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Materials System Specification

09-SAMSS-091 15 October 2011


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

Saudi Aramco DeskTop Standards


Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................ 2
3 References..................................................... 2
4 Definitions...................................................... 3
5 Material.......................................................... 4
6 Handling of Pipe............................................ 6
7 Cleaning and Surface Preparation................. 6
8 Coating Application........................................ 7
9 Quality Requirements.................................... 9
10 Inspection Requirements............................... 9
11 Recheck on Coating Material Qualities........ 15
12 Repairs......................................................... 15
13 Pipe Storage and Preparation for
Shipment.............................................. 16

Appendix A - Qualification Procedure for


Initial Product Approval................................ 17

Previous Issue: 30 March 2005 Next Planned Update: 15 October 2016 Page 1 of 1
Primary contact: MANA H. AL-MANSOUR on 966-3- 8809557
Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

1 Scope
1.1 This specification defines the minimum mandatory requirements of shop-applied
fusion bonded epoxy FBE powder coating systems for the internal surfaces of
steel tubular products 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 3000 psig pressure
and for exposure to hydro-testing at 5575 psig.
1.3 Information Required with the Quotation
1.3.1 Cost if burn-off is required to remove oily contaminants from the
surface prior to blast cleaning (see paragraph 7.1).
1.3.2 Procedure of the field girth weld internal coating application, quality
control, and coating defects repair.

2 Conflicts and 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 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
Saudi Aramco Engineering Standards
SAES-H-002 Internal & External Coatings for Steel Pipelines
& Piping
SAES-H-100 Appendix I "Qualification Procedure for Sand for
Abrasive Blasting"
Saudi Aramco Materials System Specification

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

01-SAMSS-024 Pipe Handling and Nesting


Saudi Aramco Inspection Requirement
Form 175-091300 Saudi Aramco Inspection Requirements
3.2 Industry Codes and Standards
The Society for Protective Coatings
SSPC PA 2 Measurement of Dry Coating Thickness with
Magnetic Gages
SSPC SP 1 Solvent Cleaning
SSPC SP 5 White Metal Blast
International Organization of Standardization
ISO 8501-1/SIS Pictorial Surface Preparation
[SS 05 59 00 (1988)] Standard for Painting Steel Surfaces

4 Definitions
Buyer: Saudi Aramco Purchasing Department representative.
RSA: Responsible Standardization Agency representative - Coating Engineer
designated by the Manager, Consulting Services Department. He is responsible for
product approvals and for interpretation of this specification.
Buyer's Representative: The person or persons designated by the Purchasing
Department to monitor / enforce the contract. Normally, this is the on-site inspector.
Manufacturer: Company which manufactures the required powder coatings.
Vendor: FBE coating applicator.
Pipe: For purposes of this specification "pipe" is used to refer to steel tubular,
including line pipe and OCTG casing and tubing.
Custom Coated Pieces: All pieces not coated by automated in-plant equipment.
Generally, short spools and fittings are less than 12 meter.
Fitting: For purposes of this specification, "fitting" is used to refer to any custom
coated piece including valves and pumps.
Corrosive Service: Generally, everything except treated seawater and refined
products.
Non-Corrosive Service: Treated Seawater or Refined Products.
DFT: Dry film thickness.
FBE: Fusion bond epoxy coating.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

High Temperature FBE: FBE powder that have a Tg > 105 and shall stand operating
temperatures up to 125C.

5 Material
5.1 FBE Internal Coating
5.1.1 Material for the shop-applied internal coating shall be in a form of
thermosetting resin powder suitable for application by the fusion bond
process, with or without primer, as tested and approved by Saudi
Aramco, and applied according to the Manufacturer's recommendation.
5.1.2 Use of reclaimed powder shall not exceed the Manufacturer's
recommendation. In no cases shall such use be greater than a
maximum of 10% by weight without written approval from the RSA.
If the reclaimed powder found contaminated at the end of the
production, reclaimed powder shall be stopped.
5.1.3 The Vendor should select any of the Buyer approved products. Equal
alternative products which are not in Saudi Aramco approved list must
be agreed upon by the Buyer in writing.
5.1.4 Proposed alternative coating powders must pass the relevant
qualification tests outlined in Appendix A of this specification and any
other qualification tests deemed necessary by the Buyer or the RSA.
5.1.5 Powder coating materials supplied to the Vendor shall be marked and
supplied with the following information:
a) The Manufacturer's name
b) The material identification number
c) The batch number
d) Date of manufacture
e) The shelf life and storage temperature limits
f) The material identification fingerprints from the FBE
Manufacturer certified by a third party individual laboratory.
5.1.6 The Vendor shall retain samples of each powder batch for a period of 2
years. The sample shall be of sufficient size to run duplicates for the
following tests if required:
a) Instrumental Analyses for identification, IR and DSC
b) Gel Time
c) Moisture Content
d) Bend tests

