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THERMAL SPRAY ALUMINUM COATING SPEC: TSAR09

SPECIFICATION FOR CUI PREVENTION Rev. 10 July 31, 2013

Equipment FOR NEW STEEL EQUIPMENT - SHOP

Page 1 of 9
Engineering

1. GENERAL ...................................................................................................................................................... 2

1.1 Scope ................................................................................................................................................. 2

1.2 Definitions ......................................................................................................................................... 2
1.3 Referenced Documents and Industry Standards ................................................................................ 2

2. FABRICATION DETAILS AND SURFACE PREPARATION .................................................................... 3

2.1 Fabrication Details and Shielding ..................................................................................................... 3

2.2 Surface Preparation ........................................................................................................................... 3

3. ALUMINUM COMPOSITION AND TSA LAYER THICKNESS ............................................................... 4

3.1 Composition ...................................................................................................................................... 4

3.2 TSA Layer Thickness ........................................................................................................................ 4

4. APPLICATION ............................................................................................................................................... 4

4.1 Atmospheric Conditions .................................................................................................................... 4

4.2 Application Process........................................................................................................................... 4
4.3 Pressure Vessel Nozzles, Piping and Attachments ............................................................................ 5

5. INSPECTION ................................................................................................................................................. 5

5.1 General .............................................................................................................................................. 5

5.2 Surface Profile and Cleanliness ......................................................................................................... 5
5.3 Atmospheric Conditions .................................................................................................................... 6
5.4 TSA Coating Thickness .................................................................................................................... 6
5.5 Adhesion Qualification Test.............................................................................................................. 6
5.6 Adhesion Production Testing - Dull Chisel Test ............................................................................... 6
5.7 Water Spray Test ............................................................................................................................... 6

6. REPAIRS ....................................................................................................................................................... 7

7. COMMENTS ON SHOP TSA APPLICATIONS ........................................................................................ 7/8

8. Typical Coating Systems Sketch Pressure Vessel ........................................................................................... 9

Notes to Users:
Earlier versions of this document have been successfully used worldwide to apply TSA cost effectively on new
shop fabricated equipment, pressure vessels and piping for grass roots projects, revamp projects and maintenance
type replacements. Feedback from these jobs has been incorporated in this revision. This document can be
attached to equipment purchase orders, used for site coating specifications or used in projects for review of EPC
and equipment vendor TSA specifications. Field TSA application on field-welds and existing (live) hot insulated
equipment are covered in Supplement A and B of this specification.

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SPECIFICATION FOR CUI PREVENTION Rev. 10 July 31, 2013

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Engineering

1. GENERAL

1.1 Scope

This Specification defines the minimum requirements for shop application of thermal spray
aluminum (TSA) coatings. It includes requirements for surface preparation, materials,
application and quality control of TSA. This Specification can be attached to purchase orders,
used to review vendor specifications, develop site or project job specific specifications for the
TSA coating of new steel equipment. TSA is applied on external surface to prevent corrosion
under insulation (CUI) in the operating temperature range -5C to 175C (20 to 350F); See
Section 7 Comments. The maximum design temperature for TSA coated equipment is 540C
(1000F). TSA can be applied by electric arc process, typical for large surfaces and flame
spray process, typical for smaller surfaces like piping and less accessible areas. TSAR09
Supplement A covers field welds and TSAR09 Supplement B covers existing hot-insulated
equipment TSA applications.

1.2 Definitions

1.2.1 The term "Owner" as used in this document shall mean ExxonMobil.

1.2.2 The term "Vendor" as used in this document shall include those who have been
contracted to provide the specified materials or services.

1.3 Referenced Documents and Industry Standards

AWS C2.23-2003, Specification for the Application of Thermal Spray

NACE No.12, Coatings (Metallizing) of Aluminum, Zinc and Their
SSPC-CS 23.00 Alloys and Composites for the Corrosion Protection of Steel

ANSI/AWS C2.18 Guide for the Protection of Steel with Thermal Sprayed Coatings of
Aluminum and Zinc and their Alloys.

