09 SAMSS 089 (Final Draft_2018)

Materials Syste Syst em Specific pecif ica ation ti on 09-SAMSS-089 09-SAMSS- 089

XX December 2017

Qualification Requirements for Shop-Applied External FBE Coatings Document Responsibility: Responsibility: Paints and Coatings Coatings Standards Committee Committee

Draft before publication Contents 1 Scope ................................................. ................................................................ ............... 2 2 Conflicts and Deviations Deviations .................................... .................................... 2 3 References .................................................. ........................................................ ...... 3 4 Definitions............................................... .......................................................... ........... 5 5 Health, Safety, and Environment Environment ....................... 7 6 Material............................................... .............................................................. ............... 7 7 Handling of Pipe Before Coating ....................... 9 8 Cleaning and Surface Surface Preparation Preparation................... 10 9 Coating Application Application.......................................... .......................................... 12 10 Quality Requirements Requirements ...................................... ...................................... 14 11 Inspection Requirements Requirements ................................. ................................. 14 12 Recheck on Coating Material Qualities ............ ....... ..... 22 13 Repairs ............................................... ............................................................ ............. 22 14 Pipe Storage and Preparation for Shipment .... 23 Revision Summary ...................................... .................................................. ............ 23 Appendix A - Qualification Qualification Procedure Procedure for Initial Product Approval ........................................ 24 24

Previous Issue: 7 February 2017

Next Planned Update: XX December 2020 Page 1 of 29

Contact: Mansour, Mana H. (mansmh0c) on (mansmh0c) on phone +966-13-8809557 ©Saudi Aramco 2017. All rights reserved.

Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089 Issue Date: XX December 2017 Qualification Requirements for Shop-applied Next Planned Update: XX December 2020 External FBE Coatings

1

Scope 1.1

This specification, together with the Purchase Order and appropriate Data Sheets, defines the minimum mandatory requirements of shop-applied, heat-cured external fusion-bonded epoxy (FBE) coating systems for the external surfaces of steel pipes, single or double joint, and associated fittings, and couplings.

1.2

Information Required in Requests for Quotation and in Purchase Orders Requests for Quotation and Purchase Orders shall identify which of the following service conditions applies for the coated products:

2

1.2.1

APCS-104A for buried or immersed, with temperatures not exceeding 65°C in Subkha soil or subsea, or up to 93°C in dry soil condition.

1.2.2

APCS-104B for buried or immersed, with temperatures not exceeding 90°C in Subkha soil or subsea, or up to 110°C in dry soil condition.

1.2.3

APCS-104C for buried or immersed with temperature up to to 130°C.

1.3

For projects reviews, all protective coating requirements, specifications and coatings map as per SAEP-303, shall be consolidated in Index H.

1.4

This standard shall be attached to, and made part of, purchase orders when required.

1.5

Information Required with the Quotation 1.5.1

Cost if burn-off is required to to remove oil contamination from the surface surface prior to blast cleaning (see paragraph 8.1).

1.5.2

Cost of UV protection if coated pipes pipes will be stacked in the vendor’s yard more than six months.

Conflicts and Deviations Deviations 2.1

Any conflicts between this specification and other Saudi Aramco Materials System Specifications (SAMSSs), Engineering Standards (SAESs), Standard Drawings (SASDs), or industry standards, codes and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2.2

Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 procedure SAEP-302 Saudi Aramco: Company General Use

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and forward such requests to the Manager, Consulting Services Department of Saudi Aramco, Dhahran.

3

References Referenced standards and specifications shall be the latest edition, revision or addendum in effect on the date of the purchase order, unless stated otherwise. 3.1

Saudi Aramco Documents Saudi Aramco Engineering Procedure SAEP-302

Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

SAEP-303

Engineering Reviews of Project Documentation

SAEP-1200

Qualification Procedures for Protective Coatings and Abrasive Blasting Materials

Saudi Aramco Engineering Standards SAES-H-001

Coating Selection and Application Requirements for Industrial Plants and Equipment

SAES-H-002

Internal and External Coatings for Steel Pipelines and Piping

SAES-H-200

Storage, Handling, and Installation of Externally Coated Pipe

SAES-H-201

General Specifications for Over-the-Ditch External and Internal FBE Coating of Field Girth Welds

SAES-W-012

Welding Requirements for Pipelines

Saudi Aramco Inspection Requirements Form 175-091300

3.2

Coating: Shop Applied, Internal or External

Industry Codes and Standards American Society for Testing and Materials ASTM D714

Standard Method of Evaluating the Degree of Blistering of Paint

ASTM D4060

Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber Abrader

Saudi Aramco: Company General Use

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ASTM D4940

Standard Test Method for Conductimetric Analysis of Water Soluble Ionic Contamination of Blasting Abrasives

ASTM D7393

Standard Practice for Indicating Oil in Abrasives

ASTM G8

Test for Cathodic Disbonding of Pipeline Coatings

International Organization for Standardization ISO 8501-1

Pictorial Surface Preparation Standard for Painting Steel Surfaces

ISO 8502-3

Preparation of Steel Substrates before Application of Paint and Related Products - Tests for the Assessment of Surface Cleanliness - Part 3: Assessment of Dust on Steel Surface Prepared for Painting

ISO 8502-6

Preparation of Steel Substrates before Application of Paint and Related Products - Tests for the Assessment of Surface Cleanliness - Part 6: Extraction of Soluble Contaminants for Analysis

ISO 8503-4

Preparation of Steel Substrates before Application of Paints and Related Products - Surface Roughness Characteristics of Blast-cleaned Steel Substrates Part 4: Method for the calibration of ISO Surface Profile Comparators and for the Determination of Surface Profile - Stylus Instrument Procedure

ISO 8503-5

Preparation of Steel Substrates before Application of paints and Related Products - Surface Roughness Characteristics of Blast-cleaned Steel Substrates - Part 5: Replica Tape Method for the Determination of the Surface Profile

ISO 21809-2

Petroleum and Natural Gas Industries - External Coatings for Buried or Submerged Pipelines Used in Pipeline Transportation Systems - Part 2: Single layer Fusion-bonded Epoxy Coatings

