............................7

6.4. Determine The Priority of Assest to be Repaired/Replaced7

6.5. Report and Presentation.................................7

7. Attachments..............................................8

Blistering – ISO 4268-2.....................................8

Rusting – ISO 4268-3........................................9

Rusting – ASTM D-610/SSPC-VIS 2............................10

Cracking – ISO 4268-4......................................13

Flaking – ISO 4268-5.......................................15

Chalking – ISO 4268-6......................................17

Corrosion Mapping and Survey Guideline for Ferrous and Non-Ferrous Material | 2

1.IntroductionCorrosion is the destructive result of chemical reaction between a

material (metal or metal alloy) and its environment and will be met

definitely around refinery, both Offshore and Onshore Site Facilities.

Carbon Steel (CS) and Stainless Steel (SS) are the most used material

in refinery, both in Offshore and Onshore, and tend to be corroded

externally caused of extremely and highly corrosion environment. They

have similar forms of external corrosion, including coating damage,

and can be seen visually, but they unfortunately hard to be identified

and defined so that is why Corrosion Mapping and Survey Guideline is

existed for serving Company to solve all problem relating to external

corrosion and retain Company asset relating to integrity.

2.ObjectiveThe objective of Corrosion Mapping and Survey Guideline is to help

Company to know, identify and define external corrosion visually and

non-destructively whether or not their assets need to be

repaired/replaced with following scope of work.

Measure and document the environmental condition;

Determine and document the corrosion form and categorization;

Determine the damaged area (in square meters);


Determine the priority of assest to be repaired/replaced based

on corrosion form and categorization;

Report and presentation.

All details of scope of work are mentioned on article 4 and 5 of this

guideline.

3.Work LocationAs mentioned above, this document can be used as a guideline to do

corrosion mapping and survey at both Onshore and Offshore Site

Refinery Facilities.

4.Standard ReferencesThere are many standards relating to corrosion mapping and survey, and

the most important Institutes of used standardisation are:

ISO : International Organisation for Standardisation.

ASTM : American Society for Testing and Materials.

SSPC : The Society for Protective Coating.

ISO 4628-1 : Paint and varnishes – Evaluation of degradation of

paint coatings – Designation of quantity and size of

defect, and of intensity of uniform changes in

appearance – Part 1: General introduction and

designation system.ISO 4628-2 : Paint and varnishes – Evaluation of degradation of



appearance – Assessment of degree of blistering.ISO 4628-3 : Paint and varnishes – Evaluation of degradation of




appearance – Assessment of degree of rusting.ISO 4628-4 : Paint and varnishes – Evaluation of degradation of



appearance – Assessment of degree of cracking.ISO 4628-5 : Paint and varnishes – Evaluation of degradation of



appearance – Assessment of degree of flaking.ISO 4628-6 : Paint and varnishes – Evaluation of degradation of



appearance – Assessment of degree of chalking.ASTM D-610 : Standard test method for evaluating degree of rusting

on painted steel surface.ASTM E337-02 : Method B standard test method for measuring humidity

with a psychrometer (the measurement of wet- and dry-

bulb temperatures).SSPC-VIS 2 : Standard method of evaluating degree of rusting on

painted steel surfaces.Handbook : Shreir, L.L., R. A. Jarman, G. T. Burstein. 1994.

“Metal/Environment Reaction – Third Edition – Volume

1”. UK : Butterworth-Heinemann.: Shreir, L.L., R. A. Jarman, G. T. Burstein. 1994.

“Corrosion Control – Third Edition – Volume 2”. UK :

Butterworth-Heinemann.: Lyon, S.B. 2010. “Corrosion and Degradation of

Engineering Materials – Volume 3”. UK : Elsevier B.V.: Roberge, Pierre R.2008. “Corrosion Engineering

Principle and Practice”. USA: McGraw-Hill.


5.Methodology


Plan Do Assess AdjustW ork M ethodology

Work Flow

Corrosion m apping and survey guideline for ferrous m etal and

alloy

Personneland inspecction tools

readiness

Pre-job m eeting

Ready?

