Sspc New.pdf

Joe Berish, SSPC Corporate Certification Program Manager

Who is SSPC? The Society for Protective Coatings Founded in 1950 as the Steel Structures Painting Council A not for profit 501 (c) (3) – spun off of Carnegie Mellon University

SSPC Mission “Advance the technology and promote the use of protective coatings to preserve industrial, marine, and commercial structures, components, and substrates.”

SSPC at a Glance • • • • •

Located in Pittsburgh, Pennsylvania Staff of 41 employees ~12,000 individual members worldwide >950 corporate members worldwide Global Reach

SSPC Core Products & Services • • • • •

Coatings industry standards Technical publications Training and certification courses Painting contractor certification programs Conferences, events, and webinars

SSPC Market Verticals • • • • • • •

Oil / Gas / Pipeline Water / Waste Water / Concrete Civilian Marine Department of Defense / Military Services Power Transmission / Generation Nuclear Department of Transportation (Bridges / Civil Works)

What Does SSPC Do? • Develop technically sound protective coatings standards. • Provide HIGH QUALITY certification and training programs for both organizations and individuals. • Offer a comprehensive and compete online resource for standards, information, virtual educational courses, and publications.

y Fundamentals of Protective Coatings y SSPC Surface Preparation Standards y Coating Selection and Application y Coating Assessment & Inspection y Latest Technologies y SSPC Training and Certifications for individuals y PCCP Overview

What you need for a successful protective coatings project: • For a maintenance project, perform a condition assessment or  survey of the structure (e.g., piping, storage tanks) based on  SSPC‐PA 5, in order to determine what substrate repairs are  required prior to coating and what coating system should be  selected to best protect the structure in its service environment. •

Once funding is procured, based on the results of the condition  assessment, write a clear and concise coating specification, citing  industry standards as often as possible. It is essential that the  specification be designed for the specific project to be  undertaken. The specification should be written by an  experienced and qualified (e.g., SSPC or NACE Protective  Coatings Specialist) familiar with oil & gas structures to be coated

A good specification must include, at a minimum: • Clear surface preparation (SP), coating application (CA) and curing  requirements, stated once, citing industry standards • Clear definition of what materials (e.g., caulking; coating; thinners, if  allowed; abrasive; water quality for water cleaning, etc) are allowed • What’s to be coated and what’s not to be coated, including protection of  what’s not to be cleaned and coated and protection of surroundings during  SP & CA operations • Quality Control and Quality Assurance requirements including Inspection  hold points and required reports and submission • Qualifications of contractors and subcontractors • Qualifications of personnel (e.g., craft‐workers; inspectors) • Job site restrictions (e.g., where to work and stage equipment; the time of  day and days work is allowed; utilities

NY DOT sec 573 573‐3   CONSTRUCTION DETAILS. The Contractor shall clean and paint all structural steel  members, railings, downspouts, and other miscellaneous steel  items as indicated in the contract documents. The Contractor  shall provide adequate access, suitable lighting, and time for  inspections to be made. Any work done while the Engineer has  been restricted from access, shall be recleaned and repainted, at  no additional cost to the State to the State.

NY Dot specification for  lighting E.  Lighting.  Light intensity by natural or artificial means inside the  containment enclosure shall be maintained at a minimum of  50 foot‐candles on the steel surface. During inspection  activities, light shall be maintained at a minimum of 100 foot‐ candles Auxiliary lighting shall be provided as necessary. The  Contractor shall provide the Engineer with one portable light  meter with a scale of 0 to 100 foot‐candles.  This meter will be  returned to the Contractor at the completion of work. All  lighting used in the containment shall be explosion‐proof.

Required submittals & approvals • before starting work (e.g., safety, health and environmental  compliance plans, including confined space plans if  applicable; work process plans (how the contractor is going  to clean and coat); inspection and test plans  • during production (adjustments to pre‐work plans submitted  based on approved changes; daily inspection reporting or  other daily reports; accident or injury reports; notification of  changes in key personnel; schedule changes) • after work or phases are completed (punch list; waste  disposal reports; required documentation needed for  payment)

Workshop #1 Open discussion of NY State  Specifications, Questions‐ discrepancies‐ experiences

• For new construction (e.g., painting in the shop before  delivery to the field or touch up painting or top‐ coating after field erection), require much of what’s  been described above with the exception of  performance of a condition survey • Field touch up or top‐coating of new construction;  include requirements for: • cure in the shop before delivery to the field • handling transportation and erection damage that  will affect touch up and top‐coating

