Guidelines for the application of the IMO Performance Standard for Protective Coatings

Transcription

1 Guidelines for the application of the IMO Performance Standard for Protective Coatings June 2007 Guidance Note NI 531 DT R00 E 17 bis, Place des Reflets - La Défense Courbevoie Postal Address : Paris La Défense Cedex Tel. 33 (0) Fax. 33 (0) veristarinfo@bureauveritas.com Web :

2 MARINE DIVISION GENERAL CONDITIONS ARTICLE BUREAU VERITAS is a Society the purpose of whose Marine Division (the Society ) is the classification ( Classification ) of any ship or vessel or structure of any type or part of it or system therein collectively hereinafter referred to as a Unit whether linked to shore, river bed or sea bed or not, whether operated or located at sea or in inland waters or partly on land, including submarines, hovercrafts, drilling rigs, offshore installations of any type and of any purpose, their related and ancillary equipment, subsea or not, such as well head and pipelines, mooring legs and mooring points or otherwise as decided by the Society. The Society: prepares and publishes Rules for classification, Guidance Notes and other documents ( Rules ); issues Certificates, Attestations and Reports following its interventions ( Certificates ); publishes Registers The Society also participates in the application of National and International Regulations or Standards, in particular by delegation from different Governments. Those activities are hereafter collectively referred to as Certification The Society can also provide services related to Classification and Certification such as ship and company safety management certification; ship and port security certification, training activities; all activities and duties incidental thereto such as documentation on any supporting means, software, instrumentation, measurements, tests and trials on board The interventions mentioned in 1.1., 1.2. and 1.3. are referred to as Services. The party and/or its representative requesting the services is hereinafter referred to as the Client. The Services are prepared and carried out on the assumption that the Clients are aware of the International Maritime and/or Offshore Industry (the Industry ) practices The Society is neither and may not be considered as an Underwriter, Broker in ship s sale or chartering, Expert in Unit s valuation, Consulting Engineer, Controller, Naval Architect, Manufacturer, Shipbuilder, Repair yard, Charterer or Shipowner who are not relieved of any of their expressed or implied obligations by the interventions of the Society. ARTICLE Classification is the appraisement given by the Society for its Client, at a certain date, following surveys by its Surveyors along the lines specified in Articles 3 and 4 hereafter on the level of compliance of a Unit to its Rules or part of them. This appraisement is represented by a class entered on the Certificates and periodically transcribed in the Society s Register Certification is carried out by the Society along the same lines as set out in Articles 3 and 4 hereafter and with reference to the applicable National and International Regulations or Standards It is incumbent upon the Client to maintain the condition of the Unit after surveys, to present the Unit for surveys and to inform the Society without delay of circumstances which may affect the given appraisement or cause to modify its scope The Client is to give to the Society all access and information necessary for the performance of the requested Services. ARTICLE The Rules, procedures and instructions of the Society take into account at the date of their preparation the state of currently available and proven technical knowledge of the Industry. They are not a code of construction neither a guide for maintenance or a safety handbook. Committees consisting of personalities from the Industry contribute to the development of those documents The Society only is qualified to apply its Rules and to interpret them. Any reference to them has no effect unless it involves the Society s intervention The Services of the Society are carried out by professional Surveyors according to the Code of Ethics of the Members of the International Association of Classification Societies (IACS) The operations of the Society in providing its Services are exclusively conducted by way of random inspections and do not in any circumstances involve monitoring or exhaustive verification. ARTICLE The Society, acting by reference to its Rules: reviews the construction arrangements of the Units as shown on the documents presented by the Client; conducts surveys at the place of their construction; classes Units and enters their class in its Register; surveys periodically the Units in service to note that the requirements for the maintenance of class are met. The Client is to inform the Society without delay of circumstances which may cause the date or the extent of the surveys to be changed. ARTICLE The Society acts as a provider of services. This cannot be construed as an obligation bearing on the Society to obtain a result or as a warranty The certificates issued by the Society pursuant to 5.1. here above are a statement on the level of compliance of the Unit to its Rules or to the documents of reference for the Services provided for. In particular, the Society does not engage in any work relating to the design, building, production or repair checks, neither in the operation of the Units or in their trade, neither in any advisory services, and cannot be held liable on those accounts. Its certificates cannot be construed as an implied or express warranty of safety, fitness for the purpose, seaworthiness of the Unit or of its value for sale, insurance or chartering The Society does not declare the acceptance or commissioning of a Unit, nor of its construction in conformity with its design, that being the exclusive responsibility of its owner or builder, respectively The Services of the Society cannot create any obligation bearing on the Society or constitute any warranty of proper operation, beyond any representation set forth in the Rules, of any Unit, equipment or machinery, computer software of any sort or other comparable concepts that has been subject to any survey by the Society. ARTICLE The Society accepts no responsibility for the use of information related to its Services which was not provided for the purpose by the Society or with its assistance If the Services of the Society cause to the Client a damage which is proved to be the direct and reasonably foreseeable consequence of an error or omission of the Society, its liability towards the Client is limited to ten times the amount of fee paid for the Service having caused the damage, provided however that this limit shall be subject to a minimum of eight thousand (8,000) Euro, and to a maximum which is the greater of eight hundred thousand (800,000) Euro and one and a half times the above mentioned fee. The Society bears no liability for indirect or consequential loss such as e.g. loss of revenue, loss of profit, loss of production, loss relative to other contracts and indemnities for termination of other agreements All claims are to be presented to the Society in writing within three months of the date when the Services were supplied or (if later) the date when the events which are relied on of were first known to the Client, and any claim which is not so presented shall be deemed waived and absolutely barred. ARTICLE Requests for Services are to be in writing Either the Client or the Society can terminate as of right the requested Services after giving the other party thirty days' written notice, for convenience, and without prejudice to the provisions in Article 8 hereunder The class granted to the concerned Units and the previously issued certificates remain valid until the date of effect of the notice issued according to 7.2. hereabove subject to compliance with 2.3. hereabove and Article 8 hereunder. ARTICLE The Services of the Society, whether completed or not, involve the payment of fee upon receipt of the invoice and the reimbursement of the expenses incurred Overdue amounts are increased as of right by interest in accordance with the applicable legislation The class of a Unit may be suspended in the event of non-payment of fee after a first unfruitful notification to pay. ARTICLE The documents and data provided to or prepared by the Society for its Services, and the information available to the Society, are treated as confidential. However: Clients have access to the data they have provided to the Society and, during the period of classification of the Unit for them, to the classification file consisting of survey reports and certificates which have been prepared at any time by the Society for the classification of the Unit ; copy of the documents made available for the classification of the Unit and of available survey reports can be handed over to another Classification Society Member of the International Association of Classification Societies (IACS) in case of the Unit s transfer of class; the data relative to the evolution of the Register, to the class suspension and to the survey status of the Units are passed on to IACS according to the association working rules; the certificates, documents and information relative to the Units classed with the Society may be reviewed during IACS audits and are disclosed upon order of the concerned governmental or inter-governmental authorities or of a Court having jurisdiction. The documents and data are subject to a file management plan. ARTICLE Any delay or shortcoming in the performance of its Services by the Society arising from an event not reasonably foreseeable by or beyond the control of the Society shall be deemed not to be a breach of contract. ARTICLE In case of diverging opinions during surveys between the Client and the Society s surveyor, the Society may designate another of its surveyors at the request of the Client Disagreements of a technical nature between the Client and the Society can be submitted by the Society to the advice of its Marine Advisory Committee. ARTICLE Disputes over the Services carried out by delegation of Governments are assessed within the framework of the applicable agreements with the States, international Conventions and national rules Disputes arising out of the payment of the Society s invoices by the Client are submitted to the Court of Nanterre, France Other disputes over the present General Conditions or over the Services of the Society are exclusively submitted to arbitration, by three arbitrators, in London according to the Arbitration Act 1996 or any statutory modification or re-enactment thereof. The contract between the Society and the Client shall be governed by English law. ARTICLE These General Conditions constitute the sole contractual obligations binding together the Society and the Client, to the exclusion of all other representation, statements, terms, conditions whether express or implied. They may be varied in writing by mutual agreement The invalidity of one or more stipulations of the present General Conditions does not affect the validity of the remaining provisions The definitions herein take precedence over any definitions serving the same purpose which may appear in other documents issued by the Society. BV Mod. Ad. ME 545 j - 16 February 2004

