Materials System Specification: Draft before publication

Materials Syste Syst em Specific pecif ica ation ti on 09-SAMSS-091 09-SAMSS- 091

XX December 2017

Qualification Requirements for Shop-Applied Internal 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 References .................................................. ........................................................ ...... 2

4

Definitions............................................... .......................................................... ........... 5

5

Health, Safety, and Environment Environment ....................... 6

6

Material............................................... .............................................................. ............... 6

7

Handling of Pipe ................................................ ................................................ 8

8

Cleaning and Surface Surface Preparation Preparation..................... 9

9

Coating Application Application.......................................... .......................................... 11

10 Quality Requirements ...................................... ...................................... 13 11 Inspection Inspection Requirements Requirements ................................. ................................. 13 12 Recheck on Coating Material Qualities............ ....... ..... 21 13 Repairs ............................................... ............................................................ ............. 21 14 Pipe Storage Storage and Preparation Preparation for Shipment .... 22 Revision Summary ............................ .................................................. ...................... 22 Appendix A - Qualification Qualification Procedure Procedure for Initial Product Approval Approval .......................... .......................... 23

Previous Issue: 6 February 2017

Next Planned Update: XX December 2020 Page 1 of 27

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-091 Issue Date: 6 February 2017 Next Planned Update: XX December 2020 Qualification Requirements for Shop- Applied Internal FBE Coatings

1

2

3

Scope 1.1

This specification defines the minimum mandatory requirements of shop-applied primed fusion bonded epoxy FBE powder FBE powder coating systems s ystems for the internal surfaces of steel pipes and associated fittings and couplings.

1.2

Unless stated otherwise in the Purchase Order, pieces coated in accordance with this specification shall be suitable for continuous service at 3,000 psig pressure and for exposure to hydro-testing at 5,575 psig.

1.3

For projects reviews, all protective coating requirements, specifications and coatings map as per SAEP-303, shall 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 oily contaminants from from the surface prior to blast cleaning (see paragraph 7.1).

1.5.2

Procedure of the field girth weld internal coating application, quality control, and coating defects repair.

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

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 Procedures SAEP-302

Instructions Instructions for Obtaining Obtaining a Waiver Waiver of a Mandatory Mandatory Saudi Aramco Engineering Requirement Saudi Aramco: Company General Use

Page 2 of 27


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 External and Internal FBE Coatings of Pipeline Field Girth Welds

SAES-W-012

Welding Requirements for Pipelines

Saudi Aramco Inspection Requirement Form 175-091300

3.2

Coating: Shop Applied, Internal or External

Industry Codes and Standards The Society for Protective Coatings SSPC PA 2

Procedure for Determining Conformance to Dry Coating Thickness Requirements

SSPC SP 1

Solvent Cleaning

SSPC-SP 5/NACE No. 1 - White Metal Blast Cleaning SSPC-AB2

Cleanliness of Recycled Ferrous Metallic Abrasives

SSPC-AB3

Ferrous Metallic Abrasive

International Organization of Standardization ISO 8501-1

Pictorial Surface Preparation

ISO 8502-3

Assessment of Dust on Steel Surface Prepared for Painting

ISO 8502-6

Extraction of Soluble Contaminants for Analysis The Bresle Method

ISO 8503-4

Method for the calibration of ISO surface profile comparators and for the determination of surface profile — Stylus instrument procedure Saudi Aramco: Company General Use

Page 3 of 27


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 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

ISO 11126-10

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

ISO 11127

Test Methods for Non-metallic Blast-Cleaning Abrasives

American Society for Testing and Materials ASTM D4417

Field Measurement of Surface Profile of Blasted Cleaned Steel

ASTM D6677

Standard Test Method for Evaluating Adhesion by Knife

ASTM D7393

Standard Practice for Indicating Oil in Abrasives

NACE International NACE SP0188

Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

NACE TM0185

Evaluation of Internal Plastic Coatings for Corrosion Control of Tubular Goods by Autoclave Testing

NACE SP0394

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

Canadian Standards Association CSA Z245.20 Series-14 Plant-Applies External Coatings for Steel Pipe

