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Materials System Specification

09-SAMSS-090 27 March 2012


Shop-Applied Extruded P.E.
External Coating System for Line Pipe
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 Prior to Coating......…......... 5
7 Cleaning and Surface Preparation.........…..... 5
8 Coating Application........................................ 5
9 Quality and Production
Inspection Requirements........................ 6
10 Pipe Storage and
Preparation for Shipment.................…... 8
11 Repairs........................................................... 8

Appendix A - Qualification Procedure


for Initial Product Approval................... 10

Previous Issue: 1 October 2011 Next Planned Update: 27 March 2017


Revised paragraphs are indicated in the right margin Page 1 of 12
Primary contact: Al-Mansour, Mana Hamad on +966-3-8809557

Copyright©Saudi Aramco 2012. All rights reserved.


Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

1 Scope

1.1 This Specification defines the minimum requirements for the shop application of
3-layer extruded polyethylene coating for the external corrosion protection of
pipe in buried or subsea services. The coating system consists of a fusion
bonded epoxy primer plus an extruded ethylene copolymer adhesive beneath a
high density polyethylene topcoat.

1.2 Excluded from this Specification are the following:


a) Extruded polyethylene coating systems using butyl rubber adhesives
(so-called “soft adhesive systems”)
b) Sintered polyethylene coatings

2 Conflicts and Deviations

2.1 Any conflicts between this specification and other applicable 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's Representative through the
Manager, Consulting Services Department.

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

Material or equipment supplied to this specification shall comply with the latest edition
of the references listed below, unless otherwise noted.

3.1 Saudi Aramco References

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 and External Coatings for Steel Pipelines
and Piping
SAES-H-204 General Specifications and Application Procedures

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

of Heat-Shrink Sleeves to Coated Pipe


APCS-105 Shop Applied, Spirally Extruded Fused Polyethylene

Saudi Aramco Materials System Specifications


01-SAMS-024 Pipe Handling and Nesting
09-SAMSS-089 Shop-applied External FBE Coating

Saudi Aramco Inspection Requirements


Form 175-092200 Extruded 3-Layer Polypropylene and 3-Layer
Polyethylene External Coatings for Line Pipe

3.2 Industry Codes and Standards

American Society for Testing and Materials


ASTM G42 Cathodic Disbonding of Pipeline Coatings
Subjected to Elevated or Cyclic Temperature
ASTM D1505 Test Method for Density of Plastics by the Density-
Gradient Technique

Swedish Standards Institute


SIS 05 59 00 Pictorial Surface Preparation Standard for Painting
Steel Surfaces
SIS Sa 2 1/2 Near White-Metal Surface Finish

German Standards Institute


DIN 53 735 Test for Melt Flow Index
DIN 30 670 Polyethylene Coatings for Steel Pipes and Fittings

The Society for Protective Coatings


SSPC PA 2 Measurement of Dry Coating Thickness with
Magnetic Gages

4 Definitions

For purposes of this specification only, the following definitions apply:

Buyer: Saudi Aramco Purchasing Department Representative

Buyer's Representative: The person or persons designated by the Purchasing


Department to monitor and enforce the contract. Normally, this is the on-site inspector.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

DFT: Dry film thickness of the coating. It is measured in accordance with SSPC PA 2.

FBE: Fusion bond epoxy coating

High density polyethylene: Polyethylene having a density exceeding 0.940 gm/cm³.


All polyethylene materials referred to in this specification are high density polyethylene.

Manufacturer: The company that manufactures the coating materials.

RSA: Responsible Standardization Agency Representative - Coating Engineer


designated by the Manager of Consulting Services Department to act in his behalf.

Vendor: The company that applies the coating materials.

Work Procedure: The CSD-approved, Vendor's work procedure. Revisions to, or


deviations from, the work procedure require prior written concurrence from the RSA
before being implemented.

5 Material

5.1 Coating

5.1.1 The coating system shall consist of a fusion bonded epoxy primer, an
extruded ethylene copolymer adhesive, and an extruded high density
polyethylene outer layer.

5.1.2 Copolymer and polyethylene coating materials shall meet the


requirements of Appendix A of this Specification. FBE materials shall
meet the qualification requirements of 09-SAMSS-089.

5.1.3 The Vendor may select any of the Buyer-approved products or an equal
alternative agreed upon by the RSA in writing. Proposed alternative
materials must pass the qualification tests in Appendix A of this
Specification.

5.1.4 All materials (including repair and touch-up materials) supplied to the
Vendor shall be marked with the following information:
a) The Manufacturer's name
b) The material identification number
c) The batch number
d) The date of manufacture
e) The shelf life (or expiry date) and the applicable storage temperature

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

5.1.5 The Vendor shall retain samples of each batch of coating materials used
for a minimum of one year. The samples shall be of sufficient size for
the following tests, if required:
a) For FBE powders: The tests given in paragraph 4.1.5 in
09-SAMSS-089.
b) For the copolymer and polyethylene materials: Density, moisture
content, melt index, and elongation at break.