EN 22063 Metallic and other inorganic coatings - Thermal spraying - Zinc,

aluminum and their alloys

ISO 8501, 8502, 8503 Preparation of Steel Substrates Before Application of Paints and
Related Products.

ISO 14922 Part 1-4 Thermal spraying - Quality requirements of thermally sprayed
structures.

ISO 14918 Thermal Spraying- Approval testing of thermal sprayers.

NACE RP0178 Fabrication Details, Surface Finish Requirements, and Proper

Design Considerations for Tanks and Vessels to be Lined.

NACE SP0198-2010 The Control of Corrosion Under Thermal Insulation.

NORSOK M-501 Surface Preparation and Protective Coating.

SSPC-PA-2 Measurement of Dry coating Thickness with Magnetic Gages

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Engineering

2. FABRICATION DETAILS AND SURFACE PREPARATION

2.1 Fabrication Details and Shielding

2.1.1 Pressure vessels, heat exchangers, storage tanks and piping surfaces requiring TSA shall be
accessible for grit blasting and TSA coating application. Construction details of NACE
RP0178 can be used as guidance in the design and fabrication for equipment requiring TSA.

2.1.2 The clearance between insulation support rings and shell shall be twice the thickness of the
ring to enable grit blasting and TSA coating of shell section behind the rings. The name plate
bracket design shall be such that shell can be grit blasted and TSA coated behind bracket.

2.1.3 Prior to blasting sharp corners on surfaces requiring TSA shall be dressed by grinding to a
radius of 3 mm (1/8") minimum. Weld spatter, flux and slag needs to be removed by grinding
and flame cut surfaces need to be ground smooth prior to grit blasting.

2.1.4 The following parts shall be shielded and protected during surface preparation and TSA
application:
Instrumentation: pressure gauges, level and flow indicator glasses, stainless steel
thermowells and tubing, Coriolis and magnetic flow meters, conduit runs and cable
trays, control valves and motor operated valves.
Packing glands, valve stems, pump seals, threaded connections on vents and drains,
flange faces, field-weld bevels, thin wall stainless steel and nickel alloy bellows,
Teflon coated and stainless steel bolting, flanged valves with Vendor standard
coating.
Nameplates, safety valves, non-ferrous parts, non metallic parts, galvanized
structural steel, vessel skirts requiring concrete or gunite fire-proofing.

2.2 Surface Preparation

2.2.1 For surface preparation of carbon steel the blasting abrasive shall be dry, sharp, angular:
garnet, iron/steel grit, aluminum oxide, aluminum-silicate or other mineral media approved by
Owner's engineer. No silica sand or iron/steel shot or mixtures with shot shall be used. For
surface preparation of stainless steel only iron-free abrasives: garnet, aluminum-silicate, or
aluminum-oxide shall be used.

2.2.2 The surfaces to be coated shall be blasted to near white blast finish ISO 8501-1 grade SA 2.5,
NACE No 2 or SSPC SP10.

2.2.3 The anchor profile shall be measured in accordance with ASTM D 4417 or ISO 8503 - grit
comparator and be 75 micron (3 mils) to 125 micron (5 mils).

2.2.4 After grit blasting the surface shall be cleaned and free of dust as per ISO 8502-3 prior to
TSA.

2.2.5 If the blasted surface has become wet after blasting it shall be dried and re-blasted.

2.2.6 Solvent cleaning in accordance with SSPC SP 1 or ISO-12944 may be needed to remove oil,
grease, inspection fluids or other surface contaminants before blasting.

2.2.7 Owner can request chloride contamination testing of surface preparation as per ISO 8502- 6
and ISO 8502-9. If chloride contamination has occurred surface shall be washed to reduce
chloride level to 20 mg / square meter.

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3. ALUMINUM COMPOSTION AND TSA LAYER THICKNESS

3.1 Composition

Grade 1100 aluminum wire shall be used. The chemical composition shall be documented on a
mill certificate. Only aluminum wire designated by the wire manufacturer for thermal spraying
shall be used. The wire shall be dry and free of scale or organic coatings.