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

e) Autoclave tests.
5.1.7 Coating material shall be stored and handled in accordance with the
coating Manufacturer's recommendations.
5.2 Repair Material
Touch-up or repairs shall be made with FBE or other Saudi Aramco-approved
materials tested in accordance with, and meeting the applicable requirements of,
Appendix A of this specification. Touch-up material shall also be approved by
the Manufacturer. Repair and/or touch-up material shall be tested for adhesion,
hardness and autoclave performance. Repair materials shall be marked with the
information in paragraph 5.1.5.
5.3 Blast Abrasives
5.3.1 Abrasives for blast cleaning shall have less than 100 PPM sulfates and
less than 100 PPM chlorides. They shall be of a particle size that will
produce a clean, angular surface profile as specified in paragraph 7.4 of
this specification. The abrasives shall be stored in a dry condition and
kept dry during use. Sand is prohibited as an abrasive for pre-cleaning,
cleaning, and all other abrasive blasting processes.
5.3.2 The Vendor shall furnish a chemical analysis for all batches of
abrasives to verify compliance with the requirements in paragraph
5.3.1.
5.3.3 The use of reclaimed non-metallic abrasives shall be according to the
manufacturer's recommendation.

6 Handling of Pipe
6.1 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.
6.2 The stacking height of bare pipe shall be limited by the requirements of
01-SAMSS-024.
6.3 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.
6.4 Vendor shall submit his handling, loading, unloading, storage and preparation
for shipment procedures for pipe and fittings for Saudi Aramco approval to the
Buyer's representative prior to coating.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

7 Cleaning and Surface Preparation


7.1 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 - 400C 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 by 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.
7.2 The pipe or fitting surface temperature shall be at least 3C above the dew point
before and during abrasive blasting until the primer application (if required) or
until start up of pre-heating. If preheating is used, it shall be carried out in a
uniform manner to avoid distortion.
7.3 The surface to be coated shall be abrasive cleaned to a "white" metal surface
finish equal to Sa3 as described in ISO 8501-1/SIS SS 05 59 00 (1988) or SSPC
SP 5.
7.4 The anchor profile shall be 50 - 100 micrometers.
7.5 Defects
7.5.1 Weld spatter, rough weld surfaces, and sharp protrusions shall be
ground smooth.
7.5.2 When serious defects such as mentioned in paragraph 6.3 are found
following the abrasive cleaning operation, the affected pipe or fitting
shall be set aside for disposition by the Buyer's Representative.
7.5.3 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.
7.6 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
3C above the dew point.
Any metal surface showing evidence of flash rusting shall be re-blasted prior to
coating.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

7.7 Chloride Contamination


7.7.1 The blasted surface of pipes and fittings shall be tested for the presence
of residual chlorides after blasting using a test method that has been
prior-approved in writing by the RSA. Residual chlorides shall be no
greater than 40 mg/m.
7.7.2 Test a random location on the first pipe and/or fitting coated on any
given day. After that, test one pipe joint out of every 50 pipes or 50
fittings.
7.7.3 In the event of a failure, re-test the piece. If it fails the re-test, test all
pieces that were blast cleaned both before and after the contaminated
piece until three in a row pass the test. All pieces coated after the last
good test must be re-blasted, re-tested, and re-coated.

8 Coating Application
8.1 The FBE and its primer coating material shall be applied according to the
Vendor's written application procedure, which incorporates the Manufacturer's
recommendations. The Vendor shall submit his application procedure to the
RSA for Saudi Aramco approval prior to application. Already approved
procedures do not require RSA review and approval on new purchase orders,
unless otherwise it is required by the Buyer's representative or any other
standards documents.
8.2 The coating dry film thickness DFT for pipe joints shall be in the range of 375 to
625 microns (15 25 mils) unless otherwise agreed upon in writing by the
Buyer.
8.2.1 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). The
total dry film thickness in the overlap area between the girth weld
coating and the adjacent coating shall not exceed 1250 microns.
8.2.1.1 For pipes with diameters less than 24" and/or too small to
access the girth weld area, the Vendor shall submit his
proposed procedure for controlling the DFT to the RSA for
written approval, which must be obtained prior to
commencing coating application.
8.2.1.2 The girth weld coating is not required to meet the
acceptance criterion in paragraph 10.7, Bend Test.
8.2.2 Custom coated pieces shall have a nominal DFT of 625 micrometers.
The minimum DFT shall be 375 microns and the maximum DFT on
the coating overlap area shall be 1250 microns, inclusive of girth welds
and repair areas larger than 645 mm (see paragraph 10.6.8.).