5.1.6 Coating materials shall be stored and handled in accordance with the
Manufacturer's recommendations.

5.2 Abrasive blasting materials shall meet the requirements of 09-SAMSS-089,


paragraph 4.3.

6 Handling of Pipe Prior to Coating

Handling of pipe prior to coating shall be in accordance with the requirements in


09-SAMSS-089, Section 5.

7 Cleaning and Surface Preparation

Cleaning and surface preparation shall be in accordance with the requirements in


09-SAMSS-089, Section 6. Chromate treatment prior to coating is acceptable.

8 Coating Application

8.1 The FBE primer shall be applied in accordance with 09-SAMSS-089 and shall
have a minimum DFT of 350 microns (14 mils). The maximum DFT shall be as
specified in the Work Procedure. FBE powders used shall meet the qualification
requirements of 09-SAMSS-089.

8.2 The copolymer adhesive and the HDPE coating materials shall be applied in
accordance with the coating Manufacturer's recommendation for the materials
specified.

8.2.1 The DFT range for the copolymer adhesive shall be as specified by the
Manufacturer.

8.2.2 Unless otherwise specified in the Purchase Order, the minimum DFT for
the polyethylene shall result in a minimum total coating thickness of
2.5 mm. The average total coating thickness shall be 3 mm.

8.3 The finished coating shall have a minimum cut-back from each end of the pipe
of 50 mm and a maximum of 100 mm. The coating shall be evenly feathered

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

(chamfered) for a distance of at least 10 mm all around the circumference.

9 Quality and Production Inspection Requirements

9.1 Quality Program

The Vendor shall implement and maintain a quality program that shall include
clearly defined and documented procedures for the relevant quality system
functions. The quality program documents shall be made available to the
Buyer's Representative for review and audit.

9.2 Inspection Requirements

The items manufactured to this Specification are subject to verification by the


Buyer's Representative per Saudi Aramco Form 175-092200, “Inspection
Requirements,” attached to the Purchase Order.

9.3 Responsibility

The Vendor shall be responsible for all quality control checking, including
visual inspection, thickness measurements, and holiday testing, and he shall
keep records of the results of all such inspections. The records shall be
maintained for at least three years.

The Buyer's Representative shall have access to each part of the process and
shall have the right and opportunity to witness or monitor any of the quality
control tests and/or perform such tests himself on a random sampling basis.

The Buyer's Representative shall have the right to halt this work pending
alterations or corrections to the process in order to correct all faults found in the
work which constitute failure to conform to this Specification.

9.4 Thickness Measurements

9.4.1 Total coating thickness shall be checked at 10 locations approximately


evenly spaced along the length of each joint using a nondestructive-type
thickness gauge. If the coating thickness at any location fails to meet the
requirements of this specification, the pipe shall be recoated at the
Vendor's expense. All results shall be recorded.

9.4.2 The thickness of the FBE primer coat shall be checked at the start of
production and after all production interruptions. The DFT must be
within the specified range of this specification before production coating
may proceed.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

9.4.3 The coating thickness gauge shall be calibrated at the start of production
and at least every 4 hours during production.

9.5 Holiday Detection

9.5.1 100% of the coated pipe surface area shall be holiday detected with a
pulse-type DC detector employing an audible signaling device.
The electrode used for locating holidays shall be designed to ensure
direct contact with the coating (i.e., with no visible gaps) and provide
complete coverage of the whole coated surface.

9.5.2 The holiday test voltage shall be 25,000 + 1,000 volts D.C., unless
otherwise specified in the Purchase Order.

9.5.3 The holiday detector shall be calibrated, at the minimum, at the start of
each shift and at 4-hour intervals during the shift.

9.6 Adhesion and Degree of Cure of the FBE Primer Coat

The adhesion and the degree of cure of the FBE primer coat shall be checked once
per shift and after all production interruptions using the test methods and
acceptance criteria in 09-SAMSS-089. If the FBE is incorrectly adhered or cured,
all suspect pipes shall be set aside for disposition by the Buyer's Representative.

9.7 Bond Strength

Bond strength (peel strength) of the total coating system shall be determined in
accordance with DIN 30 670 once per shift, either at both ends of one pipe or on
one end of two pipes. The test may be conducted at either 20ºC or 50ºC. If the
bond strength fails to meet the requirements in DIN 30 670 for Type S coatings,
all pipe coated in that shift shall be set aside for disposition by the Buyer's
Representative.

9.8 Final Inspection

Each coated pipe leaving the facility shall be free of holidays and observable
defects.