America Petroleum Institute API 5L7

Recommended Practice for Unprimed Internal Fusion Bonded Epoxy Coating of Line Pipe

API 5L9

External Fusion Bonded Epoxy Coating of Line Pipe

Saudi Aramco: Company General Use

Page 4 of 27


4

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. 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. Corrosive Service: Generally, everything except treated seawater and refined products. Custom Coated Pieces: All pipes not coated by automated in-plant equipment. Generally, fittings, short spools and fabricated spools. Cutback: 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. Non-Corrosive Service: Treated Seawater or Refined Products Pipe: For purposes of this specification “ pipe” is used to refer to steel tubular, including line pipe and OCTG casing and tubing. Saudi Aramco: Company General Use

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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.

5

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

6

Material 6.1

FBE Internal Coating 6.1.1

Material for the shop-applied internal 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-102A, APCS-102B or APCS-102C 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 Saudi Aramco: Company General Use

Page 6 of 27


6.1.6

h)

Temperature required for transportation and storage

i)

The shelf life (or expiration date)

j)

Material identification fingerprints

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. Table 1 - Epoxy Powder Properties Property

Test Method

Density

Meets Manufacturer specification

CSA Z245 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)

Autoclave 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 Saudi Aramco: Company General Use

Page 7 of 27


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.

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 twice per shift using the 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 abrasives 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 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. Saudi Aramco: Company General Use

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8

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

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 “white” metal surface finish equal to Sa3 as described in ISO 8501-1, SSPC SP 5/NACE No. 1.

8.4

The anchor profile shall be 50 - 100 micrometers.

8.5

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

8.6

Defects 8.6.1

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

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.


Page 9 of 27


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 less than 3ºC above the dew point.

8.8

Chloride Contamination

8.9

8.8.1

The blasted surface of pipes and fittings shall be tested for the presence of residual chlorides using 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 pipe and/or fitting 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 bo th 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 re-coated.

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

Acceptance Criteria

Para. 8.3

Sa 3

All

50~100 μm

1) First 5 pipes in each shift and then one pipe out of every 20 pipes.

Para. 8.4

Frequency

2) Two fittings per production lot. Dust grade

Para. 8.5

≤ Class 2

1) First 5 pipes in each shift and then one pipe out of


Page 10 of 27


Test

Test Method

Acceptance Criteria

Frequency

every 20 pipes. 2) Two fittings per production lot. Defects

Para. 8.6

Free of weld spatter, rough weld surfaces All and sharp protrusions

Dew Point

Para. 8.7

3°C above steel temperature

Residual Chloride

Para. 8.8

Less than 20 mg/m ²

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

9

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, d ry air with instrumentation to monitor dryness is required.

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 and its primer 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 an y other standards documents.

9.4

The phenolic primer shall be applied in accordance with the coating manufacturer data sheet. The primer should be applied uniformly at dry film thickness of 13-25 microns (0.5-1.0 mils) to just wetting the blasted surface and keeps the surface profile peaks exposed to allow optimum adhesion for the FBE coating. This low thickness can not be measured by the conventional DFT gauges. Therefore, Vendor should describe in the coating application procedure his method in achieving the required primer thickness.

9.5

The coating dry film thickness DFT for pipe joints shall be in the range of 375 to 625 microns (15-25 mils) for APCS-102A and APCS-102B and 500-750 microns Saudi Aramco: Company General Use

Page 11 of 27


(20-30 mils) for APCS-102C unless otherwise agreed upon in writing by the Buyer. 9.5.1

For girth weld areas (pipe and custom coated pieces), the allowable DFT shall be in the range of 375 to 625 microns (15-25 mils) for APCS-102A and APCS-102B and 500-750 microns (20-30 mils) for APCS-102C. The total dry film thickness in the overlap area between the girth weld coating and the adjacent coating shall not exceed 1,250 microns for APCS-102A and APCS-102B and 1,500 (60 mils) for APCS-102C.