3.2 TSA Layer Thickness

For equipment with metal operating temperature from -5C to 540C (20F to 1000F) the
TSA layer thickness shall be 250 to 500 micron (10-20 mils), measured in accordance with
SSPC- PA 2. If during the inspection an area with TSA layer thickness below 250 micron (10
mils) is found an additional TSA layer shall be applied in accordance with the repair
requirements of Section 6 of this Specification.

4. APPLICATION

4.1 Atmospheric Conditions

4.1.1 The metal temperature shall be 3C (5F) above the dew-point. Relative humidity
shall be below 90% before TSA application.

4.1.2 The first layer of TSA coating shall be applied within 4 hours after grit blasting.
Subsequent layers shall be sprayed within 24 hrs after first TSA layer. If, climate
control facilities are used, or relative humidity is lower than 90% longer times are
allowed, but this needs Owners approval and documented in inspection and test plan.

4.2 Application Process

4.2.1 The electric arc process is suggested for large surface applications. The flame spray process
can be used for less accessible areas, small bore piping, repairs, and where limited overspray is
critical.

4.2.2 For manual spray gun handling the following points should be considered:

4.2.1 The gun shall be held approximately perpendicular to the surface of the work-piece.
The maximum allowable gun angle is 30.

4.2.2 Gun distance from the work-piece shall not exceed 250 mm (10").

4.2.3 The TSA coating passes shall have 50% overlap on each pass of the gun.

4.2.4. The coating shall be applied in multiple layers. The gun pass shall be at right angles
to the gun pass used for spraying of the previous layer, in cross-hatch pattern. Large
surfaces shall be TSA coated in blocks of approximately 0.6 m by 0.6 m (2' by 2').

4.2.5 If, the work-piece contains weld preparations for field welds the TSA coating shall
stop 25 mm (1") from the weld bevel. The pipe-ends shall be grit blasting up to bevel.

4.2.6 Finished prefab piping shop welds can be TSA coated in shop prior to (field)
hydrotesting. Experience has shown that TSA coating does not seal through-wall
defects in weldments during hydrotest.

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Engineering

4.3 Pressure Vessel Nozzles, Piping and Attachments

4.3.1 Flange sealing faces (Raised Face) and gaskets shall not be grit blasted and TSA
coated. CS flange bolt holes, if accessible can be TSA coated, or coated with one
layer inorganic zinc (IOZ). TSA overspray into bolt hole is allowed.

4.3.2 Carbon steel and low alloy steel bolting of fully assembled equipment flanges shall be
TSA coated, unless purchase order does not allow TSA coating of the bolting.

4.3.3 Attachments welded to equipment; clips, gussets, lifting lugs, vacuum rings that will
be covered by insulation shall be TSA coated. Welds shall be continuous and
complete.

4.3.4 Equipment nozzles and small bore piping protruding through insulation require also
surface preparation and TSA coating up to flange face. TSA coated surfaces
protruding through insulation require an additional thin, 25 micron (1 mil), seal coat
of self curing silicone-aluminum sealer or approved alternative coating system.

4.3.5 Equipment supports, piping supports, gussets, clips and attachments protruding
through insulation require surface preparation and TSA coating up to first bolted
joint.

4.3.6 Equipment surfaces requiring concrete or gunite fireproofing shall be coated with 2
layers epoxy-phenolic / novalac coating 250 micron DFT. If surface is TSA coated,
the TSA shall be top coated with 2 layers epoxy-phenolic / novolac coating.

4.3.7 If stainless steel is welded to carbon steel pressure vessels or piping, and covered
with insulation the complete stainless steel surface covered by insulation requires also
surface preparation and TSA coating up to the first bolted joint outside the insulation.