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

Within 15 cm from a butt-welding end, the maximum DFT shall be


625 microns to allow field coating of the girth weld without exceeding
1250 microns DFT in the coating overlap area.
8.3 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.
The internal root reinforcement shall be 2.5 mm or less, as per SAES-W-012,
paragraph 16.6.5.
8.4 The range of acceptable shades of color shall be established prior to production
coating. The color and gloss of the cured coating shall be within the approved
range and the cured coating shall be free of blisters and fish eyes as defined in
SSPC Vol. 1. Cosmetic sags, runs, and other non-injurious irregularities are
acceptable as long as the total DFT does not exceed 1250 microns.
8.5 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 12 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.
8.6 Custom coated fittings are subject to a size limit of maximum 36" diameter and
10 feet in length. For pieces larger than this, the Vendor must have a written
approval from the RSA prior to coating application.

9 Quality Requirements
The Vendor's quality assurance system during the coating application shall include the
following as minimum requirements:
a) Checking cleanliness of pipe and/or fittings immediately prior to blasting (see
paragraph 7.1).
b) Monitoring of size, shape, dryness and cleanliness of the blasting material and
process (see paragraph 5.3).
c) Checking visually, in good light, the inner surface for metal defects, dust and
surface debris (see paragraph 7.5). If blasting and primer applications are taking
place on the same vicinity, Primer application shall be stopped while blasting is in
progress.
d) Checking blasted surface profile (see paragraph 7.4).
e) Checking temperature control of the surface (see paragraph 7.2).
f) Checking thickness of cured coating (see paragraph 10.4).
g) Checking on the coating adhesion properties (see paragraph 10.5).

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

h) Holiday detection of 100% of the surface area of all pipes and fittings (see
paragraph 10.6).
i) Supervision of adequate and proper repair of all defects.
j) Checking of coating color, appearance and uniformity (see paragraph 8.4).
k) Cure Test - See paragraph 10.8.

10 Inspection Requirements
10.1 Notice
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.
10.2 Responsibility for Inspection
10.2.1 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.
10.2.2 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.
10.2.3 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.
10.3 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.
10.4 Thickness Test

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

Every pipe and fitting shall be checked in accordance with SSPC PA 2 at each
end using a non-destructive type of thickness gauge which has been calibrated as
required in paragraph 10.9.1. All results shall be as specified in paragraph 8.2
and shall be recorded.
10.5 Adhesion Test
10.5.1 General Requirements
10.5.1.1 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 frequency may be
reduced to once every 2 hours or 50 pipe lengths.
10.5.1.2 For custom coated pieces test one sample per production
lot.
10.5.1.3 Failure of the adhesion test shall require lot narrowing by
testing the pipes or fittings until three 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.
10.5.1.4 The weld cutback on selected pipe lengths or fittings (see
paragraph 8.3) 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
paragraph 12 of this specification.
10.5.2 Adhesion Test Procedure
10.5.2.1 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.
10.5.2.2 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

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

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
marking the 'X' cut. Therefore, for 1 mm away from the tip
of the intersection any disbondment shall be ignored.
10.5.2.3 The pipe shall be allowed to cool to below 80C 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.
10.6 Holiday Detection
10.6.1 100% 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).
10.6.2 Travel rate of the detector electrode shall not exceed 75 cm/sec. The
electrode shall not be allowed to remain stationary while the power is
on.
10.6.3 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 2200 volts 50 volts shall be used for coating
thickness in the range from 375 to 625 micrometers and a maximum
voltage of 1300 volts 50 volts shall be used for coating thickness in
the range from 225 to 475 micrometers.
10.6.4 All holidays in pipe coated above 24" diameter shall be repaired. The
maximum number allowed for repair is 20 holidays. They shall be
holiday free when re-tested after repair in accordance with paragraph
12.3. If the number is excessive than 20 holidays, the pipe joint shall
be rejected.
10.6.5 The number of holidays in a pipe joint with diameters up to 20" shall
be permitted a maximum of 4 holidays per 12.2 m length. Repair if
these holidays are accessible, otherwise leave them unrepaired and