9.5.2

For pipes with diameters less than 24 and/or too small to access the girth weld area, the Vendor should describe in the coating application procedure his method in controlling the DFT. ”

9.6

The coating thickness for custom coated pieces shall meet the requirement specified in paragraph 9.5, additional 20% of the maximum thickness is acceptable. However, the thickness at the end of the custom coated pieces, last 15 cm, should be within the specified thickness in paragraph 9.5 to maintain the same thickness in the overlap area specified in paragraph 9.5.1 of this document.

9.7

Line pipe and ancillary piping products for subsequent welding shall have a cut-back at each end in the range of 50 to 75 mm measured from the end of pipe unless otherwise specified. In the case of fittings 6 diameter or less, the cutback range of 25 to 50 mm. If longer cut-back is needed, CSD/Paints and Coating Standards committee shall be consulted. ”

9.8

The internal root reinforcement shall be 1.5 mm or less, as per SAES-W-012, paragraph 16.10.

9.9

The cured coating shall be of uniform color and gloss, and shall be free of blisters, fish eyes, orange peel, sags and runs.

9.10

Pipe or fittings which have been primed and waiting for FBE coating application must be covered to be protected against any dirt or other deleterious materials and not to be hold more than 4 hours for FBE coating application. For pipes and fittings, the final curing process of the FBE coated items must begin within two hours of the FBE application.

9.11

Custom coated fittings are subject to a size limit of maximum 36” diameter and 10 feet in length. For fabricated spools that can not be coated through the automated process, custom coating is acceptable with the following conditions: 9.11.1 During coating application, pipe temperature shall be within the minimum and maximum limits recommended by the co ating material manufacturer. Saudi Aramco: Company General Use

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9.11.2 Coating thickness shall meet the requirement of paragraph 9.6 of this document. 9.11.3 Coating should pass the testing requirements in papagraph 10. 9.11.4 Buyer’s Representative should attend, at least, the coating of the first piece to ensure the above requirements are incorporated.

10

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 inner surface for metal defects, dust and surface debris (see paragraph 8.6). If blasting and primer applications are taking place on the same vicinity, primer application shall be stopped while blasting is in progress.

10.4

Checking blasted surface profile (see paragraph 8.4).

10.5

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

10.6

Visual inspection of primer thickness. (see paragraph 9.4)

10.7

Checking thickness of cured coating (see paragraph 11.4).

10.8

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

10.9

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

10.10 Supervision of adequate and proper repair of all defects. 10.11 Checking of coating color, appearance and uniformity (see paragraph 9.9). 10.12 Cure Test (see paragraph 11.8). 10.13 Conduct required test on Production test Rings (see paragraph 11.9).

11

Inspection Requirements Saudi Aramco: Company General Use

Page 13 of 27


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.

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. For applications where internal coating failures could have serious operational impact, the Proponent should consider providing his own (or third-party) full-time inspection coverage in addition to the requirements of this specification.

11.3

Visual Inspection The internal 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 at accessible area 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 9.5 and shall be recorded.

11.5

Adhesion Test 11.5.1

General Requirements Saudi Aramco: Company General Use

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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

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, fittings and short spools, test one sample per production lot.

11.5.1.3

For custom coated fabricated spools, test the first production joint and once every ten joints.

11.5.1.4

Failure of the adhesion test shall require lot narrowing by testing the pipes or fittings until five in a row (coated both 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.

11.5.1.5

The weld cutback on selected pipe lengths or fittings (see paragraph 9.7) shall be left partly unmasked t o 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 Saudi Aramco: Company General Use

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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 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

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 done both before and after the piece which failed) are satisfactory.

Holiday Detection 11.6.1

100% of the internally 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

The holiday test voltage of the hot spark detector shall be 125 volts DC per 25 micrometers of maximum coating thickness. However, to eliminate the need for continual adjustment during shop production, a maximum voltage of 2,200 volts ± 50 volts shall be used for coating thickness in the range from 375 to 625 micrometers.

11.6.4

All holidays in pipe coated above 24” diameter shall be repaired. The maximum number allowed for repair is 10 holidays. They shall be holiday free when re-tested after repair in accordance with paragraph 13.3. If the number is more than 10 holidays, the pipe joint shall be rejected.