ISO 11124-3

Specifications for Metallic Blast-Cleaning Abrasives- Part 3: High-Carbon Cast-Steel Shot and Grit

ISO 11125

Test Methods for Metallic Blast-Cleaning Abrasives


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ISO 11126-10

Specification for Non-metallic Blast-Cleaning Abrasives- Part 10: Almandite Garnet

ISO 11127

Test Methods for Non-metallic Blast-Cleaning Abrasives

The Society for Protective Coatings (SSPC) SSPC PA 2

Procedure for Determining Conformance to Dry Coating Thickness

SSPC SP 1

Solvent Cleaning

SSPC SP 10

Very Thorough Blast Cleaning (near white metal blast)

SSPC-AB2

Cleanliness of Recycled Ferrous Metallic Abrasives

SSPC-AB3

Ferrous Metallic Abrasive

Canadian Standards Association CAN/CSA-Z245.20-14 External Fusion Bond Epoxy Coating for Steel Pipe

NACE International NACE SP0394

Application, Performance, and Quality Control of Plant-Applied Single-Layer Fusion Bonded Epoxy External Pipe Coating

NACE SP0490

Holiday detection for external fusion bonded epoxy for pipeline coatings

America Petroleum Institute API 5L9

4

External Fusion Bonded Epoxy Coating of Line Pipe

Definitions Approved Procedure: Procedure referred to in this specification that has been approved by CSD/Paints and Coating Standards committee. Approved procedures do not require re-approval in new purchase orders. Approved Product: A coating material that has been approved by CSD/Paints and Coating Standards committee as meeting the requirements of the app licable APCS, SAMSS or relevant international standards. Only approved products are allowed for use in Saudi Aramco jobs. These requirements apply to all coatings referred to in all the SAES-H-series standards.


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Batch: Specified quantity of material produced under the same uniform conditions during a continuous production run by one Manufacturer. Buyer: Saudi Aramco Purchasing Department representative. Buyer's Representative: The person or persons designated by the Purchasing Department to monitor / enforce the contract. Normally, this is the on-site inspector. Custom Coated Pieces: All pipes not coated by automated in-plant equipment. Generally, fittings, short spools and fabricated spools. Cut-back: The length of pipe left uncoated at each end for joining purposes. DFT: Dry film thickness Fabricated Spools: Spools longer than 10 feet that can’t be coated by the automated process due to connection to flanges or other spools. FBE: Fusion bond epoxy coating Fitting: For purposes of this specification, “fitting” is used to refer to any custom coated piece including valves and pumps. Holiday: A discontinuity in applied coating that exhibits electrical conductivity when exposed to a specific voltage. Manufacturer: Company which manufactures FBE powder coatings and corresponding repair materials. Maximum Operating Temperature: Maximum temperature that can be reached during operation of pipeline. Overlap: Length of the field joint coating over the plant-applied coating including the coating bevel. Pipe: For purposes of this specification “ pipe” is used to refer to steel tubular, including line pipe and OCTG casing and tubing. Production pipes: Pipes coated using automated process. Test Ring: A sample taken from production-coated pipe or a pup piece pipe, having the same specification of coated pipes, coated in the same production line. Vendor: FBE coating applicator Working shift: The maximum working shift shall be 12hrs.


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5

Health, Safety, and Environment Applicable safety requirements addressed in SAES-H-102 shall be followed.

6

Material 6.1

FBE External Coating 6.1.1

Material for the shop-applied external coating shall be in a form of thermosetting resin powder suitable for application by the fusion bond process as tested and approved by Saudi Aramco, and applied according to the Manufacturer's recommendation.

6.1.2

The use of recycled powder may be permitted if adequate recovery and screening equipment is used and maintained. In no cases shall such use be greater than 10% by weight. If the reclaimed powder found contaminated, reclaimed powder shall be stopped.

6.1.3

The Vendor shall use only Saudi Aramco approved products under APCS-104A, APCS-104B or APCS-104C for the intended service.

6.1.4

Any approved coating that is subjected to modifications and/or reformulations, or replacement including change of names or re-branding shall be requalified.

6.1.5

Powder coating materials supplied to the Vendor shall be certified by Manufacturer with the following information, which must meet initially approved material: a) The Manufacturer's name b) Product description c) Mass of material d) The material identification number e) The batch number f) Date of manufacture g) Location of manufacturing h) Temperature required for transportation and storage i) The shelf life (or expiration date) j) Material identification fingerprints

6.1.6

Each batch of FBE coating must be tested and certified by the Manufacturer in accordance with the requirement of Table 1. Vendor shall conduct the same tests to verify compliance with the requirements. Saudi Aramco: Company General Use

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Table 1 - Epoxy Powder Properties Property

Test Method

Density

Meets Manufacturer specification

CSA Z245.20 Clause 12.6

Particle Size

3.0% maximum retained on 150 μm mesh and 0.2% maximum retained on 250 μm mesh.


Gel Time



Cure Time



Moisture Content

0.5% maximum


Thermal Characteristics

Meets Manufacturer specification for Tg1 (°C), T g2 (°C), ΔH (J/g)


Bend test

No crack

NACE SP0394-2013 (Appendix H)

6.1.7

6.1.8

6.2

Acceptance Criteria

The Vendor shall retain samples of each powder batch for a period of 2 years or until the expiration date. The sample shall be of sufficient size to run duplicates for the following tests if required: a)

Instrumental Analyses: FT-IR and DSC

b)

Gel Time

c)

Moisture Content

d)

Bend tests

e)

Cathodic disbondment tests

Coating material shall be stored and handled in accordance with the coating manufacturer's recommendations. Expired material shall not be used.

Repair Material Touch-up or repairs shall be made with Saud i Aramco-approved materials. Touch-up material shall also be approved by the FBE coating manufacturer. Manufacturer should identify the repair material before starting the qualification process to be included in the testing program, if needed. Touch-up material shall be stored, handled, and applied in accordance with the manufacturer's specifications.

6.3

Blast Abrasives 6.3.1

Steel abrasives and/or garnet shall be used for surface preparation. Only Saudi Aramco approved abrasive materials are allowed to be used.