• Conducting condition assessments, writing good specifications and  contracts based on sound condition assessment, lessons learned  from similar projects performed in the past and enforcement of  requirements are essential for effective coating projects • Conducting best fundamental practices result in higher installation  costs but makes your coating projects overall less expensive by  providing • More efficiently run coating projects from both the owner’s and  contractor’s side • Greater likelihood that the coating system applied will meet or  exceed its expected service life

Surface Preparation • Types of Surface Preparation used  in industrial painting • SSPC Industry Standards

Types of Surface  Preparation

• Dry Abrasive Blast Cleaning • Wet Abrasive Blast Cleaning (e.g., slurry blasting;  vapor blasting) • Water Cleaning and Water Jetting • Hand and Power Tool Cleaning • Solvent Cleaning (Required for all SSPC cleaning  standards) • Chemical Stripping

Dry Abrasive Standards  (SSPC/ NACE)

• SSPC/NACE Joint Standards • SP 5/NACE 1 (White Metal) • SP 10/NACE 2 (Near White Metal) • SP 6/NACE 3 (Commercial) • SP 14/NACE 4 (Industrial Blast) • SP 7/NACE 5 (Brush Off Blast)

Wet Abrasive Standards  (SSPC/NACE)

• • • • •

SP‐5/NACE 1 (WAB) – White Metal SP‐10/NACE 2 (WAB) – Near White SP‐6/NACE 3 (WAB) – Commercial SP‐14/NACE 4 (WAB) – Industrial SP‐7/NACE 5 (WAB) – Brush Off • Includes:  Wet Slurry Blasting; Vapor  Blasting; Water Ring Blasting • Vapor Blasting is the up and coming  technology

Hand and Power Tool  Cleaning (SSPC)

• SSPC‐SP 3 – Power Tool Cleaning (PTC) (Removal of  Loose Material) • SSPC‐SP 15 – Commercial Grade PTC (Removal of all  material except traces in pits; some staining (33%)  allowed; 1 mil profile minimum) • SSPC‐SP 11 – PTC to Bare Metal (Removal of all material  except traces in pits; no staining allowed; 1 mil profile  minimum)

Water Cleaning/Jetting  (SSPC/NACE)

• • • •

SSPC‐SP WJ‐1/NACE‐Clean to Bare Substrate SSPC‐SP WJ‐2/NACE‐Very Thorough Cleaning SSPC‐SP WJ‐3/NACE‐Thorough Cleaning SSPC‐SP WJ 4/NACE‐Light Cleaning

•

The above cleaning levels may be achieved using low‐pressure  water cleaning or high‐pressure water cleaning, high pressure  waterjetting or ultra high pressure waterjetting methods

SSPC‐SP 16

• Surface Preparation of Non‐ferrous Metals (Galvanized Steel;  Stainless Steels; Non‐ferrous Metals) by Brush off Blast Cleaning • Removes loose material using low‐pressure dry abrasive blast  cleaning • Minimum Surface Profile (19 micrometers‐0.75 mils)

SSPC‐SP 1

• SP 1 – Solvent Cleaning • Removal of all “visible” deposits of oil and grease prior to  beginning the surface preparation process (e.g., blast cleaning;  power tool cleaning; water jetting) • Required process by all SSPC and SSPC/NACE Surface Preparation  Standards • Some specifications waive SP 1 for Water Jetting

Abrasive Qualification Standards

• AB 1* – Mineral Abrasives • AB 2 – Cleanliness of Recycled Abrasive • AB 3 – Ferrous Metallic Abrasives • AB 4 – Encapsulated Media (“sponge”) Abrasives

*SSPC has developed an AB 1 abrasive qualification program

SSPC Surface Preparation Commentary  (SP Com)

• Provides guidance and supplemental information useful to  specifying agencies • Media   • Techniques/Equipment • Standards available • Focus is on surface preparation of steel substrates • Updated in 2015 • Free download for SSPC Members

Questions?

