_QS-Manual-02_09_11 en

QA Standards Inside coating of EC dip tanks

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Version 1.0

Dürr Systems GmbH



Page

List of contents 2

1 Objective and application 4

1.1 Objective 4

1.2 Application 4

1.3 Reference to applicable standards and sets of rules 6

2 Tank design suitable for coating 7

3 Coating system 10

3.1 Description of coating 10

3.2 General requirements made of the coating system (suitability test) 10

3.3 Approval of coating system 11

3.4 Coating material 11

3.4.1 QA requirements made of the coating material 12

3.4.2 Delivery 13

3.4.3 Storage 13

3.5 Quality monitoring 14

3.6 Inspection of coating materials prior to their processing 14

4. Requirements for doing coating work 16

4.1 Qualifications 16

4.2 Condition of the surface to be coated 16

4.3 Surface preparation and cleaning of steel surfaces 18

4.3.1 Preliminary examination of surface quality 18

4.3.2 Surface preparation degrees 19

4.3.3 Roughness 19

4.3.4 Cleaning 19

4.4 Approval of steel surface preparation 20

4.5 Health and safety at work and environmental protection 20

5 Carrying out of coating work 21

5.1 General 21



5.2 Processing conditions 21

5.2.1 Preparation of coating material for processing 21

5.3 Coating method 22

5.3.1 Rework cycles of single sections 23

5.3.2 Overlapping of laminated coats and processing sections 23

5.3.3 Seal 23

5.3.4 Consumption 23

5.4 Repair 24

5.5 Method evaluation 24

6 Supervising of coating work 24

6.1 General 24

6.2 Test and measuring equipment 24

6.3 Inspection of coating 24

6.3.1 Inspection during coating work 25

6.3.2 Inspection after curing 25

6.3.3 Inspections on finished coating 26

7 Inspection panels and test plates 27

7.1 General 27

7.2 Records about inspection panels 27

7.3 Evaluation of coating 28

Annex A Check list forms 29



1 Objective and application

1.1 Objective

These QA standards summarize all regulations relevant to quality concerning the work that needs to be done on behalf of Dürr Systems GmbH when coating EC dip tanks on the inside.

These regulations shall ensure a trouble-free operation of the plant.

The QA standards are based on two things:

p A description of process steps relevant to quality (QA standards)

and

p Checklists required for checking all work done on site.

The completed checklists will have to be submitted to Dürr's site supervisor without explicit request. A process step can only be started, when the checklists of the preceding step or stage have been countersigned and taken note of by Dürr's site supervisor.

The supplier is solely responsible for deciding whether or not to start a new process step. The signature of Dürr's site supervisor does not change this general responsibility that continues to lie with the supplier.

A set of completed checklists is required for acceptance procedure.

1.2 Application

The QA standards regulate the following:

p Quality definition of the vinyl ester resin-based coating systems that shall be

used,

p Certificates of suitability for coating materials, glass fiber mats and other

material required for coating,

p Requirements made of the steel surfaces' condition,

? ?



p Application of coating material including all repair work needed and

p Examination and acceptance of the complete coating system

of mild steel tanks (EC dip tanks) that are permanently loaded with electrocoating fluids in the acid range (possibly aqueous solvent mixtures and alkaline cleaning solutions, approx. 5% sodium hydroxide).

Dürr Systems' supplier shall be responsible for conforming to technical rules and legal regulations about storage, transport, health and safety at work, pollution control and waste management. ?



1.3 Reference to applicable standards and sets of rules

DIN 4119 Overground flat bottom tank constructions made of metal materials

DIN 8201 Solid abrasives sect 6 + 9

ISO 8501 - 1 Standard reference surface rouhgness

ISO 8502-4 Air dew point

DIN ISO 8503 Preparation of steel surfaces prior to coating; surface roughness parameters

DIN EN ISO 12944 - 1 to 9 Corrosion proofing of steel structures by applying anticorrosive coats

DIN EN 10204 Metal products – types of test certificates

DIN 28051 Construction of metal elements to be corrosion- proofed when coating and lining with organic materials

DIN 28053 Chemical apparatus engineering; coating and lining with organic materials

DIN 28 054-2 Chemical apparatus engineering; coating with organic materials for elements built of metal material; laminated coating