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6.3.2

Each batch of abrasive must be tested and certified by the Manufacturer in accordance with the requirement of ISO 11124-3 or 11126-10.

6.3.3

The use of reclaimed slag abrasives is prohibited. The use of reclaimed garnet is permitted for pre-blasting work, provide it meets the requirements of ISO 11126-10 and ASTM D7393 for oil contamination.

6.3.4

The use of recycled steel abrasives is allowed, provide it meets the requirements of SSPC-AB2.

6.3.5

After blast cleaning all pipes shall be blown out with clean, dry presurized air (at least 100 psi) to remove any residual contaminants from the blast cleaning operation. The quality of air must be tested two times per shift using blotter test.

6.3.6

The abrasives shall be stored in a dry condition and kept dry/clean during use. For all abrasives, the sulfate content shall be less than 50 PPM, the chloride content shall be less than 50 PPM, and calcium carbonate shall be 1.0% by weight.

6.3.7

Garnet abrasive shall meet the requirements of ISO 11126-10 and 11127. The steel abrasives shall meet the requirements of ISO 11124-3 and 11125.

6.3.8

Abrasives shall be of a particle size that will produce a clean, angular surface profile as specified in paragraph 8.4 of this specification.

6.3.9

Sand is prohibited as an abrasive for pre-cleaning, cleaning, and all other abrasive blasting processes.

6.3.10 The Vendor shall furnish a chemical analysis for all batches of abrasives to verify compliance with the requirements in paragraph 6.3.6.

7

Handlin g of Pipe before Coating 7.1

Suitable equipment for handling, unloading, and temporary storage of bare pipe shall be used to avoid any damage to bare pipe or pipe ends, or obliteration of necessary pipe markings.

7.2

Pipe or fittings received in a damaged condition or showing serious defects that may impair the coating, such as extensive laminations, burrs, gouges, pits, metal slivers or cold laps, or uneven weld cap or weld irregularity shall be reported to the Buyer's Representative for disposition. The Vendor shall determine final disposition due to the coating inability.

7.3

Vendor shall have an approved procedure for handling, loading, unloading, Saudi Aramco: Company General Use

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storage and preparation for shipment of pipe and fittings prior to coating.

8

Cleaning and Surface Preparation 8.1

Prior to abrasive cleaning, all oil, grease and other deleterious materials shall be removed by solvent cleaning in accordance with SSPC SP 1 or by detergent washing or steam cleaning. No residue that will affect adhesion shall be left on the surface. Oven burn-off at a temperature of 370 - 400ºC may also be employed, if, in the opinion of the Vendor, this is the only satisfactory method of insuring that the steel is free of oily contaminants. The reported oily contamination shall be investigated and confirmed b y the Buyer's Representative and written approval shall be obtained from the Buyer prior to burn-off. All pipe and fittings which have been received with internal mill varnish or other deleterious coatings or have been in previous oil service shall always be burned off.

8.2

Before and after blasting, pipes or fittings surface temperature shall be at least 3ºC above the dew point. If preheating is used, it shall be carried out in a uniform manner to avoid distortion.

8.3

The surface to be coated shall be abrasive cleaned to a near white metal surface finish equal to Sa 2-½ as described in ISO 8501-1 or SSPC- SP10/NACE No 2. Internal coating shall be protected from damage b y the blasting material at all times.

8.4

The anchor profile shall be 50-100 micrometers. Anchor profile shall be measured by Stylus type profile meter (ISO 8503-4). Replica tape (ISO 8503-5) can be used in area where Stylus profile meter can not be used. Abrasives, including recycled materials, shall be maintained clean, d ry, and free from contaminants in accordance with SSPC-AB2. Vendor should have a written procedure for monitoring size, shape, dryness and cleanliness of the blasting material. Oil contamination shall be checked twice per shift on the re-circulated abrasives in accordance with ASTM D7393.

8.5

Dust level shall be Class 2 or less in accordance with ISO 8502-3. Test the first 5 pipes in every shift. After that, test one out of every 20 pipes or 2 fittings per production lot.

8.6

Defects 8.6.1

Weld spatter shall be removed. Rough welds and sharp edges shall be ground to a minimum radius of 3 mm.


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8.6.2

When serious defects such as mentioned in paragraph 7.2 are found following the abrasive cleaning operation, the affected pipe or fitting shall be set aside for disposition by the Buyer's Representative.

8.6.3

If these anomalies affect enough of the pipe or fitting to the extent that the coating process is severely disrupted, the coating process shall be stopped and the Buyer informed. The Vendor shall advise the Buyer of any remedial measures that could be taken to achieve an acceptable coating. The Vendor shall make the final decision, after consultation with the Buyer's Representative, whether the affected pipe or fittings can be coated.

8.7

Dew Point readings shall be recorded at the start and every 2 hours during the blasting operation in the immediate vicinity of the operation. Blasting and coating operations shall be suspended if the substrate temperature is le ss than 3ºC above the dew point. Any metal surface showing evidence of flash rusting shall be re-blasted prior to coating.

8.8

Chloride Contamination 8.8.1

The blasted surface of pipes and fittings shall be tested for the presence of residual chlorides in accordance with ISO 8502-6. Residual chlorides shall be no greater than 20 mg/m².

8.8.2

Test a random location on the first two blasted pipes and/or fittings on any given day. After that, test one pipe joint out of every 50 pipes. For fittings, test at least two pieces per production lot.

8.8.3

In the event of a failed test result, the piece shall be re-tested. If it fails after the re-test, test all pieces that were blast cleaned both before and after the contaminated piece until five in a row pass the test. All pieces coated after the last good test must be re-blasted, re-tested and recoated.

8.8.4

If the phosphoric acid/fresh water wash is needed prior to application of the FBE powder, Vendor must use an approved procedure by CSD/Paints and Coating Standards committee. The procedure should include, at least, the following: 8.8.4.1

Required pH level after wash shall be controlled.

8.8.4.2

Description of the acid wash process and qualification shall be provided.

8.8.4.3

Dwell time, pH, and minimum and maximum temperature controls. Saudi Aramco: Company General Use

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8.9

8.8.4.4

A thorough, clean, high-pressure water rinse more than 1,000 psi (70 bar) must follow to remove any treatment residue.