Questions / Comments on SSPC Surface Preparation  Standards and related documents

Coating Selection and Application‐ Considerations • Selection of Coatings • Considerations: • Expected Service Life (extent of surface preparation needed) • Service Environment/Operating Temperatures • Access to work site (if in situ) • Can the coating work be done in a shop environment (e.g.,  inorganic zinc vs organic zinc)? • To be done with in‐house crews vs contractor • Availability of qualified applicators (Contractors and craft‐ workers) at the location • Availability of equipment and materials for the project • Regulatory restrictions (high VOC vs. high solids)

Coating Selection and Application‐ Considerations (Cont’d)

• Time constraints (e.g., outage period; pressure to place asset back  into service; limitations on times you can prepare surface and coat) • Risks (Overcoat vs. spot repair vs. zone painting vs full removal and  recoat) • Appearance concerns (Color, gloss, texture) • Ease and cost of maintenance after installation • Painting over bare substrate or galvanized or thermal sprayed steel • Buried steel with Cathodic Protection

SSPC Environmental Zones

• 0 ‐ Dry interiors where structural steel is embedded in concrete,  encased in masonry, or protected by membrane or non‐corrosive  contact type fireproofing • 1A ‐ Interior, normally dry (or temporary protection). Very mild.  • 1B ‐ Exterior, normally dry. Coatings may be subject to exposure to  sunlight. • 2A Frequently wet by fresh water. Coating may be subject to  condensation, splash, spray or frequent immersion. 

Environmental Zones (Cont’d)

• 2C ‐ Fresh water immersion. Coating is constantly submerged.  • 2D ‐ Saltwater immersion. Coating is constantly submerged.  • 3A ‐ Chemical atmospheric exposure, acidic (pH 2.0 to 5.0)  • 3B ‐ Chemical atmospheric exposure, neutral (pH 5.0 to 10.0) 

Environmental Zones (Cont’d)

• 3C ‐ Chemical atmospheric exposure, alkaline (pH 10.0 to 12.0)  • 3D ‐ Chemical atmospheric exposure, presence of mild solvent  fumes. Intermittent contact with aliphatic hydrocarbon solvents (e.g.,  mineral spirits), lower alcohols, glycols, etc.  • 3E ‐ Chemical atmospheric exposure, severe. Includes oxidizing chemicals, fumes from strong solvents, extreme  pHs, or combinations of these with high temperatures.  • 4A ‐ Extremely high temperatures, e.g., 650° F (330° C) and higher 

Coating Material Selection

• What has worked previously on similar projects? • If new situation, what is published performance history (e.g., JPCL;  SSPC Conference Proceedings)? • If trying new coating, has there been a test patch trial? • What are the results of accelerated testing (e.g., flexibility; abrasion  resistance; weathering; chemical resistance?

Coating Material Selection Cont’d

• What are other organizations using successfully? • What do reliable coating manufacturer technical reps recommend?

Coating Application

• Methods • Brush • Roll • Mitt • Spray • HVLP, Conventional Spray, Airless, Air Assisted; • Plural Component

Coating Application

• Brush – slow but simple method; uneven paint application; good for  stripe coating and touch up; use brush type recommended by  Coating Mfr. • Roller – good for large flat areas; slow; minimum thickness 2 mils;  roller nap can leave contamination; use roller type recommended  by Coating Mfr. • Mitt – uneven application; used for difficult to access areas or  piping to get coverage 

Coating Application • Spray • Most productive method • Airless Spray (high fluid pressure) • Typical for industrial application • High production capability • Good for heavy coating • Low overspray potential • Safety concerns due to high fluid pressure • Conventional (uses air); good operator control • Good for fine applications • Safer, low pressure spraying • Not suitable for heavy, industrial coatings • Potential for Overspray

Coating Application

High Volume/Low Pressure Good control Good transfer efficiency – low overspray potential Slower production rate than other spray methods Air‐Assisted Airless Combines features of Conventional and Airless Not as productive as airless Not recommended for high solids materials

Coating Application

Plural Component Spray Used to apply large quantities of high solvent, viscous (thick), 2K  materials (e.g., epoxies or urethanes) with short pot lives Material mixed at manifold in field or at gun Can keep material heated to reduce viscosity Reduces paint waste Skilled operator required High equipment cost

Application Practices (Mixing)

• Mixing‐one of the most important steps for a successful installation • Must be done in accordance with Coating Manufacturer’s  recommendation • Mix ratios of multi‐part coatings critical for effective application and  cure • Mixing of partial kits usually not recommended‐partial kit mixing  increases chance of error • Coating (material temp) can be important • Thinning must be done carefully, if permitted. Thinner type and  amount used should be documented