10 Pipe Storage and Preparation for Shipment

10.1 Each coated length of pipe shall be stenciled externally, approximately 60 cm


from one end, with the following information:

10.1.1 Pipe manufacturer's name and the original pipe purchase order number
and pipe stock number (when known).

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

10.1.2 Pipe outside diameter, wall thickness, and API grade.

10.1.3 Coating Applicator's (Vendor's) name and the Purchase Order number.

10.1.4 Type of coating applied, date of coating application, and coated pipe
number.

10.2 All coated pipe shall be stored on polyethylene-sheathed sand berms until time
for delivery. Stacking height shall be limited so that the coating on the bottom
tier of pipe is not compressed more than 20%. Separator strips are not required
between the coated pipes during storage.

10.3 All booms, hooks, forks, supports, skids and similar equipment used in handling
coated pipe shall be designed and used in such a manner as to prevent any
damage to the pipe or to the coating, and shall be approved by Buyer's
Representative. All forks, supports, and skids in direct contact with coated pipe
shall be rubber padded.

10.4 During transportation by truck, 12 m long coated pipe stacked together shall be
separated by a minimum of 3 rubber pads at least 100 mm wide (5 rubber pads
for 24 m long pipe).

10.5 The Buyer's Representative shall 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.

11 Repairs

11.1 No more than one repair shall be allowed per joint of pipe. In addition, the area
to be repaired shall not exceed 0.09 m². Where damage exceeds this total, the
whole joint shall be rejected.

11.2 Repairs shall be made using a heat-shrink sleeve approved by Saudi Aramco.
The sleeve shall overlap sound coating by at least 50 mm on all sides.

11.3 Prior to application of the sleeve, the area to be covered shall be prepared as
follows:

11.3.1 Exposed pipe surfaces: White-metal, Sa3.

11.3.2 Sound coating: Cleaned to remove all surface contaminants and loose
or disbonded coating; the surface roughened with a file, power wire
brush, or similar tool.

11.4 Sleeve application shall be according to the requirements in SAES-H-204.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

11.5 All repairs shall be holiday inspected in accordance with Section 9.5 of this
Specification.

Revision Summary
27 March 2012 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with editorial revision.

Page 9 of 12
Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

Appendix A – Qualification Procedure for Initial Product Approval

1 General Requirements

1.1 In order to qualify a coating material as acceptable under this Specification, the
Supplier of the coating material must submit the following certification in
writing to the Responsible Standardization Agency Representative (RSA).
a) Certification from an independent testing laboratory 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 met the following:
- 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-105, “Shop
Applied, Spirally Extruded Fused Polyethylene.”
c) A record of all test reports.

1.2 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.

1.3 FBE powders used as the primer coat in this specification shall be approved
separately in accordance with the requirements of 09-SAMSS-089.

2 Qualification Tests

2.1 Preparation of Test Panels

2.1.1 Test pieces shall be as described in the applicable test method except as
modified below.

2.1.2 Prior to being coated, the surfaces of the steel test pieces shall be grit
blasted to a cleanliness level of Swedish Standard SIS Sa 2-½ and a
surface profile of 50 + 13 micrometers measured from valley to peak.

2.1.3 Coating shall be applied at a thickness of 2.5 to 3.0 mm using the same
preheat and curing schedule as proposed for use during production
application of the coating.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

2.2 Impact Resistance

Impact resistance shall be tested in accordance with (and meet the requirements
of) DIN 30 670.

2.3 Cathodic Disbonding

2.3.1 Three test panels shall be tested for cathodic disbonding at a


temperature of 80ºC, in accordance with ASTM G42 using a 3%
salt solution at 1.5 volts impressed current for 30 days.

2.3.2 None of the holidays shall show disbonding or undercutting in


excess of 15 mm from edge of holiday.

2.4 Chemical Resistance

2.4.1 Three test panels each shall be half-immersed in closed


containers for 60 days at 50ºC in each of the following solutions:
a) 5% Sodium Hydroxide by Volume
b) 5% Sodium Chloride by Volume
c) 1% Nitric Acid by Volume

2.4.2 None of the sections shall show any visual evidence of blistering,
cracking or disbonding when examined at 10X magnification.

2.5 Heat and Light Aging Resistance

Three test panels each shall be tested according to (and meet the
requirements of) DIN 30 670 for heat and light aging for Type S
coatings.

2.6 Bond Strength

The bond strength shall be determined in accordance with (and meet the
requirements of) DIN 30 670 for Type S coatings.

2.7 Indentation Hardness

Indentation hardness shall be determined in accordance with (and meet the


requirements of) DIN 30 670 for Type S coatings.

2.8 Percentage Elongation at Failure

Percentage elongation at failure shall be determined in accordance with (and


meet the requirements of) DIN 30 670.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-090
Issue Date: 27 March 2012 Shop-Applied Extruded P.E.
Next Planned Update: 27 March 2017 External Coating System for Line Pipe

2.9 Coating Resistivity

Coating resistivity shall be determined in accordance with (and meet the


requirements of) DIN 30 670.

2.10 Density of the Polyethylene

The density of the polyethylene shall be determined in accordance with ASTM


D1505 and shall exceed 0.940 gm/cm³.

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