8.8.4.5

Quality of water and control of total dissolved solids and chlorides control.

8.8.4.6

Provisions and controls to avoid acid to dry on pipe with residual heat or to avoid traces of acid or reactive products to be left on surface.

Maximum time between blasting and coating shall be 4 hours and any metal surface showing evidence of flash rusting shall be re-blasted p rior to coating. A minimum light intensity at the inspection site of 50 foot-candles (500 Lux) is required for visual inspection of the surface. Table 2 - Summary of Surface Preparation Tests Test

Surface Cleanliness

Anchor Profile

Test Method

Para. 8.3

Para. 8.4

Acceptance Criteria

Frequency

Sa 2.5

All

50~100 μm

1) First 5 pipes in every shift and then one pipe out of every 20 pipes 2) Two fittings per production lot

Dust grade

Para. 8.5

Class 2 or less

1) First 5 pipes in every shift and then one pipe out of every 20 pipes. 2) Two fittings per production lot.

Defects

Para. 8.6

Dew Point

Para. 8.7

Residual Chloride

9

Para. 8.8

Free of weld spatter, rough weld surfaces and sharp protrusions 3°C above steel temperature

Less than 20 mg/m ²

All Every 2 hours 1) First 2 pipes on any given day and then one pipe out of every 50 pipes. 2) Two fittings per production lot

Coating Applic ation 9.1

The dew point of air in the fuidized bed and powder feed lines shall be no higher than -20°F (-29°C). A source of clean, dry air with instrumentation to monitor dryness is required. Saudi Aramco: Company General Use

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9.2

Adequate screens (80 mesh (180 micron) or finer) shall be present in the powder handling system to ensure that large particles or agglomerates are no t carried to the application equipment.

9.3

The FBE coating material shall be applied according to the Vendor's approved application procedure, which incorporates the Manufacturer's recommendations. The Vendor shall submit his application procedure to CSD/Paints and Coating Standards committee for Saudi Aramco approval prior to application. Already approved procedures do not require CSD/Paints and Coating Standards committee review and approval on new purchase orders, unless otherwise is required by the Buyer's representative or any oth er standards documents.

9.4

During coating application, pipe surface temperature shall be maintained and monitored to be within coating Manufacturer specified application temperature. Surface temperature and interval time of each process shall b e measured immediately prior to coating application, after coating applic ation and before quenching by optical pyrometer or contact type thermometer.

9.5

In no case shall steel pipes and associated fittings and couplings, which have been internally coated, be exposed to a temperature detrimental to the internal coating. In all pipes, the lining shall be visually inspected after application of external FBE and result must be reported in the inspection sheet.

9.6

The coating dry film thickness shall be as follows, unless otherwise agreed upon in writing by the Buyer. 9.6.1

350 to 525 micrometers (14 to 21 mils) for the services described in paragraph 1.2.1

9.6.2

575 to 750 micrometers (23 to 30 mils) for the service described in paragraph 1.2.2

9.6.3

As recommended by coating manufacturer for the service described in paragraph 1.2.3

9.6.4

Fittings and couplings are allowed to additional 20% of maximum DFT above the values in 9.6.

9.7

Any pipes products and associated fittings and couplings having a thickness outside the specified DFT range shall be re-blasted and coated at no cost to Saudi Aramco.

9.8

The finished coating shall have a cut back at each end in the range of 50 to 75 mm measured from end of pipe, on pipes of 6” diameter and above and in the range of 25 to 50 mm on pipes with less than 6” diameter. If longer cut-back is needed, CSD/Paints and Coating Standards committee shall be consulted. Saudi Aramco: Company General Use

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10

9.9

The cured coating shall be of uniform color and gloss, and shall be free of blisters, bubbles, sags, voids fish eyes and any other irregularity. The coated surface shall be 100% visually inspected to ensure it is free of such irregularities.

9.10

In Double Jointed pipes at girth weld areas, the allowable DFT shall be in accordance with 9.6.4.

Quality Requi rements The Vendor's quality assurance system during the coating application shall include the following as minimum requirements: 10.1

Checking cleanliness of pipe and/or fittings immediately prior to blasting (see paragraph 8.1).

10.2

Monitoring of size, shape, dryness and cleanliness of the blasting material and process (see paragraph 6.3).

10.3

Checking visually, in good light, the surface for metal defects, dust and surface debris (see paragraph 8.6).

10.4

Checking blasted surface profile (see paragraph 8.4).

10.5

Checking temperature control of the surface (see paragraph 8.2).

10.6

Checking thickness of cured coating (see paragraph 11.4).

10.7

Checking on the coating adhesion properties (see paragraph 11.5).

10.8

Holiday detection of 100% of the surface area of all pipes and fittings (see paragraph 11.6).

10.9

Supervision of adequate and proper repair of all defects.

10.10 Checking of coating color, appearance and uniformity (see paragraph 9.9). 10.11 Cure Test (see paragraph 11.8). 10.12 Conduct required test on Production test Rings (see paragraph 11.9).

11

Inspection Requirements 11.1

The Vendor shall notify the Buyer not less than 5 days in advance of the start of each production run. The Vendor shall provide the Buyer's Representative with a detailed time schedule to allow him to witness or monitor all processing and testing phases. Saudi Aramco: Company General Use

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11.2

Responsibility for Inspection 11.2.1

The Vendor shall be responsible for all quality control checking including visual inspection, thickness measurements, and holiday testing, and shall keep records on the results of all such inspections in a form suitable to the Buyer's Representative.

11.2.2

Pipe coated in accordance with this specification is subject to verification by the Buyer's Representative per Saudi Aramco Form 175-091300, “Inspection Requirements”, attached to the Purchase Order. The Buyer's Representative shall have access to each part of the process, and shall have the right to witness the quality control tests and/or perform tests by himself on a random sampling basis.

11.2.3

The Buyer's Representative shall have the right to halt the application requesting alterations or corrections to the process in order to correct all faults found in the work, which conforms to this specification. Commentary Note: Quality control on custom coated pieces (including valves) has proven to be difficult. Proponent should consider providing his own (or thirdparty) full-time inspection coverage in addition to the requirements of this specification.