Application Conditions

• It is critical that coating be applied during acceptable environmental  conditions and surface temperature at the work site location • Ambient conditions (e.g., air temperature; relative humidity;  surface temperature; dew point; wind speed) must be measured  using calibrated and correctly operating inspection equipment

SSPC‐PA 1(2016)

• All coating must be performed in accordance with SSPC‐PA 1, Shop,  Field and Maintenance Coatings of Metals • SSPC‐PA 1 is the industry standard for best industrial paint  application processes • PA‐1 should be written into every industrial coating specification

Coating Assessment & Inspection

Assess Condition of Aged Coating Conduct Survey per SSPC‐PA 5 Rust Assessment tool – SSPC‐VIS 2 Coating Condition Assessment and Structural integrity & defect  assessment go hand in hand • Draft coating specification upon analysis of structure (needed  structural repairs) and coating condition • • • •

Coating Inspection

Quality Control Inspection Performed by Shop or Coating Contractor Required minimum qualifications for QC inspectors‐minimum  SSPC Level 1 with 2 years experience Require separation from production Require submission of completed & and signed inspection reports  to owner or owner’s rep within 24 hours of inspection

Inspection (cont’d.)

Quality Assurance Performed by the owner or third party owner’s rep Quality Assurance can include: witnessing of QC inspection;  reviewing/auditing of QC inspection documentation; performing  and documenting inspections and tests to confirm conforming/non  conforming work Quality Assurance inspector should be qualified (SSPC Level 3 or  equivalent)  QA inspections should be fair and reasonable

Inspection (cont’d.)

Best Practices Require contractor/shop to prepare I & TP (Inspection and Test  Plan) prior to project start Require hold point inspections at various intervals  Pre‐surface preparation Completion of Surface Preparation Just prior to prime coat application After each stripe or top coat Cure/Dry to Touch

Inspection (cont’d.)

Workshop 2 Review of the NY DOT  inspection report

Contractor Work Plan

• If work is contracted, require pre‐construction submittal of Work  Plan • Work Plan tells you how the contractor plans to perform the work • Owner’s obligation – review and comment on Work Plan – never  approve as Contractor must always be responsible for quality of  the work • Work Plan, in addition to production processes to be used, can also  include QC Plan and Safety Plan

Latest Technologies

• High Solids Coatings (Epoxies and Urethanes) • Vapor Blasting‐alternative to dry blast cleaning • Emergence of Polysiloxanes

• 2 coat systems instead of 3 coat systems (to reduce costs) – jury  still out with regard to durability of 2 coat systems vs. 3 coat  systems

Benefits of Training • Improves Standards of Safety  • Improves Workmanship • Helps You Develop and Refine Your Skills • Helps You get Promoted  • Potential to Make More Money • Helps You Stay Competitive in the Job Market • It Keeps You Motivated

Craft worker Training & Certification

SSPC has many training & certification programs. Programs  appropriate for Oil and Gas include C‐6 (Power Tool Cleaning & Brush and Roll Applicator) C‐7 (Nozzle and Centrifugal Dry Blast Operator) C‐12 (Industrial Spray Painter) C‐14/C‐15 (Plural Component Operator/Sprayer) C‐13 (High Pressure Water Jetter) CAS (Coating Application Specialist) per ACS‐1/NACE

SSPC ACS‐1/NACE 13

Application Specialist Certification Standard First published in 2008; updated in 2016 Defines qualifications of a Coating Application Specialist Level 1 – Trainee Level 2 – Certified (General knowledge; assessment of hands on  ability to abrasive blast clean and mix and correctly spray a two  component industrial coating Level 2 + Specialty Endorsements (e.g., Waterjetting; Thermal  Spray; Coating Concrete; Pipeline; Plural Component Spray) Level 3 – Lead/Supervisory Applicator

SSPC CAS Program

Developed in 2008 Qualification Process based on ACS‐1/NACE 13 Standard SSPC conducts Interim and Full Status Certification Currently ‐‐‐‐‐‐‐‐ Level 1 Certified ….....Level 2 Certified Level 3 – not yet available SSPC‐QP 1 contractor certification requires contractor to have  ratios of CAS qualfieid craft‐workers on eligible projects as a  requirement to maintain QP‐1 certification

SSPC Training & Certification  Programs Protective Coatings Inspector (PCI) The Inspector Certification Program from SSPC Independently audited and approved by ABS, Lloyd’s, RINA and Bureau  Veritas as equivalent to NACE Level 2 in accordance with the IMO PSPC.