TRbF 401 Guide concerning the inside coating of tanks used to store inflammable fluids of hazard classes AI, A11 and B

TRgA 503 Abrasives

TRgA 507 Indoor surface treatment



2 Tank design suitable for coating

pDesign engineering

Static calculation Stable design, no bulging, sheet metal thickness 6mm

Accessibility The surfaces to be treated must be accessible. Note min. measure when spacing between surfaces is narrow. Ensure that places hard to access are made accessible. See figure 1.

pManufacturing

All edges No sharp edges, edges to be chamfered, deburred, radiused (rmin = 3mm). All edges, grooves, corners and welds to be radiused min. 3mm. See detail 1.

Welds Free from flaws such as surface roughness, penetration, pores, craters and splashes. No discontinuous welding, no spot welding. Sand all welds. See detail 2.

Connections See details 3 + 4.

Flooding pipe brackets See detail 4.

Inlet connection See detail 3.

Safeguarding See detail 5.

Tank acceptance Check tank design during production process whether suitable for coating. If design is inadequate this fact needs to be taken down and requires repair in compliance with the above specs. Complete check list 6.

? Check list 6



Figure 1: Accessibility of surfaces to be coated

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3 Coating system

3.1 Description of coating

A standard coating description is given in DIN 28054 sect 2 "Laminated coating".

The description specified is a

3.1.1 Laminated coating to DIN 28054 – 2 VE 3 P 0 G 2 D V

without intermediate coat which the DIN standards allow as an option.

Deviation from the standards needs to be approved by Dürr Systems beforehand and shall be documented.

3.2 General requirements made of the coating system

(suitability test)

A suitability test shall prove the following properties:

p Good and lasting electrical insulation properties: standard test voltage

is 15 kV. If explicitly requested by customer, 20 or even 25 kV are possible. Test voltage needs to be specified in each case.

? Metal substrate

Primer coat

Intermediate layer notincluded in dip tank coating

Reinforcement layers,top layer covered by felt

Final coat

Seal



p Good paint resistance to / compatibility with the E-coating paint that

will fill the tank

p Permanent adhesion also when loaded

p Good chemical resistance, good resistance to solvents

p Antiadhesive, smooth surface, good adhesion to rigid vinyl (PVC), e.g. for laminated

structures

p The system must also be suitable for the remediation of damaged and

corroded old facilities.

3.3 Approval of coating system

p The coating system will be approved by Dürr Systems on the basis of

the following certificates submitted by the supplier:

p Coating materials and specifications

p Description of coating system, alternates if required

p Application methods

p Test results 6

Proof that suppliers meet quality management requirements (ISO-9001 certificate).

6 The approval of the coating system shall require the supplier to submit

not only appropriate laboratory tests but - if available - also a list of references of this system or its components that prove this system to meet its requirements in the long run.

3.4 Coating material

The makers/suppliers of the coating material are required to be working with a quality management system conforming to ISO 9001. The current QA manual shall be submitted on request.

?

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Exact names and types of the coating material to be used shall be specified in writing.

The coating material supplier's details shall conform to DIN 28054-1 Annex A1 and be made available to Dürr Systems.

3.4.1 QA requirements made of the coating material

The details of the coating material and glass fiber mats or felt shall be agreed between buyer and supplier and specified in writing.

Test types, test methods, test means, set points and tolerances shall be included in these specifications.

Test certificates conforming to DIN 10204 or equivalent documents submitted by the supplier shall verify that the coating material approved for this application (starting material) meets the specification.

The reinforcing glass fiber mats and felt used shall be suitable for their application. Their resistance to the fluids in question will have to be documented.

Specifications shall be agreed with all preliminary suppliers (of polyester resins, hardeners, accelerators and other raw material, glass fiber mats, glass fiber felt) and quality agreements shall be concluded under the obligation to supply in compliance with the specification and this shall be documented in the accompanying manufacturer's test reportcs.

Before delivering coating material, the maker will do batch approval tests and document these in an accompanying inspection certificate 3.1 B to DIN 10204.

The supplier will submit the relevant check list 1 to Dürr Systems.

? Check list 1



3.4.2 Delivery

The coating material delivered shall be processable in accordance with the coating processes specified.