3 GUIDANCE NOTE NI 531 Guidelines for the application of the IMO Performance Standard for Protective Coatings Section 1 Section 2 Section 3 Introduction Main Contents and Requirements of the Performance Standard for Protective Coatings - An Overview The Performance Standard for Protective Coatings Step by Step June 2007

4 Section 1 Introduction 1 General Purpose 1.2 Scope of application of IMO PSPC 1.3 Scope of application of IACS PR 34 2 Reference documents IMO PSPC 2.2 IACS PR 34 3 Terms and definitions General 3.2 Coating components Section 2 Main Contents and Requirements of the Performance Standard for Protective Coatings - An Overview 1 General PSPC overview 1.2 Flow chart of the PSPC 2 Design of the coating system General 2.2 Definition of the coating system 2.3 Approval of the coating system 3 Parties involved in the coating process and their main duties General 3.2 The coating inspector 3.3 The coating manufacturer 3.4 The shipyard 3.5 The Classification Society and/or Recognised Organisation 4 Documents used for inspection agreement General 4.2 Basic documents 4.3 Documents applicable during construction process 5 The implementation of the coating standard into the shipyard environment General 6 The Coating Technical File (CTF) - The evidence of the PSPC implementation General 2 Bureau Veritas June 2007

5 Section 3 The Performance Standard for Protective Coatings Step by Step 1 Achieving the coating quality level General 2 Designing the coating system Design requirement of the coating system 2.2 Approval requirement of the coating system 2.3 Preparation of the application procedure 2.4 Preparation of the inspection procedure 2.5 Submission of documentation (CTF) 2.6 Approval and verification requirement by the Society 3 Agreement between parties The pre-job conference 4 Coating works inside the shipyard Shop primer 4.2 Block assembly 4.3 Erection 5 Procedure requirement during application Coating application requirement 5.2 Inspection procedure requirement 5.3 Submission of document (CTF) 5.4 After finishing the coating application 5.5 Verification procedure requirement 6 Procedure requirement for in-service maintenance General June 2007 Bureau Veritas 3