5. INSPECTION

5.1 General

The Vendor is responsible for making a TSA specific Inspection and Test Plan (ITP), and
performing the required QC tests and inspections. A pre-inspection meeting, specific for TSA
application with TSA contractor is required. For pressure vessels, when TSA is used next to
other coating systems, a sketch showing the coating systems shall be made; See Section 8.
Owner can assign third party inspector to monitor the Vendor, witness TSA equipment and
applicator qualification, review inspection procedures and test results. Only inspectors
experienced with TSA inspection shall perform non destructive examinations (NDE). All
work-pieces shall be visually inspected prior and after TSA coating, prior to insulation
application. After TSA coating application the surface shall be uniform and free of lumps,
loosely adherent spattered metal, bubbles, ash formation, defects, uncoated spots, foreign
particles and slag.

5.2 Surface Profile and Cleanliness

The surface profile shall be measured every day or shift before starting the TSA coating
application. Additionally, one test shall be done for every 10 sq m. (100 sq ft). The surface
shall be cleaned and free of dust prior to TSA.

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5.3 Atmospheric Conditions

Humidity, work-piece temperature and dew-point shall be measured not more than 1 hour
before starting of TSA application. These measurements shall be performed also each
morning, or shift before starting surface preparation.

5.4 TSA Coating Thickness

The TSA coating thickness shall be measured with a non destructive thickness gauge during
application as an ongoing process quality control activity in accordance with SSPC-PA 2. The
gauge shall be calibrated using certified coating thickness standards. For measuring TSA
thickness on stainless steel eddy-current thickness gauges with job specific calibration
procedure can be proposed to Owner. The coating thickness measurement frequency and
report format shall be listed in ITP and approved at pre-inspection meeting. The thickness
shall meet the requirements of section 3.2.

5.5 Adhesion Qualification Test

Vendors TSA equipment and applicator shall be qualified prior to start of TSA work as per
ISO 14918. Adhesion shall be measured on a TSA coated test plate, 6 mm (1/4) min. thick, or
pipe at three points. The minimum adhesion value shall be 6.9 MPA (1000 psi) per ISO 4624,
ASTM D4541 or EN 582. A change in equipment or applicator requires a new qualification.

5.6 Adhesion Production Testing - Dull Chisel Test

For production testing inspector shall check adhesion of the TSA coating with dull chisel 1
(40 mm) wide cutting edge and procedure below.
Place the chisel so that it is between perpendicular to 60 degrees to the TSA
surface; See photo below from AWS C 2.23-2003/NACE No. 12.
Use a lb. (450 gram) hammer to apply impact force to the chisel head.
Visually check the coating cut made by the chisel. If there is no disbonding or
peeling other than immediately on the coating cut, the TSA is acceptable.
If disbonding of the TSA occurs, the TSA is unacceptable and requires repair as
per Section 6.

5.7 Water Spray Test

Shop TSA coated surfaces shall be wetted with potable water before application, if required,
of seal coating. The surface shall be re-examined for discoloration, rusting or bleed thru. The
water spraying and re-examination is a QC witness point. The re-examination time, minimum
24 hours, depends on atmospheric conditions. In dry or moderate temperature conditions

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longer times, 3-5 days are suggested. The agreed time needs to be documented in TSA ITP. If
discoloration, rusting or bleed thru is present the layer thickness at these spots shall be
measured. If the coating thickness is below 250 micron (10 mils) the section needs to be
repaired, as per Section 6. After the water spray test, TSA coated piping shall not be wrapped
or sealed in polyethylene or other polymeric foils during transportation and storage.

6. REPAIRS

6.1 If, the TSA coating disbonds the application needs to be stopped. The inspector needs to be
informed. The TSA coating up to 0.6m (2') adjacent to the defect needs to be inspected for
layer thickness and adhesion per Section 5. The surface preparation of Section 2 needs to be
repeated on all defective surfaces and coated areas that do not meet the requirements of this
specification.

6.2 If, the TSA coating is too thin, below 250 micron an additional layer of TSA shall be applied
in accordance with the requirements of Section 4 of this document. Application of a seal-coat
is not acceptable for repairing too thin or defective (cracks, disbonded, rust stained, etc.) TSA.