The technical data sheets shall include all details required for a proper use of the coating material.

Permissible transport conditions (climatic requirements with maximums, maximum duration for the respective conditions), especially in climatic zones different from Central European ones and long transportation times, shall be agreed with the companies in charge and compliance shall be documented accordingly (è check

list 2).

Requirements that are different from standard conditions (e.g. temperatures between + 3° C and + 40° C) for example for peroxide hardeners shall be specified in the contract and suitable ways of delivery shall be found.

All tote tanks shall be fitted with temperature indicators to allow checking of excess temperatures. After storage temperature has been exceeded the supplier shall check precisely whether the material is still fit for processing.

Closed tote tanks or packages with clear marking conforming to traffic regulations shall be used for transport.

3.4.3 Storage

Permissible storage conditions (climatic requirements with maximums, maximum duration for the respective conditions) on the maker's and coater's premises and on site shall be specified by the supplier and compliance documented accordingly (è

check list 2).

This particularly applies to any special conditions relating to, for example, peroxide hardener or the provision of adequate storage facilities.

Resins and reactants will have to be stored separately and protected from heat and exposure to the sun.

Safety data sheets shall be made available.

In general the specifications as set out in EC Safety Data Sheet, item 7 "Handling and storage" shall apply.

?

? Check list 2

Check list 2



Moreover the following shall be taken into consideration after delivery of the coating material on site:

Original tote tanks must be sealed and there must be a safety band in a straining ring.

Open tote tanks shall be marked and used up as soon as possible.

Compliance with legal specifications and technical rules about storage, transport, health and safety at work normally is responsibility of the company contracted by Dürr Systems. Any deviation requires special agreements.

3.5 Quality monitoring

The quality of the products supplied shall be checked and documented by the maker prior to delivery.

The makers/suppliers of coating material, glass fiber mats and felt and the processing company shall agree on possible quality conformance inspections on receipt of goods and which tests can be replaced by manufacturer's test reports to DIN 10204.

All material used shall allow complete traceability (batch, production date/use before date, mixing ratios etc.).

The relevant check list 3 will have to be completed.

3.6 Inspection of coating materials prior to their processing

By making quality conformance inspections the supplier ensures the following on receipt of goods:

p Coating materials and other products are delivered with inspection certificate to

DIN 10204 ”3.1.B”

p Shipment and labeling correspond to purchase order and delivery note

p Storage time until being used on site is permissible

p Additional random tests of viscosity, processing time, odor, condition.

? Check list 3



Before coating materials are processed they will be subjected to testing by the supplier.

p Identification check of all components of the coating materials

(label, appearance and condition, odor etc.)

p Shelf life may not be exceeded

p Cleanness

p Viscosity

p Processing times for specified hardener/accelerator parts and

temperature/tank size (e.g. to TL/TP KOR Annex 6, Item 6)

Complete check list 4. ? Check list 4



4 Requirements for doing coating work

4.1 Qualifications

Companies doing coating work on behalf of Dürr Systems must have properly skilled personnel and the technical equipment required to allow due workmanship and operating safety.

At least one person (per shift if necessary) shall be responsible and named for supervising and doing the coating work.

The professional skills of the person(s) responsible shall be certified by at least 5 years of experience and a certificate showing that they were responsible for managing/supervising at least two comparable projects (è check list 5).

Submit check list 5 before dispatching the site supervisor in charge.

4.2 Condition of the surface to be coated

Construction (DIN 28051, DIN EN ISO 12944-2, DIN EN IS012944-3)

Steel surfaces must be designed suitable for coating (e.g. DIN 4119, API650).

Surfaces to be coated must be accessible.

Cavities are not permitted and shall be gas-welded tight.

Joints

p Welded joints

Joined by continuous welding.

Spot welds are not permitted. Remove weld beads and sand all welds including overlapping welds (cf. DIN 28051).

p Screwed joints

Shall be avoided, or made of resistant material.

? Check list 5



p Riveted joints

Rivets shall not be permitted.

q Through pipes and flanged joints

DN 80 through pipes for bottom or side flooding systems will have to be insulated where they come into contact with fluids. Inside piping this can be achieved by applying a laminated "inliner" to flanges:

q Tank mounting devices

Tank mounting devices such as holders for flooding pipes or anodes that have been welded on to the tank inside will have to be perfectly coated too to allow electrical insulation.