11.3

Visual Inspection The external surfaces being coated shall be inspected visually at each stage of the operation, using suitable illumination and inspection tools with sufficient frequency to ensure full compliance with the requirements of this specification.

11.4

Thickness Test Coating thickness for every pipe and fitting shall be checked in accordance with SSPC PA 2 by using a non-destructive type of thickness gauge which has been calibrated as required in paragraph 11.10.1. All results shall be as specified in paragraph 9.6 and shall be recorded.

11.5

Adhesion Test 11.5.1

General Requirements 11.5.1.1

For pipe, determine the adhesion of the coating at one location for each of the following cases: a)

The first production joint,

b)

The first joint after any interruption in production, and


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c)

Once every hour or every twenty pipe lengths, whichever is more frequent. If 3 tests have been successful, the test frequenc y may be reduced to once every 2 hours or 50 pipe lengths.

11.5.2

11.5.1.2

For custom coated pieces, test one sample per production lot.

11.5.1.3

Failure of the adhesion test shall require lot narrowing by testing the pipes or fittings until five in a row (coated b oth before and after the piece that failed) show satisfactory adhesion. A lot is defined as one shift's production, except in the case of custom coated pieces where a lot is defined as any number of pieces processed through the custom coating oven at the same time.

11.5.1.4

The weld cutback on selected pipe lengths or fittings (see paragraph 9.5) shall be left partly unmasked to facilitate the adhesion test. The unmasked area shall be cleaned of coating following the test. Where this procedure is not practical, the test may be conducted on a selected area of the coating, and the test area be repaired in accordance with Section 13 of this specification.

Adhesion Test Procedure 11.5.2.1

With a sharp, narrow bladed knife, two incisions (approximately 13 mm long) shall be made, in the form of an X, through to the metal substrate.

11.5.2.2

At the intersection of the X, an attempt shall be made to force the coating from the steel substrate with the knife point. The point of the knife shall be inserted horizontally, i.e., the flat of the blade under the coating at the point of intersection of the X such that the blade point is on the metal surface. Using a levering action, the flat point shall be forced away from the steel in an attempt to pry off the coating. Refusal of the coating to disband from the substrate shall be recorded as a “ pass”. A “ pass” shall also be recorded where the coating fails cohesively. Partial or complete adhesive failure between the coating and the substrate shall be recorded as a failure. Disbondment at the point of the intersection is common due to the action of


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marking the 'X' cut. Therefore, for 1 mm away from the tip of the intersection any disbondment shall be ignored. 11.5.2.3

11.6

11.7

The pipe shall be allowed to cool to below 80°C prior to conducting the adhesion test. Failure of the test shall require each piece coated on that day to be subjected to the test until a total of three tests in a row (three do ne both before and after the piece which failed) are satisfactory.

Holiday Detection 11.6.1

100% of the externally coated surface area of the pipe shall be tested with a hot spark, pulse-type DC holiday detector employing an audible signaling device. The electrode used for locating holidays shall be designed to ensure direct contact with the coating (with no visible gaps).

11.6.2

Travel rate of the detector electrode shall not exceed 30 cm/sec. The electrode shall not be allowed to remain stationary while the power is on.

11.6.3

Holiday test voltage shall be 125 volts DC per 25 micrometers (0.001 in) of maximum coating thickness. However, to eliminate the need for continual adjustment during shop production, a maximum voltage of 2,400 volts ± 50 volts may be used for the coating thickness range 350 to 750 micrometers (14 to 30 mils). Holidays shall be clearly marked for repair.

11.6.4

The allowable number of holidays rate that can be repaired before other special measures are required, is as follows: 11.6.4.1

For pipe smaller than 14 inches OD, one holiday per meter length, determined by dividing the total number of holidays by the total pipe length, expressed in meters, for the individual pipe tested.

11.6.4.2

For pipe of 14 inches OD or larger, 0.7 holiday per square meter, determined by dividing the total number of holidays by the total outside surface area, expressed in square meters, for the individual pipe tested.

11.6.4.3

If the quantity of holidays exceeds the limit specified above, the affected pipe shall be stripped and recoated.

Bend Test 11.7.1

Two test bars measuring approximately 25 mm x 192 mm x (6.0-10.0) Saudi Aramco: Company General Use

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mm shall be coated at a dry film thickness specified for each coating system. 11.7.2

The coating thickness shall be measured at 5 locations 25 mm apart on each sample, and the thickness recorded. The average of these readings shall fall in the range in paragraph 9.6.

11.7.3

The test bars shall be holiday detected in accordance with paragraph 11.6 of this specification, and all holidays marked and recorded.

11.7.4

The specimens shall be clamped in the bender with the coated side up. The specimens shall be bent flat wise.

11.7.5

The bend angles and temperatures are specified in table 3. Table 3 – Bend test condition Test Angle Test Temperature APCS-104A/B

APCS-104C

5 °C

3.0°/PD

2.0°/PD

10°C

3.75°/PD

2.5°/PD

25°C

5.5°/PD

3.0°/PD

11.7.6

Bending shall be accomplished in less than 30 seconds.

11.7.7

The coated specimens shall show no cracks, tears, delamination, or disbondment. The presence of strain marks alone do es not constitute a failure.

11.7.8

At the start of using a new batch of powder, the flexibility of the coating shall be determined by bend test. The test shall be conducted on test bars at 5, 10 and 25ºC.

11.7.9

The bend test shall be conducted on test bars once per shift at 25ºC for custom coating. The powder utilized for the test shall be taken from the plant application fluidizing bed.

11.7.10 For production pipes, the bend test shall be conducted in accordance with table 4.


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11.7.11 For production pipes not covered in table 4, the bend test shall be conducted on test bars once per shift at 25ºC. The powder utilized for the test shall be taken from the plant application fluidizing bed. 11.7.12 FBE coating of valves and pumps do not require bend test during application. 11.7.13 If any of the specimen fail the bend test, the tests shall be repeated for that teperature. 11.7.13.1 If the result of retest is satisfactory, the bend test shall be accepted. 11.7.13.2 If any of the specimen fail the retest, immediately discontinue further coating with the suspect batch of powder and proceed as follows: a)

Powder : If any specimen fails the retest, the suspected batch of powder shall not be used.

b)

Pipe: All pipes coated since the previous successful bend test shall be set aside. Two specimens with the same dimensions as given in paragraph 11.7.1 shall be cold cut from the production coated pipes in question and subjected to the bend test. The edges of the specimens as necessary shall be chamfered to remo ve stress raisers. As many specimens as necessary shall be tested until the Buyer's Representative is satisfied that all pipes with substandard coatings have be en identified. These pipes shall be rejected.

