09-SAMSS-089

Previous Issue: 31 May 2005 Next Planned Update: 25 October 2016

Revised paragraphs are indicated in the right margin Page 1 of 22

Primary contact: Khashram, Maher Saud on 966-3-8809561

Copyright©Saudi Aramco 2011. All rights reserved.

Materials System Specification

09-SAMSS-089 25 October 2011 Shop-Applied External Fusion Bonded Epoxy Coating for Steel Line Pipes

Document Responsibility: Paints and Coatings Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2

2 Conflicts and Deviations................................. 3

3 References..................................................... 3

4 Materials......................................................... 5

5 Handling of Pipe Prior to Coating................... 6

6 Cleaning and Surface Preparation................. 7

7 Coating Application........................................ 8

8 Quality Requirements.................................... 9

9 Inspection Requirements............................. 10

10 Recheck on Coating Material Quality........... 14

11 Repairs......................................................... 14

12 Pipe Storage and Preparation for Shipment...................... 16 Appendix A – Qualification Procedure for Initial Product Approval................... 18

Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089

Issue Date: 25 October 2011 Shop-Applied External Fusion

Next Planned Update: 25 October 2016 Bonded Epoxy Coating for Steel Line Pipes

Page 2 of 22

1 Scope

1.1 This Specification, together with the Purchase Order and appropriate Data

Sheets, defines the minimum mandatory requirements of shop-applied, heat-

cured external fusion-bonded epoxy (FBE) coating systems for the external

surfaces of steel tubular products and associated fittings and couplings.

1.2 Information Required in Requests for Quotation and in Purchase Orders

Requests for Quotation and Purchase Orders shall identify which of the

following service conditions applies for the coated products:

1.2.1 Buried or immersed, with temperatures not exceeding 65°C in subkha

soil or subsea, or up 93°C in dry soil condition.

1.2.2 Buried or immersed, with temperatures not exceeding 82°C in subkha

soil or subsea.

1.2.3 Buried or immersion with temperature up to 110°C in subkha soil or

subsea.

1.3 Information Required with the Quotation

Cost if burn-off is required to remove oily contaminants from the surface prior

to blast cleaning. (See Paragraph 6.1)

1.4 Definitions

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

Approved (Pre-Qualified) Procedure: Procedure referred to in this

specification that has been approved in writing by the RSA. Approved

procedures do not require re-qualification in new purchase orders.

Batch: The quantity of coating material produced during a continuous

production run of not more than eight hours.

Buyer: Saudi Aramco Purchasing Department Representative.

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

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

inspector.

Custom Coated Pieces: All pieces not coated by automated in-plant

equipment. Generally, anything less than a 40 foot pipe joint.




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Cutback: The length of pipe left uncoated at each end for joining purposes.

DFT: Dry film thickness.

FBE: Fusion bond epoxy coating.

Manufacturer: Company manufactures the required coatings.

Pipe: Steel tubular, including line pipe and OCTG casing and tubing.

RSA: Responsible Standardization Agency Representative - Coating Engineer

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

behalf.

Vendor: Pipe and custom coating applicator.

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 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

http://standards/docs/Saep/PDF/SAEP-302.PDF

http://standards/docs/Saep/PDF/SAEP-302.PDF

http://standards/docs/Saes/PDF/SAES-H-002.PDF




Page 4 of 22

SAES-H-100 Appendix I Qualification Procedure for Sand for

Abrasive Blasting

Saudi Aramco Materials System Specification

01-SAMSS-024 Pipe Handling and Nesting

Saudi Aramco Inspection Requirements

Form 175-091300 Shop-Applied External FBE Coating

3.2 Industry Codes and Standards

American Society for Testing and Materials

ASTM D714 Standard Method of Evaluating the Degree of

Blistering of Paint

ASTM D4060 Standard Test Method for Abrasion Resistance of

Organic Coatings by the Taber Abraser

ASTM G8 Test for Cathodic Disbonding of Pipeline Coatings

ASTM G14 Test for Impact Resistance of Pipeline Coatings

ASTM G42 High temperature test for Cathodic Disbonding of

Pipeline Coatings

International Organization for Standardization

ISO 8501-1/SIS Pictorial Surface Preparation Standard for

Painting Steel Surfaces

Swedish Standard Institute

SS 05 59 00 Pictorial Surface Preparation Standard for

Painting Steel Surfaces

The Society for Protective Coatings (SSPC)

SSPC PA 2 Measurement of Dry Coating Thickness with

Magnetic Gages

SSPC SP 1 Solvent Cleaning

SSPC SP 10 Very Thorough Blast Cleaning (near white metal

blast)

Canadian Standards Association

CAN/CSA-Z245.20 - 02 External Fusion Bond Epoxy Coating for Steel

Pipe


http://standards/docs/Samss/PDF/01-SAMSS-024.PDF

http://standards/docs/Inspection_Requirements/PDF/175-091300.PDF




Page 5 of 22

NACE International

NACE PR0394 - 94 Application, Performance, and Quality Control of

Plant-Applied Fusion Bonded Epoxy External

Pipe Coating

4 Materials

4.1 Coating

4.1.1 Material for the shop-applied external coating shall be thermosetting

resin powder 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. Use of reclaimed powder shall

not exceed the Manufacturer's recommendation. In no case shall such

use be greater than a maximum of 10% by weight without written

approval from the RSA.