No

Needed supporting data collection

M edical checkup

T-Bosiet

Inspection tools

1. sling psychrom eter;2. dft gauge3. digital cam era

Corrosion m apping and survey

Yes

Environm entalcondition

ASTM E337-02

Surfacecondition

1. ISO 4628-1;2. ISO 4628-2;3. ISO 4628-3;4. ISO 4628-4;5. ISO 4628-5;6. ISO 4628-6;7. ASTM D -610;8. SSPC VIS-2.

Actual coating thickness (if

any)1. ISO 2808;2. SSPC-PA 2.

Photosand docum entation

Daily inspection report

Finalreport developm ent and

analysis1. Envirom ental condition;2. Corrosion form and categorization;3. Dam aged area (Sqm );4. Priority judgem ent as per Com pany specification and requirem ents;5. Repairor Replace.6. Reportpresentation.

Finalreport subm ission

1. All photos and docum entation;2. All daily inspection report;3. Final report

Result and presentation

Finish

6.Scope of WorkThis document provides a guideline to do corrosion mapping and survey

at both Onshore and Offshore Facilities where Company operates their

production activities. As mentioned on article 2 of this document,

this is to help Company to know, identify and define external

corrosion visually and non-destructively whether or not their assets

need to be repaired/replaced with following scope of work.

6.1.Measure and Document The Environmental conditionAs defined on article 1 of this document, environmental condition is

one of main factors causing corrosion on material (metal or metal

alloy). ASTM E337-02, Method B standard test method for measuring

humidity with a psychrometer (the measurement of wet- and dry-bulb

temperatures), explains about how to determine relative humidity and

dew point temperature of atmospheric air by taking of wet and dry bulb

temperature readings using sling psychrometer and psychrometric

table/chart/calculator. Also, this stage measures steel temperature as

an additional information to analyze whether or not the existing

coating is compatible with application. All data will be wholly

collected and well documented as a deliverable of this stage.

6.2.Determine and Document The Corrosion Form and

CategorizationThere are several categorized corrosion form-most likely known as

coating damage, and captured on this guideline as follow.

Blistering is a dome or circular shape taken place on coating

caused by either solvent or water/moisture entrapment during


cure cycle, and even rust. ISO 4628-2 is a used standard for

determining this damage.

Rusting is a product of damaged ferrous metal or alloy due to no

existing coating or coating damaged so that it is exposed to

environment. ISO 4628-3, ASTM D-610 and SSPC-VIS 2 are used

standards for determining this damage.

Cracking is occured due to stress causing moisture absorption. ISO

4628-4 is a used standard for determining this damage.

Flaking is an adhesion failure of coating caused by fail to

prepare the substrate and apply the coating well. ISO 4628-5 is

a used standard for determining this damage.

Chalking is a powdery layer on the coating surface caused by

exposure to UV light. ISO 4628-6 is a used standard for

determining this damage.

Essentially, all corrosion form are categorized and compared with

mentioned references on article 4 of this guideline, and will be

documented as a deliverable of this stage.

6.3.Determine The Damaged AreaThis stage is undertaken in parallel with article 6.2 of this

guideline by determining damaged area to be repaired/replaced in

square meter, and this will be documented as a deliverable of this

stage.

6.4.Determine The Priority of Assest to be Repaired/ReplacedGenerally, this guideline divides 3 types of assest as follow.

Production equipment;

Non-production equipment;

Structure.


This stage are compiled with article 6.2 and 6.3 of this guideline to

get the priority asset to be repaired and replace, and widely rusting

on production equipment is a first priority to be repaired/replaced.

Essesntially, this stage is depend on Company specification and

request, and will be documented as a deliverable of this stage.

6.5.Report and PresentationAll reports, including daily activity reports and documentations, will

be submitted 10 working days after doing corrosion mapping and survey

at Company Site Facilities, and will do presentation to explain all

reports and results then.


7.Attachments

Blistering – ISO 4268-2


Rusting – ISO 4268-3


Rusting – ASTM D-610/SSPC-VIS 2


Cracking – ISO 4268-4


Flaking – ISO 4268-5


Chalking – ISO 4268-6


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