11.7.14 If deemed necessary in some critical applications or according to an end-user request, CSD/Paints and Coating Standards committee ma y request the Vendor to prepare the Bend test samples from a coated pipe section. 11.7.15 Bend test is not required for girth weld coating. 11.8

Cure Test Twice per shift the coating on production pipes shall be tested by Differential Scanning Calorimeter analysis in accordance with CSA Z245.20 Clause 12.7 for cured coating. Custom coated fittings and spools shall be subjected to the same test at a frequency of two sample per production lot. For double joint girth welds, it shall be checked twice per day. Failure of the test shall require each piece coated on that day to be subjected to the test until a total of three tests in a Saudi Aramco: Company General Use

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row (three done both before and after the piece which failed) are satisfactory. The glass transition temperature difference (Tg4-Tg3) must be in the range specified by the FBE Manufacturer, within ±3°C. Any co ated pipes, girth welds, or fittings fail the test within the acceptable range shall be rejected. 11.9

Production Test Ring 11.9.1 The vendor should obtain a test ring from the pipe end, at least 500 mm, to be subjected to the tests listed in Table 4. 11.9.2 The minimum test frequency, for each production line, shall be one test ring per pipe diameter and specified wall thickness every working shift. 11.9.3 Test ring is only required for daily production more than 25 pipes, provided the total project pipes are more than 100 pipes. 11.9.4 Test ring is not required for valves, pumps and custom coatings. 11.9.5 If the coating failed any of following test, the tests shall be repeated for that specific test. If the result of the retest is acceptable, the production test shall be accepted. If the coating failed the retest, immediately discontinue further coating with the suspect batch of powder and proceed as follows: 11.9.6 All pipes coated since the previous successful tests shall be set aside. Three pipes before/after the tested pipes shall be subjected to the tests listed in table 4. If the coating continue to fail, the tests should continue until consecutive three pipes are passed test. 11.9.7 Test ring shall be prepared 4 inch and above diameter pipe. Table 4 - Production Test Ring Requirements Test

Flexibility: 5.5°/ PD at 25°C for APCS-104A/B Flexibility: 3°/ PD at 25°C for for APCS-104C

Ac cep tan ce Criteria No cracks, tears, delamination, or disbondment No cracks, tears, delamination, or disbondment

Test Specimens

Test Method

2

NACE SP0394-2013, (Appendix H)

2

NACE SP0394-2013, (Appendix H) NACE SP0394-2013, (Appendix J)

Hot-water soak Hot-water adhesion: (24 hours) 75 ± 3°C

Rating of 2

1

Interface contamination

20%

1

Cathodic Disbondment 24 hours @ 65°C, -3.5 V

10 mm

1

CSA Z245.20, Clause 12.9.3 CSA Z245.20, Clause 12.8


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Ac cep tan ce Criteria

Test

Cross-section porosity

Test Specimens

Rating of 1-3

CSA Z245.20, Clause 12.10.3 CSA Z245.20, Clause 12.7.3.2.2

1

Thermal characteristics

ΔTg = ±3°C, 95% conversion

1

DFT

Para 9.6

1

Test Method

SSPC-PA2

11.10 Calibration of Inspection Equipment 11.10.1 The coating thickness gauge (see paragraph 11.4) shall be calibrated in accordance with SSPC PA 2 at the start of production and every 3 hours during production, against a certified or known standard. 11.10.2 The holiday detector shall be calibrated at least twice per 8-hour shift against a suitable calibrated voltmeter. 11.11 Internal coating shall not be subjected to double heating, in case the external coating is rejected and recoating is required. Table 5 - Summary of Coating Application Requirements Test

Dry Film Thickness Cutback

Test Method

Ac cep tan ce Criteria

Frequency

Para. 11.4

As specified in Para. 9.6

All

Para. 9.8

25-50 mm (less than 6 inch dia.) 50-75 mm (larger than 6 inch)

All

Adhesion Test

Para. 11.5

Pass

First joint or once every hour or every twenty pipe lengths. If three tests successful, every 2 hours or 50 pipe lengths for pipe. One sample per production lot for custom coated pieces

Holiday Detection

Para. 11.6

Para. 11.6

All

Bend test

Para. 11.7

Para. 11.7

Para. 11.7

Cure Test

Para. 11.8

(Tg4-Tg3) = ±3°C

For pipe twice per shift For fittings two samples per production lot


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12

Powder Moisture Content

CSA Z245 Clause 12.4

0.5% maximum

Production Test Ring

Para. 11.9

Table 4

Once per shift from fluidized bed Once per shift

Recheck on Coating Material Qualities The Buyer's Representative at any time may require that the Vendor prepare a set of test specimens as defined in Appendix A, and arrange for the performance of any or all of the tests covered by Appendix A at a laboratory agreeable to the Buyer. Provided the coating on the specimens passes the tests, the Bu yer shall pay for the tests; otherwise the Vendor shall pay the costs.

13

Repairs 13.1

Repair materials shall be as specified under paragraph 6.2 of this specification, and repairs shall be in accordance with the approved procedure.

13.2

Abrasive blasting and patch repair work shall not be conducted when the metal surface temperature is less than 3ºC above the dew point.

13.3

Repaired areas shall be retested for holidays per paragraph 11.6 and shall be holiday free.

13.4

Each length of coated pipe leaving the Vendor's premises shall be free of holidays and any visual coating defects.

13.5

Defects shall be repaired in accordance with the criteria and methods below: 13.5.1

Small Defects (Areas up to 2 mm diameter or 3.2 mm² such as small pinholes and metal slivers repair) shall be done with either hot melt stick or two part liquid epoxy coating.