11.6.5

The number of holidays in a pipe joint with diameters up to 20” shall be permitted a maximum of 3 holidays per 12.2 m length. Repair if these holidays are accessible; otherwise, leave them unrepaired and inform the Buyer's representative and log it in the quality control document.

11.6.6

Internal girth weld coatings on the double-joints pipe shall be tested in accordance with the following: Saudi Aramco: Company General Use

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11.7

11.6.6.1

Pipe diameters equal and greater than 24 : All holidays shall be repaired. The coating on the girth weld area shall be holiday free when tested in accordance with Section 13. The maximum number allowed for repair is 3 holidays.

11.6.6.2

Pipe diameters less than 24”, but large enough to allow visual inspection of the girth weld area coating b y remote controlled crawling equipment; holiday(s) shall be marked and repaired. Otherwise, the coating shall be rejected.

11.6.6.3

Pipe diameters too small to allow visual inspection of the girth weld area coating: The holiday test shall be made. If there is a holiday in the girth weld, the coating shall be rejected.

”

11.6.7

Custom coated fittings and short spools shall be free of holidays.

11.6.8

For custom coated fabricated spools, more than 3 meters and up to 6 meters, the maximum number allowed is one holiday. For more than 6 meters, follow the requirement addressed in sections 11.6.3, 11.6.4, and 11.6.5.

Bend Test 11.7.1

Two test bars measuring approximately 25 mm x 192 mm x (6.0-10.0) 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 9.5.

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 Temperature

Test Angle

5°C

3.0°/PD


Page 17 of 27


10°C

3.75°/PD

25°C

5.5°/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 d oes 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 should 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. 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 specimen fail the bend tests, the test shall be repeated for that temperature. 11.7.13.1 If the result of the 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


Page 18 of 27


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 Clause 12.7 for cured coating. Custom coated fittings and spools shall be subjected to the same test at a frequency of two samples 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 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 coated 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 not required for valves, pumps and custom coatings. 11.9.4 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: 11.9.5 All pipes coated since the previous successful tests shall be set aside. Three pipes before/after the tested pipes shall be sub jected to the tests listed in table 4. If the coating continue to fail, the tests should continue until consecutive three pipes are passed test. Saudi Aramco: Company General Use

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11.9.6 Test ring is required for 4 inch and above diameter pipes. 11.9.7 Test ring is only required for a daily production of more than 25 pipes, provided the total project pipes are more than 100 pipes. Table 4 - Production Test Ring Requirements Ac cep tan ce Criteria

Test

Test Specimens

Test Method

No cracks, tears, delamination, or disbondment

2

NACE SP0394-2013 (Appendix H)

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

Rating of 2

1

NACE SP0394-2013, (Appendix J)

Interface contamination

20%

1

Cross-section porosity

Rating of 1-3

1

Flexibility: 5.5°/ PD at 25°C Hot-water soak

Thermal characteristics

ΔTg of ±3°C, or 95% conversion

1

DFT

Para 9.5

1

CSA Z245 Clause 12.9.3 CSA Z245 Clause 12.10.3 CSA Z245 Clause 12.7.3.2.2 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 Visual inspection is required for internally coated pipes subjected to external FBE coating to ensure the internal coating is not affected. Inspection result must be reported in the inspection sheet. 11.12 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

Para. 11.4

As specified in Para. 9.5

Para. 9.7

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

Frequency

All All

50-75 mm Saudi Aramco: Company General Use

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Test

Test Method

Ac cep tan ce Criteria (larger than 6 inch)

Frequency

Internal Root Reinforcement

Para 9.8

1.5 mm or less

All

Adhesion Test

Para. 11.5

Pass

Para. 11.5

a) Pipe (≥ 24 inch) Max. 10 holidays Holiday Detection

Para. 11.6

b) Pipe joint (≤ 20 inch) Max. 3 holidays per 12.2 m

All

Bend Test

Para. 11.7

No crack

Para. 11.7 For pipe twice per shift*

Cure Test

Para. 11.8

(Tg4-Tg3) = ±3°C

Powder Moisture Content


0.5% maximum

Production Test Ring

Para. 11.9

Table 4

For fittings two samples per production lot Once per shift from fluidized bed Once per shift

* One shift is maximum twelve hours.