6.3 Areas that do not meet the requirements of SSPC-6 and fail the dull chisel test shall be
removed and coated as per Section 2 and 4 of this Specification.

7. COMMENTS ON TSA APPLICATIONS

7.1 This Specification does not require the application of a sealer under insulation. Vendor shall
apply only a thin silicone-aluminum sealer on TSA coated surfaces protruding through
insulation.

7.2 On vertical vessels with skirts the TSA shall extend 12 mm (1/2) over the preferably stainless
steel rain water shed ring on top of fireproofing on skirt OD. TSA shall not be exposed to wet
concrete, because the high alkaline (pH 12) concrete can attack the TSA.

7.3 Surface preparation is the most important variable to achieve high (>1000 psig /6.9MPa) TSA
"pull off" strength when preheat of 65C (150F) minimum is not used. A rounded blast
profile and inadequate blast depth will reduce adhesion.

7.4 TSA shall be applied on insulated austenitic stainless steel if one of the following conditions
apply:

cyclic sweating service, if the temperature cycle includes both sweating service and
operating temperatures above 50C (120F),
insulated stainless steel equipment, piping or nozzles are welded to insulated carbon
steel equipment, or
stainless steel equipment or piping is steam traced.

7.5 This Specification uses, for new equipment, as upper range for CUI 175C (350F) in line with
EFC (European Federation of Corrosion) publication and 2010 update of NACE SP 0198. It
is recommended to use 175C (350F) upper range for TSA application on new equipment,
especially when the exact operating and metal temperatures, close to upper limit of the CUI
range, are not known during equipment design phase. Company documents; GP and EDD 1A
list 150C (300F) typical used for existing CS equipment.

7.6 Owner may waive TSA of insulated CS bottom head and nozzles within the skirt of vertical
vessels in hot service, above dew point. TSA is required in skirts with insulated CS bottom

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head and nozzles in sweating service, below dew point. TSA scope, application, preferably
with flame spray process inside skirt and acceptance criteria shall be discussed at pre-
inspection meeting.

7.7 Consider for new insulated vertical vessels in CUI temperature range lifting trunnions in-stead
of lifting lugs, or remove lugs after vessel installation.

7.8 TSA shall be applied on the un-finned external tubing surfaces between the finned portion and
headers of carbon steel airfins, prior to inserting tubing into headers. The TSA shall extend 1.5
mm (1/16") into tubesheet hole.

7.9 Aluminum is stable in pH range from 4 to 8. TSA shall not be in contact with wet concrete,
gunite, or shotcrete. Alkaline cooling water, often with pH above 8 can attack TSA.

7.10 Besides a good durable coating system like TSA, CUI prevention requires a systems approach:

Equipment design enables good insulation system installation that prevents water
ingress into insulation system, preferably without the need of sealants and has no
water traps.
Weather sheeting, or jacketing, to protect the insulation system from mechanical
damage and to prevent water ingress into insulation system.
Vapor barrier(s) need to be air-tight to prevent water and moisture ingress into cold
insulation systems and condensation on cold equipment surface.
Insulation materials to provide insulation and save energy. Insulation materials should
not add corrosives to the system by being free of any leachates. Examples are
chlorides and bromides in flame retardants in PUR or sulfides from cellular glass
blowing agent.
Protective coatings are the last line of defense to prevent corrosion of the steel
substrate in case water or moisture gets into system. Since insulation systems, their
installation and maintenance are never flawless, it is imperative to optimize on the
selection and overall quality of a coating. If and when the quality of the insulation
system is compromised, coating life will be reduced. These durable coatings must be
capable of covering the complete operating temperature.
QA and QC of the insulation system to assure good insulation system design and
installation. Focus should be on details that could result in system failure: protrusions,
vapor barrier damage, insulation of flanges and cold/ hot bridges. Proper QA/QC
around these areas is essential.
Maintenance of the insulation system. If system is damaged, timely repairs are needed
to prevent situations when the insulation system remains wet continuously.

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8. Typical Coating System Sketch Pressure Vessel

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