13.5.2

Large Defects (Areas greater than 2 mm in diameter and less than 250 cm²) repair shall be done with two part liquid coating. Repairs shall be in accordance with the coating Manufacturer's recommended procedure.

13.5.3

Areas exceeding 250 cm², the joint shall be rejected.

Exception: Hot melt sticks shall not be used for the repair of FBE used for services described in paragraphs 1.2.2 and 1.2.3.


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14

Pipe Storage and Preparation for Shipment 14.1

Each coated length of pipe shall be externally stenciled at a point approximately 60 cm (2 ft) from the end to reproduce the original marking and to identify the type of coating applied, Purchase Order number, pipe size, pipe grade and date coated. For pipe double-jointed at the Vendor's shop, the shop weld number shall be included in the stencil.

14.2

All pipes shall be stored on padded elevated racks or polyethylene sheathed sand berms until time for delivery. Non-compressible rubber pads 10 mm thick 3 per 12.2 m length, 5 per 24.4 m length shall be used to separate the pipe for yard transportation and storage. Alternatively, the Nylon/PP rope of thickness >19mm can be installed 3 per 12.2 m length and 5 per 24.4 m length.

14.3

Padding material and procedures shall be approved by the Buyer's Representative.

14.4

All booms, hooks, forks, supports and skids used in handling or storing coated pipe shall be designed and maintained in such a manner as to prevent any damage to the pipe or to the coating, and shall be approved by Buyer's Representative. Pipe shall not be stored directly on the ground.

14.5

If FBE coated pipes are to be stored at Vendor’s yard for more than six (6) month, the stacked pipes must be protected from UV exposure by using tarpaulins or other approved means of protection as per SAES-H-200. If stored pipes are not protected for a year or more, the coating must be requalified by taking test rings from several pipes to be tested in accordance with Table 4.

14.6

The Buyer's Representative will have authority to stop any storage procedure or means of transport from the yard, if in his opinion there is a possibility of damage to the coating because of improper procedures.

Revisio n Summary 25 October 2011

Revised the “Next Planned Update”. Reaffirmed the contents of the document, and reissued with editorial revisions including removing the committee members list.

7 February 2017

Major revision to clarify some of the requirements, summarize required tests in tables, specify coating thickness for each system, revise acceptance criteria, highlight safety requirements, add new tests to be in line with international standards such as dust level, porosity, abrasion, EIS and production test ring. In addition, qualification requirements of high temperature FBE coatings (APCS 104C) were added and addressed the provisions for the long term storage of FBE coated pipe in applicator yard.

XX December 2017

Revision to clarify some test requirements, revise production test frequency to enhance productivity and be align with international standards.


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Appendix A - Qual if ication Procedure for Init ial Product App ro val 1.

General Requirements

Qualification of any product under this specification shall be in strict compliance with SAEP-1200. In order to qualify a coating system as acceptable under this specification, the coating supplier must submit a certified test report documenting to CS D/Paints and Coating Standards committee that the proposed coating system meets the qualification tests and requirements of this SAMSS. Preparation and testing shall be performed and/or witnessed by an independent laboratory or inspection agency. This report shall be submitted to Saudi Aramco Coating / CSD for review and approval. Laboratory Report

Testing can only be considered if conducted at a third party laboratory that is accepted by Saudi Aramco. The third party test report shall include all the tests mentioned in this specification, unless otherwise specified by CSD approved test protocol. The final report shall include illustrative photos of all panels before and after testing. The third party laboratory shall report the results of the tests to Saudi Aramco, first. Upon approval, the report can be then released to the Manufacturer. The third party laboratory can only report the results. However, interpretation of the results and making the final conclusion is solely the role and responsibility of CSD. All initial product qualification tests shall be carried out at no cost to Saudi Aramco. Along with any coated sample supplied for testing, the coating manufacturer/vendor shall submit the following documents: coating manufacturer’s location, date of manufacturing, batch/lot numbers of coatings used and product data sheet. Test specimens shall be coated using electrostatic flocking method. If the operating conditions for a certain project are not addressed in Tables 6 and 7, re-qualification test is required at the R&DC. 2.

References

2.1

Saudi Aramco Engineering Standard SAES-H-002

2.2

Internal and External Coating for Steel Pipelines and Piping

Industry Codes and Standards ASTM D714

Evaluating the Degree of Blistering of Paints Saudi Aramco: Company General Use

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3.

ASTM D4541

Pull Off Strength of Coatings

ASTM D4060

Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber Abrader

ISO 8501-1

Preparation of Steel Substrates Before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness

Qualification Tests

3.1

Instrumental Analysis Instrumental analysis of the coating powder material shall be conducted by the Fourier transform infrared spectroscopy (FT-IR) and Differential scanning calorimetry (DSC) techniques in a laboratory approved b y CSD/Paints and Coating Standards committee.

3.2

3.3

Preparation of Test Specimens 3.2.1

Test specimens shall be as outlined in the applicable test specification unless otherwise stated.

3.2.2

Surface preparation, application, dry film thickness, and curing parameters for the test specimens shall be identical to that used in this coating specification.

3.2.3

Prior to each test the specimens shall be conditioned for 24 hours at 25°C and 50% relative humidity.

Flexibility/Bending Test Three (3) test specimens as detailed in paragraph 1 1.7.1 of this specification shall be tested and evaluated in accordance with paragraphs 11.7.2 through 11.7.6 of this specification.

3.4

Adhesion Test (ASTM D4541) An adhesion test shall be conducted on specimens after exposure (up to 24 hours recovery time allowed) to the chemical resistance tests in p aragraph 3.10 below using an Elcometer or Hate Adhesion Tester. A pull-off value of not less than 2,000 psi is required. Tester must be run and a pull-off value of not less than 2,000 psi is confirmed.