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7 NI 531, Sec 1 SECTION 1 INTRODUCTION 1 General 1.1 Purpose This Guidance Note provides information about coating inspection to be carried out in accordance with the Performance Standard for Protective Coatings in dedicated seawater ballast tanks of all types of ships and double-side skin spaces arranged in bulk carriers referred to in SOLAS Regulation II-1/3-2 as adopted by IMO Resolution MSC.216 (82). 1.2 Scope of application of IMO PSPC The Performance Standard for Protective Coatings, hereinafter referred to as PSPC, applies to ships of not less than 500 gross tonnage: for which the building contract is placed on or after 1 July 2008 or in the absence of a building contract, the keels of which are laid or which are at a similar stage of construction on or after 1 January 2009 or the delivery of which is on or after 1 July All dedicated seawater ballast tanks arranged in ships and double-side skin spaces arranged in bulk carriers of 150 m in length and upwards shall be coated during construction in accordance with the PSPC (excluding ballast hold in bulk carriers, see [3.1.1]) The PSPC covers protective coating requirements for the ship steel structure. It is noted that other independent items are fitted within the tanks to which coatings are applied to provide protection against corrosion It is recommended that the PSPC is applied, to the extent possible, to those portions of permanent means of access provided for inspection not integral to the ship structure, such as rails, independent platforms and ladders. Other equivalent methods of providing corrosion protection for the non-integral items may also be used, provided they do not impair the performance of the coatings of the surrounding structure. Access arrangements that are integral to the ship structure, such as increased stiffener depths for walkways and stringers, are to comply with the PSPC It is also recommended that supports for piping and measuring devices, be coated in accordance with the nonintegral items indicated in [1.2.3]. 1.3 Scope of application of IACS PR IACS has developed the Procedural Requirement (PR) 34 to be applied by IACS Societies to ships subject to the IACS Common Structural Rules for Bulk Carriers and for Oil Tankers which are contracted for construction on or after 8 December 2006 and until the date of application referred to in para.1 of SOLAS Regulation II-1/3-2 as adopted by IMO Resolution MSC.216 (82) Prior to 1 July 2008 IACS Common Structural Rules invoke the PSPC for verification and inspection in accordance with IACS PR34. 2 Reference documents 2.1 IMO PSPC IMO PSPC is the Performance Standard for Protective Coatings for dedicated seawater ballast tanks in all types of ships and double-side skin spaces of bulk carriers adopted on 8 December 2006 by IMO Maritime Safety Committee under Resolution MSC.215(82). 2.2 IACS PR IACS PR 34 is the Procedural Requirement on application of the IMO PSPC, under IACS Common Structural Rules for Bulk Carriers on Oil Tankers. 3 Terms and definitions 3.1 General Seawater ballast tank Seawater ballast tank is a tank which is used solely for salt water ballast. It includes: segregated ballast tanks side ballast tanks ballast double bottom spaces topside tanks hopper side tanks peak tanks. Holds of bulk carriers used for both cargo and salt water ballast are not considered as seawater ballast tanks in the scope of this Guidance Note Edge grinding Edge grinding is the treatment of edge before secondary surface preparation GOOD condition GOOD condition is the condition with minor spot rusting as defined in Resolution A.744(18). June 2007 Bureau Veritas 5

8 NI 531, Sec Hard coating Hard coating is a coating that chemically converts during its curing process or a non-convertible air drying coating which may be used for maintenance purposes. It can be either inorganic or organic DFT DFT is the Dry Film Thickness NDFT and 90/10 practice NDFT is the Nominal Dry Film Thickness. 90/10 practice means that 90% of all thickness measurements shall be greater than or equal to NDFT and none of the remaining 10% measurements shall be below 0.9 NDFT Primer coat Primer coat is the first coat of the coating system applied in the shipyard/manufacturer after shop primer application Shop-primer Shop-primer is the prefabrication primer coating applied before the first coat of a coating system to steel plates Target useful life Target useful life is the target value, in years, of the durability for which the coating system is designed Dust Dust is loose particle matter present on a surface prepared for painting, arising from blast-cleaning or other surface preparation processes, or resulting from the action of the environment Dew point Dew point is the temperature at which air is saturated with moisture Technical Data Sheet The Technical Data Sheet (TDS) is coating manufacturer s product data sheet which contains detailed technical instruction and information relevant to the coating and its application. It is part of the coating system definition. 3.2 Coating components Pigments Pigments are discrete particulate solids used to provide specific protective or decorative properties to the coating. They are organic/inorganic chemical products Vehicle Vehicle is the liquid part of the coating. It consists of the binder, solvent and any liquid additives Binders Binders (resins) are part of nonvolatile film-forming components. Their function is to bond coating material to object surface during drying and after drying Solvents Solvents are volatile components. They may be classified as: a) Primary solvent (active): dissolves the resin to form a liquid solution b) Latent solvent: often used together with the primary solvent (easiness of application, evaporation rate control, enhancement of film properties) c) Diluents are used with active solvents to dilute the coating. In some cases diluents may improve smoothness and toughness of the film. The two major characteristics of solvents, which influence their use are: a) Solvency power: their ability to dissolve other chemical compounds b) Volatility: their ability to quit the coating (it governs the evaporation rate) Solvent safety is concerned with two types of hazards: a) Fire hazards: Flash point 1) LEL (Lower Explosive Limit) is the lowest concentration of solvent vapor in air that can be ignited 2) UEL (Upper Explosive Limit) is the highest concentration of solvent vapor in air that can be ignited b) Health hazards: all solvents to be handled with care (ventilation, breathing apparatus and protective clothing) 6 Bureau Veritas June 2007