This requires not only carefully following the surface preparation as described but also taking into account mechanical and other loads, as well as future fixing and mounting of components.

Accordingly grooves and edges will have to be radiused with maximum radii and coated carefully, with additional glass fiber reinforced layers if necessary, with coats not under 3 to 4mm, to avoid temperature and stress cracks.

Other fixing methods such as gluing and laminating of plastic (PVC) pieces will have to be agreed with the buyer and documented accordingly.

Edges and corners

Contrary to what is specified in DIN 28051 edges, grooves, corners and welds shall be radiused min. 8mm.

Check welds throughout, report poor workmanship and repair in compliance with the above specification on the basis of this report.

Follow the acceptance procedure for the system's fitness for coating as described in check list 6.

? Check list 6



4.3. Surface preparation and cleaning of steel surfaces

In general the standard cleanness degree Sa 2 ½ - 3 (DIN EN ISO 12944-4) shall be achieved.

4.3.1 Preliminary examination of surface quality

By visually checking the tarnishing behavior, it can be etablished in several test fields if the standard cleanness degree of Sa 2 ½ - 3 can be achieved directly by one sand blasting operation or if intensive HP water jet wash cycles need to be included to remove all corrosion stimulators.

A minimum waiting time shall be observed before doing such an evalution to allow recognizing visual differences such as surface tarnishing caused by mineral salts and corrosion stimulators (see table):

Relative humidity of air

Examination after ... hours

< 40 % Evaluation not possible (rel. humidity of air has to be increased for examination)

> 40 - 60 % 12 - 24 h

> 60 - 80 % 3 - 12 h

Here dew point interval shall be > 3 K

If standard cleanness degree of Sa 2 ½ - 3 cannot be achieved with one sand blasting operation, wet cleaning will be required for removing corrosion stimulators.

Then sand blast again.

If another visual inspection shows that standard cleanness degree of Sa 2 ½ - 3 is still not achieved, even after repeating wet cleaning / sand blasting cycle, special action such as etching shall be agreed.

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4.3.2 Surface preparation degrees

ISO 8501-1 includes representative photos that can be used as comparison standards for surface preparation degrees.

It makes a difference whether surface preparation degree Sa 2 ½ - 3 is based on the steel surface's initial condition A, B, C or D.

With a permanent relative humidity of air < 40 % it is possible to sand blast in one operation as described in the above evaluation of cleanness degree (requiring over 40 % relative humidity of air). This shall be documented accordingly.

If the relative humidity of air cannot be decreased permanently < 40 %, it shall be necessary to sand blast by sections and coat within 12 hours after doing the sand blast process (see chapter 3).

4.3.3 Roughness

Roughness and examination of steel surfaces

The necessary "mean" roughness degree of RZ = 60 - 100 µm shall be assessed and recorded across the whole area (DIN EN ISO 12944-4. section 5.1 and DIN ISO 8503 section 2). The cleanness degree of the sand blasted surface will be assessed on the basis of the relevant standards.

If need be, mean roughness Ry 5 shall be determined using brush analyzers as described in DIN ISO 8503 section 4.

Abrasives

The abrasive's hardness and particle size chosen shall allow mean roughness of 60-100 µm. Use no abrasives with edges. You may only use abrasives approved by DIN 8201 sections 6 and 9.

4.3.4 Cleaning

All surfaces must be absolutely free from dust immediately before coating. This can be achieved by using a heavy duty industrial vacuum cleaner.

Remove deposits of abrasives (e.g. from scaffolding and internal assemblies).

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You can check the surface's cleanness for instance by wiping it with a clean and bright cloth.

4.4 Approval of steel surface preparation

Steel surface preparation shall be approved and documented immediately on site by the supplier's site supervisor in charge with regard to preliminary testing, sand blasting quality and cleaning (dust removal) (è check list 7) .

After the approval, the surface shall be primed immediately as specified in the coating description.

4.5 Health and safety at work and environmental protection

All relevant laws and regulations about health and safety at work and pollution control will have to be observed.