3.5

Electrochemical Impedance Spectroscopy (EIS) At ambient temperature, conduct electrochemical impedance spectroscopy (EIS) Saudi Aramco: Company General Use

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measurements, after exposing the coated panels to 3% NaCl solution for no less than 24 hours, to obtain initial electrochemical impedance values. The initial values must be greater than 1 x 108 ohm·cm2 at an applied signal frequency of 0.01 Hz. Coatings with the recommended film thickness exhibiting lower electrochemical impedance values shall be rejected. EIS shall be conducted after the chemical resistance test and the value shall be more than 1 x 108 ohm·cm2. 3.6

Cathodic Disbondment Tests Cathodic disbondment shall be performed according to CSA Z245.20 -2014 (clause 12.8) with the following modification: the sodium chloride solution and the coated sample shall be heated separately and temperature shall be as follows: Table 6 - Cathodic Disbondment Tests Temperature

3.7

Coating System

Sample Temperatur e (°C)

Sodium Chloride Solution Temperature (°C)

APCS 104A

65

65

APCS 104B

95

80-90

APCS 104C

130

85-95

Abrasion Resistance Test The test should be conducted in accordance with ASTM D4060. The abrasive wheels shall be CS-17 with a load of 1,000 grams on each wheel and for 1,000 cycles. The mass lose should be below 100 milligrams.

3.8

Porosity of the Coating The test should be conducted in accordance with CAS Z245.20, Clause 12.10. The acceptance criteria for both cross-section porosity and interface po rosity is Rating 1-3.

3.9

Impact Resistance 3.9.1

3.10

The test should be conducted in accordance with CAS Z245.20, Clause 12.12 with the following modification: 3.9.1.1

Testing temperature is 10°C.

3.9.1.2

Impact energy is 4.0 Joules for APCS-104A/B, 3.0 Joules for APCS-104C.

Chemical Resistance Chemical Resistance, Immersion Test 3.10.1

Chemical resistance test shall be conducted in glass beakers covered with watch glass to prevent evaporation. The glass beaker was filled Saudi Aramco: Company General Use

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with enough medium to immerse half the len gth of the test specimen securely held in the non-conducting sample holder. Electrochemical Impedance Spectroscopy (EIS) before and after immersion shall be conducted to assure the coating maintain the barrier property after chemical exposure. Three (3) specimens of all side coated test specimen of 4” × 4” ×0.25” shall be half immersed for 30 days in each of the following solutions at 80°C for APCS 104A and 95°C for APCS 104B and APCS 104C:

3.10.2

a)

Distilled water

b)

5% Sodium Hydroxide

c)

5% Sodium Chloride

3.10.3

Specimens shall also be tested in synthetic seawater at 65°C for APCS-104A, 95°C for APCS-104B and APCS-104C for 90 days. Longer period test may be required if the specimens showed irreproducible results.

3.10.4

None of the coated specimens shall show evidence of cracking, softening, swelling, blistering, and discoloration

Table 7 - Coating System Qualification Requirements for APCS-104A and APCS- 104B Test

5.5°/Pipe Diameter Flexibility @ 25 Celsius 3.75°/Pipe Diameter Flexibility @ 10 Celsius Impact Resistance @ 10 Celsius Cathodic Disbondment 30 days @ 65°C, -1.5 V Cathodic Disbondment 30 days @ 95°C, -1.5 V Chemical Resistance: Distilled Water Chemical Resistance: 5% NaOH Chemical Resistance: 5% NaCl Chemical Resistance: Synthetic Sea Water

Ac cep tan ce Cr it eri a

Test Method

No. of Specimens


3


3

CSA Z245.20, Clause 12.12

3

APCS-104A

APCS-104B

No cracks, tears, delamination, or disbondment No cracks, tears, delamination, or disbondment 4.0 Joules minimum

No cracks, tears, delamination, or disbondment No cracks, tears, delamination, or disbondment 4.0 Joules minimum

10 mm

N/A

CSA Z245.20

3

N/A

10 mm

CSA Z245.20

3

(Para. 3.10)

(Para. 3.10)

(Para. 3.10)

3

(Para. 3.10)

(Para. 3.10)

(Para. 3.10)

3

(Para. 3.10)

(Para. 3.10)

(Para. 3.10)

3

(Para. 3.10)

(Para. 3.10)

(Para. 3.10)

3


Page 27 of 28


Test

Ac cep tan ce Cr it eri a APCS-104A

APCS-104B

Test Method

No. of Specimens

Interfacial Porosity

Rating 1-3

Rating 1-3

CSA Z245.20

3

Cross Section Porosity

Rating 1-3

Rating 1-3

CSA Z245.20

3

Electrochemical Impedance - as per 3.5

(Para. 3.5)

(Para. 3.5)

(Para. 3.5)

3

Table 8 - Coating System Qualification Requirements for APCS-104C Test

Acceptance Criteria

Test Method

No. of Specimens

Tg

Greater than 145°C

1

Cure — Delta Tg

Less than ±3°C

2

3.0°/Pipe Diameter Flexibility @ 25 Celsius 2.5°/Pipe Diameter Flexibility @ 10 Celsius Impact Resistance @ 10 Celsius Cathodic Disbondment 30 days @ 130°C, -1.5 V Chemical Resistance: Distilled Water Chemical Resistance: 5% NaOH Chemical Resistance: 5% NaCl Chemical Resistance: Synthetic Sea Water

No cracks, tears, delamination, or disbondment No cracks, tears, delamination, or disbondment

NACE SP0394-2013 (Appendix H) NACE SP0394-2013 (Appendix H)

3.0 Joules minimum

(Para. 3.9)

3

10 mm

(Para. 3.6)

3

(Para. 3.10)

(Para. 3.10)

3

(Para. 3.10)

(Para. 3.10)

3

(Para. 3.10)

(Para. 3.10)

3

(Para. 3.10)

(Para. 3.10)

3

Interfacial Porosity

Rating 1-3

(Para. 3.8)

3

Cross Section Porosity

Rating 1-3

(Para. 3.8)

3

Electrochemical Impedance - as per 3.5

(Para. 3.5)

(Para. 3.5)

(See 3.5)

3.11

3 3

Fingerprinting for Coating Identification As part of the qualification procedure of a coating system, the supplier shall submit to CSD/Paints and Coating Standards committee, a fingerprint of the coating obtained in accordance with ISO 20340 (Annex B). The fingerprint shall be used in subsequent routine batch testing of coating supplied for use in the field, to confirm that the supplied coating is similar to the coating tested in the qualification stage.


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09 SAMSS 089 (Final Draft_2018)

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