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

inform the Buyer's representative and log it in the quality control


document.
10.6.6 Internal girth weld coatings on the double-joints pipe shall be tested in
accordance with the following:
10.6.6.1 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 paragraph
12.3. There is no limitation on the number of holidays that
can be repaired (see paragraph 12.4).
10.6.6.2 Pipe diameters less than 24", but large enough to allow
visual inspection of the girth weld area coating by remote
controlled crawling equipment; holiday(s) shall be marked
and repaired. Otherwise, the coating shall be rejected.
10.6.6.3 Pipe diameters too small (less than 6") to allow visual
inspection of the girth weld area coating: The holiday test
shall be made and the presence of holiday(s) shall be
recorded for information purposes only.
10.6.7 Custom coated fittings shall be free of holidays when tested in
accordance with paragraph 10.6 of this specification.
10.6.8 The total dry film thickness of coating in repaired areas shall not
exceed 1250 microns for repair areas exceeding 645 mm and 1875
microns for repair areas less than or equal to 645 mm.
10.7 Bend Test
10.7.1 Once per shift (or, for pipe, every one hundred pipe lengths, whichever
is the more frequent) and at the start of using a new batch of powder
the flexibility of the coating shall be determined by a bend test. The
powder utilized for the test shall be taken from the plant application
fluidizing bed.
10.7.2 Two test bars measuring approximately 25 mm x 192 mm x 9.5 mm
shall be coated at a dry film thickness of 475 - 575 micrometers.
10.7.3 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 10.7.2.
10.7.4 The test bars shall be holiday detected in accordance with paragraph
10.7.7 of this specification, and all holidays marked and recorded.
10.7.5 The specimens shall be at three different temperatures 5, 10, and 25C
3C when clamped in the bender with the coated side up. The

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

specimens shall be bent flat wise at 60 degrees over a 25.4 mm thick


shoe of the following dimensions:
Shoe radius 95.2 mm
Chord 152 mm
Arc 178 mm
10.7.6 Bending shall be accomplished in less than 30 seconds.
10.7.7 The coated specimens shall show no cracks to base metal when
examined at 10X magnification except where gripped or clamped. If
visual examination cannot determine whether a crack extends to base
metal, holiday testing using the hot spark detector method with a
conductive rubber electrode shall be used. Tests are to be carried out
as required in paragraph 10.6.3 of this specification. If no holidays are
signaled, the crack-like defect is acceptable.
10.7.8 If either of the bend tests fail, the tests shall be repeated.
10.7.8.1 If both bend retests are satisfactory, the bend test shall be
accepted.
10.7.8.2 If either (or both) of the retests fail, immediately
discontinue further coating with the suspect batch of
powder and proceed as follows:
a) Pipe: All pipes coated since the previous successful
bend test shall be set aside. Two specimens with the
same dimensions as given in paragraph 10.7.2 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 remove
stress raisers. As many specimens as necessary shall
be tested until the Buyer's Representative is satisfied
that all pipes with substandard coatings have been
identified. These pipes shall be rejected.
b) Fittings: All fittings coated with the suspect powder
shall be re-blasted and recoated.
10.7.9 If deemed necessary in some critical applications or according to an
end-user request, the RSA shall request the Vendor to prepare the Bend
test samples from a coated pipe section. Samples shall be cut in both
radial and longitudinal directions from the pipe section to suit the Bend
test requirements. The procedure of the test shall be as shown above.
10.8 Cure Test

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

Twice per shift the coating on production pipes shall be tested by Differential
Scanning Calorimeter analysis. Custom coated fittings shall be subjected to the
same test at a frequency of one sample per production lot. Girth welds 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
difference (Tg2-Tg1) must be in the range specified by the FBE Manufacturer.
Any coated pipes, girth welds, or fittings fail the test within the acceptable range
shall be re-cured and retested.
10.9 Calibration of Inspection Equipment
10.9.1 The coating thickness gauge (see paragraph 10.4) 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.
10.9.2 The holiday detector shall be calibrated at least twice per 8-hour shift
against a suitable calibrated voltmeter.

11 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 Buyer shall pay for the tests; otherwise
the Vendor shall pay the costs.

12 Repairs
12.1 Repair materials shall be as specified under paragraph 5.2 of this specification,
and repairs shall be in accordance with the approved, written procedures.
12.2 Abrasive blasting and patch repair work shall not be conducted when the metal
surface temperature is less than 3C above the dew point.
12.3 Repaired areas shall be retested for holidays per paragraph 10.6 and shall be
holiday free.
12.4 Any coated joint with defective or damaged coating exceeding 930 cm shall be
rejected and completely recoated at the Vendor's expense.
12.5 Custom coated fittings or girth welds with defective or damaged coating
exceeding 233 cm shall be rejected and recoated at the Vendor's expense.