9 NI 531, Sec 2 SECTION 2 MAIN CONTENTS AND REQUIREMENTS OF THE PERFORMANCE STANDARD FOR PROTECTIVE COATINGS -AN OVERVIEW 1 General c) Secondary surface preparation (including cleanliness before and after surface preparation) 1.1 PSPC overview The PSPC is addressing the following items/tasks: a) design of the coating system b) parties involved in the coating process and their main duties c) agreement between parties with respect to contractual documents d) the implementation of the coating standard into the shipyard environment e) the Coating Technical File (CTF) - Demonstrating the PSPC implementation 1.2 Flow chart of the PSPC A general flow chart, pointing items listed in [1.1.1] and tasks that are included inside of the PSPC, is presented in Fig 1. 2 Design of the coating system 2.1 General The design of the coating system is consisting of: a) Definition of the coating system b) Approval of the coating system. 2.2 Definition of the coating system The definition of the coating system is consisting on the following items: a) Selection of the coating products: complete number and types of coats applied to a substrate in a predetermined order b) Primary surface preparation (including cleanliness before and after surface preparation) d) Mixing and thinning operations regarding each type of coat e) Checking of environmental conditions during all coating operations f) Coating application manner, wet film thickness (uniformity of film thickness), nominal dry film thickness (per layer, and for the total multi-coat). Listed items a) to f) are specified inside of the PSPC, to referenced standards. Application of the referenced international standards footnoted in the PSPC is mandatory under the IACS PR 34. The definition of the coating system, covering listed items a) to f), is to be included into the manufacturing coating specification, which has to make reference to specific coating Technical Data Sheets (TDS), and Material Safety Data Sheets (MSDS). The manufacturing coating specification must be in compliance with the PSPC's coating system definition. At this stage, the manufacturing coating specification is to be agreed upon between the shipowner, the shipyard and the coating manufacturer (and coating applicator, as well), with respect to the coating system definition. The manufacturing coating specification is to address, beyond of the coating system definition, other aspects, such as safety and health, inspection, metrology. 2.3 Approval of the coating system Within the scope of the CSR, the defined coating system must be qualified according to IACS PR 34, article 1, IACS procedure for coating system approval. A collection of relevant documents/reports regarding the approval of the coating system is made by the coating manufacturer and provided to the shipyard. Statement of Compliance (SOC) or Type Approval Certificate of the coating system is to be kept inside the Coating Technical File (CTF). June 2007 Bureau Veritas 7

10 NI 531, Sec 2 Figure 1: PSPC Flow Chart Designing Coating coating system system Third Party issue statement of compliance or TAC review Definition and specification of the coating system Approval of the coating system Agreement on the inspection procedures & plan Agreement between parties agree request Coating Manufacturer check approval Coating specifications (Technical data sheets & statement of compliance or TAC) review Inspection procedures & plan Coating specification, TDS check qualification Qualification Selection of Coating the coating Inspector inspector (CI) submit New Construction Bureau Veritas check ID on containers check review Steel preparation and Coating application Shop primer Block construction Erection Coating work records Inspection Inspection logs of CI checked for proper equipment, Ship verified inspection report techniques, and methodology CTF: Coating COATING Technical TECHNICAL File (maintained FILE onboard) Agreement between parties Statement of compliance or TAC of coating system Coating technical data sheets Shipyard work records Inspection procedures Coating inspection logs of CI Shipyard inspection report verified by CI In-service procedures and records implement maintain compile Shipowner Shipyard In-service maintenance, repair and re-coating implement 8 Bureau Veritas June 2007