PCI Coating Inspector PCI (Protective Coating Inspector)‐Recognized world wide‐ Classification Society Accredited for IMO‐Applicable to pipeline,  storage tanks, refinery works and other Oil & Gas facilities  Level 1* – Training Level 2 – Certified Coating Inspector Level 3 – Lead Coating Inspector Documented experience required to qualify for Level 2 & 3  Certification *SSPC does not grant certification at Level 1‐must achieve Level 2  with inspection experience to become PCI certified

CCI Coating Inspector

Concrete Coating Inspector (CCI) Advanced certification to train individuals in the proper methods of  inspecting surface preparation and installation of industrial protective  coatings on concrete industrial structures and facilities.

SSPC Training & Certification Programs

Protective Coatings Specialist (PCS) Premier industry certification for individuals who have in‐ depth knowledge in the principles and practices of industrial  coatings technology.

What is a SSPC QP Certification? • SSPC QP is an industry specific and internationally recognized Quality Management System. • Quality Management System (QMS) is a system of specific policies and procedures intended to improve and control various processes which will ultimately lead to improved business performance.

What is the QP Program? • Programs that provide tools for evaluating a contractor’s primary capabilities to perform the specified work

• Evaluation provided by SSPC using trained auditors familiar with coating operations

SSPC Quality Program History • DAC – Disciplinary Action Criteria (1998) • QS 1 Certification Introduced (2003) • QP 8 Certification Introduced (2006) • QN 1 Certification Introduced (2012)

Benefits of QP Certification • FREE to the facility owner 3rd party evaluation tool, based on industry accepted coating standards. • Contractors are capable of a higher quality installation. • Aids in extending coating system service life. • QP certification is an industry-specific adaption of ISO Quality Systems concepts.

Benefits of QP Certification • Helps reduce risk management and corporate liability. • Confirms the contractor has an established safety and quality program. • Shows commitment to worker safety, protection of the environment, and public welfare. • Allows facility owners and specifiers to require current coating technologies.

Process for QP Certification • Information Review > Application > Written programs and procedures • On-Site Audit > Office > Active job site (field)

Eligibility for QP Certification • Industrial Painting Contractor OR General Contractor with an established industrial painting capability + actively working. • Quality Program in place for a minimum of one year with successful completion of at least two (2) industrial projects + six (6) production months of program implementation.

The Job Site Certification Audit • Certification requires an annual audit on an active contractor job site. Verify contractor application information. Confirm program implementation: Quality control Safety / Environmental Maintain technical capabilities

The On-Site Certification Audit • Annual maintenance audits Example: QP 1 has 33 total audit and evaluation points. • Unannounced and complaint audits Initiated as per QP program rules Initiated by facility owner deficiency report

Technical Capabilities • Personal Qualifications Training and Evaluation is recorded • Technical Resources and References • Technical Procedures Receipt of specs and revisions Clear definition of Q.A. methods/criteria Safety and Health compliance program

Management Procedures • Written descriptions outlining: Company Policy – quality, health, safety Organization and Personnel (org chart) Administration and Management: Method of financial record keeping Procedures for spec/bid review Plan – federal, state, local regulations

Types of SSPC QP Certification • • • • • • • •

QP 1 – Field Application of Coatings QP 2 – Field Removal of Hazardous Coatings QP 3 – Shop/Fixed Coating Operations QP 5 – Coatings Inspection Company QP 6 – Metalizing Operations in Shop/Field QP 7- Introductory Qualification program QP 8 – Coating/Surfacing to Concrete QP 9 – Architectural Paints and Coatings

Types of SSPC QP Certification • QN 1 – Supplement to QP 1, QP 3, QP 8 Certification, related to coatings work in or coatings of items for installation in a Nuclear Power Plant. • QS 1 – Supplement to contractor QP dealing with “Advanced Quality Management System” for coatings processes.

Disciplinary Action Criteria (DAC) >The DAC was developed as a tool to maintain certification quality and address violations of program standards. Facility owners and the SSPC work together to maintain the quality of QP Certification.

Areas of investigation: Safety Environmental Quality/Service Ethical practices

Penalties issued: Warning (1 year) Probation Suspension (6 mo MIN) Revoke (2 yrs MIN)

SSPC Mobile App

Thank You! Joe Berish Certification Program Manager (877) 281-7772 Ext. 2235 [email protected]