? Check list 7



5 Carrying out of coating work

5.1 General

This kind of work may only be done by properly skilled and trained personnel. The person in charge must meet the requirements as set out in chapter 4.1 of this guide.

A workflow and inspection plan shall be prepared listing single process steps and will have to be approved by Dürr Systems. An example is shown in check list 8.

5.2 Processing conditions

5.2.1 Preparation of coating material for processing

Only properly trained personnel may be assigned to do this.

For one object to be coated all starting points will be done by the same expert.

However, it will be necessary to check whether all requirements are met as listed in chapter 3.6 (è check list 4).

Resin filled in hobbocks will be mixed thorougly with other components using a pneumatic agitator (approx. 300 to 400 rpm) and taking into consideration the mixing ratios specified. Stir up and mix in any sediment to eliminate all air bubbles in the resin.

However, mixing time is at least three minutes and finishes only when we get a homogeneous mixture without lumps, sediments, etc.

Manual mixing will not be sufficient.

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Check list 8

Check list 4



Mixing ratios

The mixing ratios to be prepared, i.e. the quantities of hardener and accelerator added to base coat and top coat resin depend on the coating job to be done as well as material and processing temperatures. They are specified in the technical documentation of the coating material maker (è check list 9).

5.3 Coating method

It will be necessary to check whether ambience conditions on site meet the requirements specified for the coating material to ensure that the coating lasts for the time specified. This also applies to drying and curing times.

Temperatures of object and ambient air may not be above or below the maximum and minimum respectively as specified in the technical data sheet.

Coating material may not be applied to surfaces if the surface's temperature is less than 3° C above the air's dew point determined as set out in ISO 8502-4.

Coating may be done manually by roll and brush coating or spray application, preferably airless.

In general glass fiber reinforcement mats shall be inserted manually in the polyester resin with the help of spiked or normal rollers, taking care to eliminate all air bubbles.

Maximum and minimum quantities of binding agent shall be specified, checked and documented per layer or process for saturating glass fiber mats.

5.3.1 Rework cycles of single sections

Document the times allowed for processing the coating material mixed, depending on temperature (è check list 9).

When there's a risk of exceeding rework cycles, processing must be ended to allow the surface coated to cure completely. Before continuing the work it will be necessary to roughen the surface, such as slightly sand blasting.

? Check list 9

? Check list 9



5.3.2 Overlapping of laminated coats and processing sections

Textile glass fiber mats shall overlap at least 5cm.

When coating by sections, one strip of the adjacent coating already cured will have to be carefully sanded to ensure adequate adhesion for the overlap. The adjacent surface finished shall be covered by plastic sheeting to avoid any overspray to settle on it.

5.3.3 Seal

Only when the coating already applied and cured has been tested and documented, 150 - 200 µm of final seal will be applied curing without bonding using a lambskin roller or airless spraying.

Once the coating has cured examine it and document results in accordance with chapter 7.2.

5.3.4 Consumption

The coating supplier shall be responsible for supplying the quantities required for the coating job on time. If possible they should all be the same batch.

5.4 Repair

Damaged and insufficiently coated spots will have to be conically sanded down to the undamaged substrate and repaired in accordance with the coating maker's specification.

5.5 Method evaluation

The coating method specified and material used must be well proven.

This can be documented by corresponding Dürr Systems references and their long-time behavior.



6 Supervising of coating work

6.1 General

All work processes shall be supervised by properly skilled personnel of the supplier (as described in chapter 4.1, check list 5). The scope of supervision shall depend on the difficulty of the work and the importance of the object. Dürr Systems is allowed to make additional inspections or commission somebody to do so.

6.2 Test and measuring equipment

The equipment used will have to be serviced, checked and calibrated at regular intervals. The results documented shall be submitted to Dürr Systems on request (è check list 10).

6.3 Inspection of coating

The coating shall be checked wheter complying with the specification, that is

p visually, acoustically if need be by tapping and

p with test equipment.

6.3.1 Inspection during coating work

Complete check lists 11 and 11 a.

p Wet coating thickness

Thickness of the freshly applied wet coat shall be checked continually with a measuring comb.

All measuring points shall be repainted manually immediately after measuring, then resprayed immediately with sprayed surfaces.