11 NI 531, Sec 2 3 Parties involved in the coating process and their main duties 3.1 General The parties identified inside of the PSPC are: a) The coating inspector (CI), with a specific qualification level b) The coating manufacturer c) The shipyard d) The Administration, or the Recognised Organisation e) The Classification Society f) The shipowner. The duties of the coating inspector, the coating manufacturer, the shipyard, the Classification Society as the Recognised Organisation are addressed under [3.2] to [3.5]. 3.2 The coating inspector The main activities of the coating inspector are: a) Before the job coating works starts: read, and comprehend the manufacturing coating specification, referenced codes, and standards study coating material data sheets, checking for any conflict with the specification visit the site. b) At the pre-job conference: resolve any questions about the specifications, including specific reports, test instruments, and procedures if required, be ready to state exactly what tests and reports to adopt determine what are the responsibilities and authority of the coating inspector. c) During work: perform Quality Control tasks; report and record all these Quality Control activities checks the compliance of the work with the specification requirements report all non conformities and relevant corrective actions. 3.3 The coating manufacturer The coating manufacturer: a) provides the coating material, selected to ensuring the 15 years of product target useful life, as required by PSPC b) provides TDS & MSDS related with relevant coating material c) advises and assists the shipyard & the coating applicator if needed. 3.4 The shipyard The shipyard: a) ensures that all technical aspects of the PSPC are addressed, with reference to relevant standards b) enforces the application of the manufacturing coating specification and checks that relevant standards are met c) ensures that the Quality Assurance system is addressing all aspects regarding coating activities, including non conformities and their relevant corrective actions. 3.5 The Classification Society and/or Recognised Organisation The Classification Society and/or Recognised Organisation will check, at random, that: a) Basic documents listed in [4.2], including Technical Data Sheet and Statement of Compliance or Type Approval Certificate comply with the PSPC b) Coating identification on representative containers is consistent with respect to Technical Data Sheet and Statement of Compliance or Type Approval Certificate c) Coating inspector s qualification is in accordance with the qualification level of the PSPC d) Coating inspector's reports of surface preparation and coating's application indicate compliance with Technical Data Sheet and Statement of Compliance or Type Approval Certificate e) Documents listed in [4.3] are duly filled in/written/signed, and form part of the CTF. The Classification Society and/or Recognised Organisationwill also monitor implementation of the coating inspection requirements Reference to IACS PR 34 The main duties of the Classification Society are stated in the IACS PR Documents used for inspection agreement 4.1 General All the coating works shall be expressed in terms of technical procedures and documents specific to the project, which are to be agreed upon between involved parties. These documents can be divided into two main classes: basic documents and documents applicable during construction process, as listed in [4.2] and [4.3]. 4.2 Basic documents These documents are: Manufacturing coating specification Technical Data Sheet Material Safety Data Sheet June 2007 Bureau Veritas 9

12 NI 531, Sec 2 Procedure of coating application It is the responsibility of the shipyard to provide clear instructions regarding important steps of the coating application TAC or SOC of coating system Inspection procedure of surface preparation and coating process (specification review, pre-job meeting minutes, scope of work, safety data, coating inspector's check list and inspection details) Certificate of coating inspector Procedures for in-service maintenance and repair of coating system. 4.3 Documents applicable during construction process Synthesis document issued by the shipyard A synthesis document, containing the list of all seawater ballat tanks and double-side skin spaces of the ship under construction, including their respective identification numbers, is to be issued by the shipyard. This document should allow to trace the coating works and records. It should clearly indicate, for each concerned tank, the identification numbers of construction blocks, sub-items and tasks, that are included in the CTF Documents during construction process Documents applicable during construction process that are to be added to the CTF are: shipyard work records of coating application coating log issued by coating inspector non conformity report if any, and relevant corrective action shipyard's verified inspection report. 5 The implementation of the coating standard into the shipyard environment 5.1 General The approved coating system must be integrated into the whole ship construction process. This will be demonstrated by making sure that the following aspects are respected: The approved coating system, which is defined in the manufacturing coating specification, is the one being implemented to the process The manufacturing coating specification is complying with the PSPC requirements Raw materials are marked, stored and correspond to those specified in the manufacturing coating specification and TDS All coating operations are performed in accordance with the manufacturing coating specification Traceability of all coating operations is ensured along the whole coating process, by keeping records on reports and documents. These records are also to include non conformities and corrective actions. The PSPC is ensuring the implementation of the designed coating system by clearly providing the list of minimum inspection items to be covered by the coating inspector. Each process is ensuring the maintenance of the quality level within the PSPC requirements and/or the workmanship preliminary defined by the shipyard as shown in the attached example, given in Tab 1. 6 The Coating Technical File (CTF) - The evidence of the PSPC implementation 6.1 General All documents listed under [4.2] and [4.3] are to be part of the Coating Technical File (CTF), providing the evidence that the designed coating system has been implemented into the whole ship construction process. The CTF is to be submitted to the Administration or Recognized Organization, for review. Table 1 : Implementation of PSPC Construction process Critical pass Possible causes Quality Control action Shop primer Water soluble salt 50 Improper cleaning process To confirm cleaning process mg/m 2 before surface treatment Surface treatment after erection Damaged area < 2% Overhaul of structure or outfitting after coating Proper Quality Control and production planning/control 10 Bureau Veritas June 2007

