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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
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.
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
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
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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
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
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
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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
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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
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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.
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.
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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
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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
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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
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