? Check list 5

? Check lists 11, 11 a

? Check lists 13 and 13 a

? Check list 10



When applying resin to a glass fiber mat, this method cannot be used. The quantity applied must be determined visually on the basis of the coating quantities specified. The coating material quantities required shall be documented for each processing section and surface.

Check and record material temperatures when processing.

p Climatic details

Measure and record air humidity, surface and air temperatures, and their temperature difference with dew point (è check list 12).

6.3.2 Inspection after curing

Coating will be inspected after the final coat has cured, moreover it will be inspected again later after the seal coat has been applied and cured. Record the inspection results:

? Looking for air und dust inclusions, pores, air bubbles, delamination, pinholes, overspray, surface irregularities, flaws at connecting and overlapping sections, processing defects and the like;

pCoating thickness with gauged or calibrated instruments;

p Pore tester with test voltage 15 kV or 20 - 25 kV

Pores and other coating flaws detected shall be touched up as described in the repair instructions.

6.3.3 Inspections on finished coating

Complete check list 14.

? Check list 12

? Check list 14

? Check list 13

? Check list 13 a

? Check list 13



The finished coating shall be subjected to at least the following inspections:

p Visually checking surface quality, whether poreless

p Coating thickness measurements to DIN EN ISO 12944-6

p Buchholz / Barcol hardness:

Hardness is determined on test plates painted simultaneously (see 7.1)

Desired Buchholz hardness after 24 h at 20° C: > 80 or

Desired Barcol hardness after 24 h at 20° C: > 30

p Adhesion test for valuating adhesion in conformance with DIN EN 24624

(ISO 4624)

p High voltage test

A high voltage test shall be done to prove that the coating is poreless.

Test voltage shall be approx. 7.5 KV per 1 000 µm, depending on tester, i.e. 15 kV for an approx. coat thickness of 2mm. Other test voltages shall be agreed separately.

The meter used shall be agreed upon, because the designs of different testers may have a strong effect on the reading.

pWipe test

Put cloths soaked with butyl glycol on four different places of the final coat cured, i.e. on the tank bottom in entry, exit and middle zones and on a vertical wall and allow them to react for two hours. Then wipe the damp surface with the cloth. Ensure the coating does not soften, abrade or stick.

7 Inspection panels and test plates

7.1 General

Test plates Check list 11 a



Complete check list 11 a.

Traveling test plates allowing tests such as adhesive strength, Barcol/Buchholz hardness, and resistance tests, if need be, shall be coated in one go with the tank coating process and are part of the quality assurance system.

(The scope of testing (number of test plates) shall be defined in each case.)

Inspection panels

Inspection panels shall be applied as described in DIN EN ISO 12944-7.

It will be necessary to agree with the buyer where to put the inspection panels, namely in areas where the object is susceptible to corrosion.

The panels, for instance, are 1m x 1m mounted on a side wall, on the floor or on the entry/exit front wall.

7.2 Records about inspection panels

Prepare a full report about inspection panels conforming to DIN EN ISO 12944-7/ -8, Annex B for each panel. Their position shall be marked clearly.

Make a drawing showing the position of the inspection panels. If possible the buyer provides drawings where size and position of the inspection panels can be marked.

7.3 Evaluation of coating

Dürr Systems will accept and approve the coating job on the basis of

p the test plates made during the work and their test results.

p tests and visual inspections made at representative spots of the object.

p inspection and approval of all records about all work and testing done during

the coating job.

Complete check list 14.

?

? Check list 14



Dürr Systems may elect to supervise the process stages, or commission someone to do so, while a job is being carried out. This can be done for instance with product and process audits.



Annex A

Check list forms

No. 1 Manufacturer's test reports

No. 2 Transport and storage

No. 3 Traceability

No. 4 Examination before processing

No. 5 Certificate of competence

No. 6 Acceptance procedure of steelwork

No. 7 Preliminary examination and preparation of steel surface

No. 8 Workflow and inspection plan for coating and preparation

No. 9 Mixing ratios/ processing time

No. 10 Calibration of instruments

No. 11 Report of coating work

No. 11 a Report of coating work with test plates coated at the same time

No. 12 Climatic details with annex

No. 13 Examination of the finished coating/ seal

No. 13 a Coat thickness report

No. 14 Acceptance report

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