13 NI 531, Sec 3 SECTION 3 THE PERFORMANCE STANDARD FOR PROTECTIVE COATINGS STEP BY STEP 1 Achieving the coating quality level 1.1 General The achievement of the coating quality level requested by the PSPC is not only the challenge of the coating applicator, but a work to be conducted jointly by all parties intervening in the various stages of the ship construction process. Since the very beginning of the project, at the design stage, the various aspects of the coating process are to be taken into consideration. Complicated details of the structure, difficult access to certain areas, creation of regions of poor ventilation, and poor drainage should be avoided. In other cases, design deficiencies regarding the coating may add difficulties to obtain the required level of standards referred into the PSPC, for surface preparation activities, for the nominal dry film thickness, or related with any other specific coating characteristic. The PSPC is considering these aspects under paragraph 3.3.2, as follows: The coating performance can be improved by adopting measures at the ship design stage such as reducing scallops, using rolled profiles, avoiding complex geometric configurations and ensuring that the structural configuration permits easy access for tools and to facilitate cleaning, drainage and drying of the space to be coated. After the design, the specification of the coating works is to be prepared in tightly contact with the coating manufacturer, to take into consideration some practical aspects of the application process, such as: the easiness of the coating application the need of very high level of skilled labor, required for the application of some modern coatings, and may be, not available at the construction site the availability of necessary sophisticated equipment, required for some types of coatings. The subject of specifications and selection of coating systems is to be addressed taking into consideration all possible coating application problems that could exist for the specific project under consideration. Special attention is to be drawn to temporary construction aids, to make sure they are removed after construction, and not left in place, and coated along with the original coating application. These aids are to be removed, and the surface at this area prepared to the relevant standard, for the coating application. The production of a quality coating is much dependent of the ability of the coating applicator to perform its job, with an appropriate application technique. Special attention is to be paid to make sure that he has the required level of qualification. Typical problems caused by poor qualification level and faulty application techniques could include: improper thickness of the coat, pinholes, overspray, holidays and pinpoint rusting. 2 Designing the coating system 2.1 Design requirement of the coating system The definition of the coating system must meet all relevant requirements of Table 1 of the PSPC. Coating manufacturers shall provide a specification of the protective coating system to satisfy the requirements oftab 1, which is an extract of Table 1 of the PSPC, regarding the design of the coating system. 2.2 Approval requirement of the coating system Coating type is epoxy based systems. Coating pre-qualification test should comply with Tab 1, item 3. Epoxy based systems tested prior to the date of entry into force of the PSPC, except for CSR, for which IACS PR 34 applies (December 8, 2006 is the entry into force date), in a laboratory by a method corresponding to the test procedure in annex 1 of the PSPC or equivalent, which as a minimum meets the requirements for rusting and blistering; or which have documented field exposure for 5 years with a final coating condition of not less than "GOOD" may be accepted. For all other systems, testing according to the procedure in annex 1 of the PSPC, or equivalent, is required. Results from prequalification tests (Tab 1, item 3) of the coating system shall be documented, and a Statement of Compliance or Type Approval Certificate shall be issued if found satisfactory by a third party, independent of the coating manufacturer. June 2007 Bureau Veritas 11

14 NI 531, Sec 3 Table 1 : Basic coating system requirements for dedicated seawater ballast tanks of all type of ships and double-side skin spaces of bulk carriers of 150 m and upward Item Characteristic Requirement 1 Selection of the coating system The selection of the coating system should be considered by the parties involved with respect to the service conditions and planned maintenance. The following aspects, among other things should be considered: location of space relative to heated surfaces frequency of ballasting and deballasting operations required surface conditions required surface cleanliness and dryness supplementary cathodic protections, if any (where coating is supplemented by cahodic protection, the coating should be compatible with the cathodic protection system). Coating manufactures shall have products with documented satisfactory performance records and Technical Data Sheets. The manufactures should also be capable of rendering adequate technical assistance. Performance records, Technical Data Sheet and technical assistance (if given) shall be recorded in the Coating Technical File. Coating for application underneath sun-heated decks or on bulkheads forming boundaries of heated spaces shall be able to withstand repeated heating and/or cooling without becoming brittle. 2 Coating type Epoxy based systems. Other coating systems with performance according to the test procedure in annex 1 of PSPC. A multi-coat system with each coat of contrasting colour is recommended. The top coat shall be of a light colour in order to facilitate in-service inspection. 3 Coating pre-qualification test Epoxy based systems tested prior to the date of entry into force of the PSPC in a laboratory by a method corresponding to the test procedure in annex 1 of PSPC or equivalent, which as a minimum meets the requirements for rusting and blistering; or which have documented field exposure for 5 years with a final coating condition of not less than "GOOD" may be accepted. For all other system, testing according to the procedure in annex 1 of PSPC, or equivalent, is required. 4 Job specification There shall be a minimum of two stripe coats and two spray coats, except that the second stripe coat, by way of welded seams only, may be reduced in scope where it is proven that the NDFT can be met by the coats applied in order to avoid unnecessary over thickness. Any reduction in scope of the second stripe coat shall be fully detailed in the CTF. Stripe coats shall be applied by brush or roller. Roller to be used for scallops, ratholes, etc., only. Each main coating layer shall be appropriately cured before application of the next coat, in accordance with coating manufacturer's recommendations. Surface contaminants such as rust, grease, dust, salt, oil, etc. shall be removed prior to painting with proper method according to the paint manufacturer's recommendation. Abrasive inclusions embedded in the coating shall be removed. Job specifications shall include the dry-to-recoat times and walk-on time given by the manufacturer. 5 NDFT (Nominal Dry Film Thickness) NDFT 320 µm with 90/10 rule for epoxy based coatings, other systems to coating manufacturer's specifications. Maximum total dry film thickness according to manufacturer's detailed specifications. Care shall be taken to avoid increasing the thickness in an exaggerated way. Wet film thickness shall be regularly checked during application. Thinner shall be limited to those types and quantities recommended by themanufacturer. IACS interpretation of PSPC: as for the IACS CSR for Bulk Carriers and for Oil Tankers, which are contracted for construction on or after 8 December 2006 and until the date of application referred to in para.1 of SOLAS Regulation II-1/3-2, as adopted by IMO Resolution MSC.216(82), the procedure for coating system approval refer to PR34, article 1. Type Approval Certificate showing compliance with the PSPC section 5 shall be issued if the results of either method A+D, or B+D, or C+D are found satisfactory by the Society. Method A: Laboratory Test a) Coating pre-qualification test shall be carried out by the test laboratory which is recognized by the Society and meets the requirements set out in IACS UR Z17 paragraphs 4, 5, 6 and 7 (except for 4.6 & 5.3) as below. b) Results from satisfactory pre-qualification tests (PSPC table 1, paragraph 1.3 of the PSPC) of the coating system shall be documented and submitted to the Society. 12 Bureau Veritas June 2007