12

Recheck on Coating Material Qualities The Buyer's Representative at any time ma y 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, written procedures.

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. Saudi Aramco: Company General Use

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14

Pipe Storage and Preparation for Shipment 14.1

Each coated length of pipe or fitting shall be externally or internally stenciled to identify the type of coating applied, coating Purchase Order number, original pipe or fitting Purchase Order number (if known), pipe size, pipe grade, fitting size, fitting class and date coated. 14.1.1

Pipe diameters of 16 inches and less shall be stenciled externally starting at a point approximately 60 cm from the end. Size permitting, fittings of these diameters shall be stenciled externally at any convenient location.

14.1.2

Pipe diameters greater than 16 inches shall be stenciled internally starting at a point approximately 15 cm from the end. Size permitting; fittings of these diameters shall be stenciled internally at any convenient location.

14.1.3

Fittings that cannot be stenciled as required above shall be marked in accordance with the Buyer's written instructions.

14.2

All pipes shall be stored on polyethylene-sheathed sand berms until time for delivery. Fittings shall be stored on pallets or padded elevated racks.

14.3

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.

14.4

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 30 March 2005

Revised the “Next Planned Update”. Reaffirmed the contents of the document, and reissued with minor revisions.

15 October 2011

Editorial revision to remove the committee members list.

6 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, this revision resolved some of the challenges faced in previous projects to eliminate conflicts and support project schedule.

XX December 2017 Revision to clarify some test requirements, revise production test frequency to enhance productivity and be align with international standards. In addition, steel abrasives were accepted for internal surface preparation.


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Appendi x A - Qualif ication Procedure for Init ial Product App ro val 1.

General Requir ements

1.1

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 CSD/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.

1.2

Laboratory Report 1.2.1

Testing can only be considered if conducted at a third party laboratory that is accepted by Saudi Aramco.

1.2.2

The third party test report shall include all the tests mentioned in this specification, unless otherwise specified by CSD approved test p rotocol.

1.2.3

The final report shall include illustrative photos of all panels before and after testing.

1.2.4

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.

1.2.5

All initial product qualification tests shall be carried out at no cost to Saudi Aramco.

1.2.6

All coating systems supplied for use in potable water service as in (APCS-102A) or any other systems shall have bee n tested to meet Food and Drugs Administration (FDA), National Sanitation Foundation (NSF) or Saudi Aramco-considered equivalent requirements for suitability for use in contact with drinking/potable water. The certification shall be valid for 4 years from the date of issuance, and thereafter, it shall be renewed every 4 years to maintain the approval consecutively.

1.2.7

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. Saudi Aramco: Company General Use

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2.

1.3

Test specimens shall be coated using electrostatic flocking method.

1.4

If the operating conditions for a certain project are not addressed in Table 6, re-qualification test is required at the R&DC.

References

2.1

Saudi Aramco Engineering Standard SAES-H-002

2.2

3.

Internal and External Coating for Steel Pipelines and Piping

Industry Codes and Standards ASTM D714

Evaluating the Degree of Blistering of Paints

ASTM D4541

Pull Off Strength of Coatings

ASTM D4060

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

ISO 8501-1

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

Qualific ation Tests

3.1

Instrumental Analysis Instrumental analyses of the coating powder and its primer shall be conducted by the infrared (IR) approved method, and FBE differential scanning calorimetric (DSC) analysis.

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.

Flexibility/Bending Test Three (3) test specimens as detailed in paragraph 11.7 .1 of this specification shall be tested and evaluated in accordance with paragraphs 11.7.2 through 11.7.6 of this specification.


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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 paragraph 3.8 below. A pull-off value of not less than 2,000 psi is required.

3.5

Electrochemical Impedance Spectroscopy (EIS) At ambient temperature, conduct electrochemical impedance spectroscopy (EIS) 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

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.