13 Pipe Storage and Preparation for Shipment


13.1 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

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

pipe or fitting Purchase Order number (if known), pipe size, pipe grade, fitting
size, fitting class and date coated.
13.1.1 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.
13.1.2 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.
13.1.3 Fittings that cannot be stenciled as required above shall be marked in
accordance with the Buyer's written instructions.
13.2 All pipes shall be stored on polyethylene-sheathed sand berms until time for
delivery. Fittings shall be stored on pallets or padded elevated racks.
13.3 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.
13.4 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.

Revision 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.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

Appendix A Qualification Procedure for Initial Product Approval


1. General Requirements
In order to qualify a coating material as acceptable under this specification, the
Supplier of the coating material shall submit the following certification in
writing to the Responsible Standardization Agency (RSA):
a) Certification from an independent testing laboratory or inspection agency
that they witnessed or performed the preparation and testing of the
samples, and that all procedures were in accordance with this qualification
procedure.
b) Certification by the Supplier that the proposed coating meets the following
criteria:
- Has passed all the tests and met all the requirements of this
qualification procedure.
- Is suitable for the intended service conditions as detailed in Saudi
Aramco Engineering Standard SAES-H-002, APCS-102 "Shop or
Field-applied Fusion Bonded Epoxy (Internal)".
c) A record of all test results:
Any and all initial qualification tests shall be carried out at no cost to Saudi
Aramco. The RSA shall decide if the data presented by the Supplier
satisfy the requirements of the tests outlined below.
2. References
2.1 Saudi Aramco Engineering Standard
SAES-H-002 Internal and External Coating for Steel Pipelines
and Piping
2.2 Industry Codes and Standards
ASTM D714 Evaluating the Degree of Blistering of Paints
ASTM D4541 Pull Off Strength of Coatings
ISO 8501-1/ Pictorial Surface Preparation Standard For
SIS SS 05 59 00 Painting Steel Surfaces (1988)
3. Qualification 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

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

scanning calorimetric (DSC) analysis. Both tests shall be conducted in a


laboratory acceptable to the RSA.
3.2 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.
3.3 Flexibility/Bending Test
Three (3) test specimens as detailed in paragraph 10.7.2 of this
specification shall be tested and evaluated in accordance with paragraphs
10.7.3 through 10.7.7 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
paragraph 3.6 below using an Elcometer or Hate Adhesion Tester. A
pull-off value of not less than 2000 psi is required. Tester must be run
and a pull-off value of not less than 2000 psi confirmed.
3.5 Chemical Resistance (ASTM D714)
3.5.1 High temperature - high pressure (autoclave) chemical
resistance test results shall not show more than a few blisters of
size 8 or greater, as defined in ASTM D714 and no loss of
adhesion per the procedure outlined in paragraph 10.5.2 of this
specification. The tested samples shall not show any cracking
or delamination.
3.5.2 The fully cured specimens will be immersed half-way in the
specified test solutions in the autoclave. After sealing, the test
chamber shall be heated to the test temperature specified in
Table A1 below. Stable condition (temperature/pressure) shall
be maintained for a minimum of 18 hours, after which the heat
shall be discontinued. The unit shall be cooled to 90C and the
pressure released over a time period of a minimum of one
minute and a maximum of three minutes. The specimens shall
be conditioned for one hour at 25C prior to being assessed.
3.5.3 The pressurizing gas shall be Nitrogen (N2) unless otherwise
specified.

Table A1 Chemical Resistance Test Parameters

Page 17 of 18
Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 15 October 2011 Qualification Requirements
Next Planned Update: 15 October 2016 for Shop-Applied Internal FBE Coatings

Service Test Medium Test Temp. Test Pressure Test Time


a) Treated ASTM D1141, Stock 95C 20.68 MPa 24 hrs
Seawater Solution 1 plus (3000 psig)
Stock Solution 2
b) Brine Formation Water Brine 95C 20.68 MPa 24 hrs
Reinjection Wet, 3 mole% CO2 (3000 psig)
Sour Gas or Crude 3 mole% H2S
94% mole%
Methane
c) Wasia Water Wasia Water 95C 20.68 MPa 24 hrs
100% CO2 (3000 psig)
d) Acid 10 vol. % HCl 50C Covered Vented 24 hrs
Container

Formation Water Brine Composition (mg/l):


Na = 65,000; Ca = 23,000; Mg = 3,000; Cl = 150,000;
SO4 = 100; HCO3 = 300
Wasia Water Composition (mg/l):
Na = 2,500; Ca = 600; Mg = 120; Cl = 4,000; SO4 = 1,000;
HCO3 = 200; pH = 6.8 - 7.2
Note: 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.

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