15 NI 531, Sec 3 Method B: 5 years field exposure a) Coating manufacturer's records are to be examined to confirm coating system has 5 years field exposure. b) A joint (coating manufacturer/society) survey of all ballast tanks of a selected ship is to be carried out for the purpose of verification of compliance with the requirements of item a) and item e). The coating manufacturer's representative is to be qualified as defined in 2.2 of PR34. c) The selected ship is to have ballast tanks in regular use, of which: at least one tank approx 2000 m 3 at least one tank shall be adjacent to heated tank and at least one tank underdeck exposed to sun. d) In the case that the selected ship does not meet the requirements in 1.5 then the limitations shall be clearly stated on the type approval certificate. For example, the coating cannot be used in tanks adjacent to heated tanks or underdeck or tanks with volume greater than the size surveyed. e) All ballast tanks are to be in "GOOD" condition, without touch up or repair in the prior 5 years. GOOD" is defined as: condition with spot rusting on less than 3% of the area under consideration without visible failure of the coating. Rusting at edges or welds, must be on less than 20% of edges or welds in the area under consideration. Examples of how to report coating conditions with respect to areas under consideration should be as those given in IACS Recommendation 87, Appendix 1. Method C: Existing Marintek B1 approvals. a) Epoxy coatings systems with existing satisfactory Marintek test reports minimum level B1 issued before Dec 8th 2006 can be accepted. b) Such coatings are to be applied in accordance with Table 1 of the PSPC rather than the application conditions used during the approval test which may differ from the PSPC, unless these are more stringent than table 1 of the PSPC. Method D: Coating manufacturer a) The coating manufacturer shall meet the requirements set out in IACS UR Z17 paragraphs 4, 5, 6 and 7, (except for 4.6), which is to be verified by the Society. b) In the case that a manufacturer wishes to have products which are manufactured in different locations under the same name, then infrared (IR) identification and specific gravity shall be used to demonstrate that they are the same coating, or individual approval tests will be required for the paint manufactured in each location. 2.3 Preparation of the application procedure Shipyard application procedure is to be verified by coating inspectors and coating manufacturer to check its conformance with the PSCPC. This verification should be performed with respect to: a) Surface preparation and allied discipline: steel surface staging, lighting, ventilation, dehumidifying, and heating contamination, abrasive blasting and water jetting b) Application: stripe coating application method conditions for painting application work c) Repairs during new building: materials for repair repair process d) Supplementary cathodic protection. 2.4 Preparation of the inspection procedure The procedure of inspection of surface preparation and coating processes shall be agreed upon between the shipowner, the shipyard and the coating manufacturer and presented to the Society for review. The Society may, if it so requires, participate in the agreement process. Clear evidence of these inspections shall be reported and be included in the Coating Technical File (CTF) (PSPC, section 3.2 and PR34, article 3) Procedures for inspection and repair procedures at new construction stage are to give sufficient details for: - Equipment and condition (staging, accessibility lighting, ventilation, dehumidifying, and heating) - The inspection items as a minimum, identified in section 6.2 of PSPC (surface preparation, coating application) - Acceptance criteria: Visual appearance Measurements of DFT Control for adhesive/cohesive properties, for holidays and for mechanical damage Qualification - The coating inspector is to have at least one of the following qualifications: NACE coating inspector Level 2 FROSIO inspector Level III Equivalent qualifications accepted by the Society. Moreover, only coating inspectors with at least 2 years relevant coating inspector experience, can write and\or authorize procedures, or decide upon corrective actions to overcome non-compliances Equivalent qualification: Equivalent qualification is the successful completion, as determined by course tutor, of an approved course. The course tutors shall be qualified with at least 2 years relevant experience and qualified to NACE coating inspector Level 2 or FROSIO inspector Level III, or with an equivalent qualification. June 2007 Bureau Veritas 13