3.7

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 porosity is Rating 1-3.

3.8

Chemical Resistance 3.8.1

The test should be conducted using high pressure (autoclave) in accordance with NACE TM0185 with the following modification.

3.8.2

Three test panels shall be Carbon Steel plates, which are of a size at least 100 mm x 100 mm x 6 mm (4” x 4” x 0.25”).

3.8.3

The test chamber shall be heated to the test temperature specified in Table 6 below.

3.8.4

The specimens should be immersed half-way in the specified test solutions in the autoclave.

3.8.5

The pressurizing gas shall be Nitrogen (N2) unless otherwise specified.

3.8.6

Stable condition (temperature/pressure) shall be maintained for a minimum of one week, after which the heat shall be discontinued. Saudi Aramco: Company General Use

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The unit shall be cooled to 90ºC and the pressure released over a time period of a minimum of one minute and a maximum of three minutes. 3.8.7

The specimens shall be conditioned for one hour at 25ºC prior to being assessed.

3.8.8

The test results shall not show blistering, cracking, swelling, or softening. Slight discoloration is acceptable.

3.8.9

The pull off adhesion shall be more than 90% of the initial adhesion.

3.8.10 Electrochemical Impedance Spectroscopy (EIS) shall be more 1 x 108 ohm·cm2. 3.9

Density Test 3.9.1

The test shall be conducted in accordance with CSA Z245.20-14, Method A. The density of the coating should be reported in grams per liter. Table 6 - Chemical Resistance Test Parameters

Service

Test Medium

ASTM D1141, Stock Solution 1 plus Stock Solution 2 b) Brine Formation Water Brine Reinjection Wet, 3 mole% CO2 Sour Gas or 3 mole% H2S Crude 94 mole% Methane Wasia Water c) Wasia Water 100% CO2 a) Treated Seawater

d) Acid e) Sour gas

f) Sour gas with dehydrator

10 vol. % HCl 8 mole% CO2 5 mole% H2S 87 mole% Methane 70% Formation Water 30% MEG 8 mole% CO2 5 mole% H2S 87 mole% Methane

Test Temp.

Test Pressur e

Test Time

90ºC

20.68 MPa (3,000 psig)

One week

95ºC

20.68 MPa (3,000 psig)

One week

95ºC 70ºC

20.68 MPa (3,000 psig) Covered Vented Container

One week One month

95ºC

20.68 MPa (3,000 psig)

One week

60ºC

20.68 MPa (3,000 psig)

One week

Formation Water Brine Composition (mg/l): Na = 65,000; Ca = 23,000; Mg = 3,000; Cl = 150,000; SO4 = 100; HCO3 = 300 Saudi Aramco: Company General Use

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Wasia Water Composition (mg/l): Na = 2,500; Ca = 600; Mg = 120; Cl = 50,000; SO4 = 1,000; HCO3 = 200; pH = 6.8 - 7.2 Table 7 - Summary of the FBE Qualification Tests Test

Test Method

Acceptance Criteria

Flexibility/Bending Test

Para. 3.3

No crack

Adhesion Test

Para. 3.4

More than 2,000 psi

Electrochemical Impedance Spectroscopy (EIS)

Para. 3.5

Greater than 1 x 10 8 ohm·cm²

Abrasion resistance Test

Para. 3.6

Below 100 mg

Chemical Resistance Test

Para. 3.8

Porosity Test

Para. 3.7

Density

Para. 3.9

Manufacturer specification

Thermal characteristics Tg1, Tg2, Tg3, Tg4, ΔTg (Tg4-Tg3), ΔH


Manufacturer specification, ΔTg = ±3°C

Note:

No blistering, cracking, swelling or softening or loss of adhesion Rate 1-3 (Cross section) Rate 1-3 (Interface)

In order for full and unrestricted approval of a coating system it must pass all above tests and also pass the bending tests. However, it is possible to get limited approval by passing the individual tests in a specific service. All systems shall pass (d) as well as be bendable in order to qualify except as otherwise noted in this SAMSS.


Page 27 of 27

Materials System Specification: Draft before publication

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