16 NI 531, Sec 3 Approved course: a course that has a syllabus based on the issues associated with the PSPC including the following: Health environment and safety Corrosion Materials and design International standards referenced in PSPC Curing mechanisms Role of inspector Test instruments Inspection procedures Coating specification Application procedures Coating failures Pre-job conference MSDS and product data sheet review Coating technical file Surface preparation Dehumidification Water jetting Coating types and inspection criteria Specialized application equipment Use of inspection procedures for destructive testing and non destructive testing instruments. Inspection instruments and test methods Coating inspection techniques Cathodic protection Practical exercises, case studies. Examples of approved courses may be internal courses run by the coating manufacturers or shipyards. Such a course shall have an acceptable measurement of performance, such as an examination with both theoretical and practical elements. The course and examination shall be approved by the Society. Equivalent qualification arising from practical experience is considering an individual who: has a minimum of 5-years practical work experience as a coating inspector of ballast tanks during new construction within the last 10 years, and has successfully completed the examination given hereabove. 2.5 Submission of documentation (CTF) Documents issued by the coating manufacturer The following documents are to be provided by the coating manufacturer to the shipyard: a) Copy of Statement of Compliance or Type Approval Certificate b) Documents on products with satisfactory performance records c) Technical Data Sheet of the coating system complying with the IMO PSPC and containing at least: product name and identification mark and/or number materials, components and composition of the coating system, colours minimum and maximum dry film thickness application methods, tools and/or machines condition of surface to be coated (de-rusting grade, cleanness, profile), and environmental limitations (temperature and humidity). d) Safety data sheet: identification of the preparation and of the company composition/information on ingredients hazards identification first aid measures fire-fighting measures accidental release measures handling and storage exposure control/personal protection physical and chemical properties transport information regulatory information additional information. e) Specification of the coating system to satisfy the requirements of PSPC, including: project name and application area steel preparation and surface preparation and surface cleanliness product information: paint system, physical constant, application method, recoating interval, etc. environmental conditions how to do: - application procedure - acceptance criteria and - inspection In case of a technical assistance, if any: refer to service agreement Documents issued by the shipyard The following document, issued by the shipyard, with the assistance of the coating manufacturer, is to be provided: Verified coating application procedure of shipyard. 2.6 Approval and verification requirement by the Society The procedure for inspection of surface preparation and coating processes shall be agreed upon, between the shipowner, the shipyard and the coating manufacturer. It should be presented by the shipyard to the Society for review Coating system approval: Type Approval Certificate showing compliance with the PSPC section 5 shall be issued if the results of either method A+D, or B+D, or C+D are found satisfactory by either the Society or a third party recognised by the Society (see IACS PR34) Check that the Technical Data Sheet and Statement of Compliance or Type Approval Certificate comply with the PSPC. 14 Bureau Veritas June 2007

17 NI 531, Sec Check that the inspector is qualified in accordance with the qualification standards in paragraph to of PR34. 3 Agreement between parties 3.1 The pre-job conference General The shipyard prior to starting works, notifies the coating manufacturer, the shipowner and the coating inspector in advance, about the pre-job conference. During this meeting, the parties can analyse and discuss the following contractual documents: manufacturing coating specification technical data sheet material safety document sheet procedure of coating application complied by shipyard It is the responsibility of the Shipyard to provide clear instructions regarding all important steps of the coating application, including time schedule TAC or SOC of coating system inspection (procedure) of surface preparation and coating process (specification review, scope of work, safety data, coating inspector's check list, inspection details) certificate of coating inspector procedures for in-service maintenance and repair of coating system Topics to cover in the meeting The items to be discussed should cover: a) review of standards and work procedures, to resolve any ambiguities or errors inside of these documents b) scope of coating works: list of all items/sub items to be coated, indicating areas not to be coated c) surface preparation: cleaning process - pre-inspection - a procedure to inspect for, mark, and correct fabrication defects - pre-cleaning - removal of contaminants (oil, grease, dirt) by solvent cleaning to a known standard - cleaning operations to referenced standards (hand tool, or power tool, or abrasive blasting cleaning operations) anchor profile d) coating material standards (TDS/MSDS are provided, and suitably written) e) workmanship f) work schedule g) inspection methods and interpretation of results / reporting forms (formats) h) frequency of tests i) non conformities and corrective actions j) accessibility to all items and sub-items to be coated k) all capabilities at site (power supplies, water, shower, toilets) l) scaffold, tarpaulins m) communication means n) safety issues. A collection of applicable standards and relevant technical documents should be available during the meeting, permitting to clarify any specific technical issue, if necessary Minutes of meeting All involved parties in the scope of the PSPC should be represented in this meeting. As an example, a list of persons participating in this meeting could be: shipowner, shipyard (management: construction operator, project manager; purchasing agent, design engineer, safety engineer, Quality Assurance), subcontractors (suppliers, coating applicator, coating manufacturer), coating inspector, etc. The coating inspector is a key party, and may be in contact with all these persons during the project. The pre-job conference is in general a good opportunity to permit all parties to be in contact. Clear minutes of the meeting should be written, covering all questions and answers. At the end of the meeting all potential sources of problems should be raised, and appropriate solutions adopted. The minutes will become a contractual document, which is a part of the agreement between parties, containing the issues covered during the meeting. 4 Coating works inside the shipyard 4.1 Shop primer Coating works according to Table 1 of PSPC Before starting the surface preparation, all steel defects have to be treated according to the standards referred into the PSPC. These defects are including, amongst others, surface laminations, shelling, and inclusions. The soluble salt content should be checked to the acceptable limit of the PSPC (50 mg/m 2 ). Oil, grease, and any other contaminations should also be checked according to the PSPC. All these operations are to be performed taking into account the environment conditions (air and surface temperatures, relative humidity and dew point.) Inspection requirement Raw materials should be confirmed to meet the requirements of the approved coating manufacturer s documents (TDS, MSDS). Cleanliness should be monitored, and oil grease be checked by relevant method such as 'chalk mark test". Measurement of salt content and, if necessary, removal before going into shot blasting is to be considered. Otherwise shipyard procedures are to check salt content after shot blasting. The whole conductivity value is calculated to NaCl equivalent. DFT shall be confirmed to conform to the specified values. June 2007 Bureau Veritas 15