4.1.2 The Vendor may select any of the Saudi Aramco-approved products

given in APCS-104 or another equal alternative agreed upon by the RSA

in writing.

4.1.3 Proposed alternative coating materials must proceed and pass the

relevant qualification tests in Appendix A of this Specification.

4.1.4 Powder coating materials (and materials used for touch-up and repairs)

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) Date of manufacture

e) The shelf life (or expire date)

4.1.5 The Vendor shall retain samples of each powder batch for a period of

1 year. The sample shall be of sufficient size for the following tests, if

required:

a) Instrumental Analyses, IR and DTA

b) Gel Time

c) Moisture Content

d) Bend tests




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e) Cathodic disbonding tests

4.1.6 Coating material shall be stored and handled in accordance with the

coating Manufacturer's recommendations.

4.2 Repair Materials

Touch-up or repair shall be made with FBE or other Saudi Aramco approved

materials tested in accordance with, and meeting the requirements for adhesion,

hardness, and cathodic disbonding performance in Appendix A of this

specification. Touch-up material shall also be approved by the Manufacturer.

4.3 Blast Abrasives

4.3.1 Material for blast cleaning shall be steel grit or other abrasives that contain

less than 100 ppm sulfates, and chlorides, less than 2% carbonates, and of

a particle size that will produce a clean angular surface profile as specified

in paragraphs 6.3 and 6.4. The abrasives shall be stored in a dry condition

and maintained dry during use. Sand is prohibited and shall not be used as

an abrasive in accordance with SAES-H-100.

4.3.2 The Vendor shall furnish a chemical analysis for all batches of abrasives

to verify that carbonates, chlorides, and sulfates do not exceed the limits

in paragraph 4.3.1.

5 Handling of Pipe Prior to Coating

5.1 Proper equipment for handling, unloading and temporary storage of bare pipe

shall be used to avoid any damage to bare pipe, pipe ends or obliteration of

necessary pipe markings.

5.2 The Vendor shall take special care to avoid damage to any internal coatings

during all phases of the external coating process and to avoid corrosion damage

to bare steel surfaces during storage.

5.3 The stacking height of bare pipe shall be limited by the requirements of

01-SAMSS-024.

5.4 Pipe or fittings received in a damaged condition or showing serious defects that

may impair the coating, such as extensive laminations, burrs, gouges, metal slivers

or cold laps, shall be reported to the Buyer's Representative for disposition.

The Vendor shall determine final disposition due to the surface coat ability.

5.5 Vendor shall have an approved procedure (see paragraph 1.4) for handling,

loading, unloading, storage and preparation for shipment for pipe and fittings

prior to coating.


http://standards/docs/Samss/PDF/01-SAMSS-024.PDF




Page 7 of 22

6 Cleaning and Surface Preparation

6.1 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 370-400°C may also be employed, if, in the

opinion of the Vendor, this is the only satisfactory method of ensuring 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. (See paragraph 1.3.1.)

6.2 The surface temperature of pipe or fittings shall be at least 3°C above the

dew point before and during abrasive blasting and until start of pre-heating.

If preheating is used, it shall be carried out in a uniform manner to avoid

distortion of the pipe and/or damage to any internal coating.

6.3 The surface to be coated shall be abrasive cleaned to a near white metal surface

finish equal to Sa 2-1/2 as described in ISO 8501-1/SIS SS 05 59 00 or SSPC

(SP10). Any internal coating shall be protected from damage by the blasting

material at all times.

6.4 The blast pattern shall be a uniform angular anchor profile with a height of

38 - 100 micrometers (1.5 to 4 mils).

6.5 Chloride Contamination

6.5.1 The blasted surface of pipes and fittings that will not be subsequently

treated with a phosphoric acid and fresh water wash 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/m². Test the first pipe and/or fitting coated on

any given day. After that, test one out of every 50 pipes or 50 fittings.

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 since the last

good test must be re-blasted, re-tested, and re-coated.

If the phosphoric acid and fresh water wash is permitted prior to

application of the FBE powder. The Vendor must use an approved

procedure (see paragraph 1.4). Pipe or fittings treated in this manner do

not require testing for chloride contamination.




Page 8 of 22

Commentary:

For high temperature FBE powder coatings application, the residual Chlorides shall be not greater than 25 mg/m².

6.6 Defect Repair and Disposition

6.6.1 After abrasive cleaning and before coating, the surface to be coated shall

be carefully inspected for metal defects. The Vendor shall be responsible

for the repair of any defects, which can be repaired by filing or grinding,

and for restoring the anchor pattern at the locations of such repairs when

the size exceeds 75 mm in any direction. The tools and manner employed

to remove metal defects shall not contaminate the surface.

6.6.2 Any pipes or fittings containing surface defects that are significantly

serious or extensive that they cannot be readily repaired shall be set aside

for disposition by the Buyer's Representative.

6.6.3 If these defects are significant so that the production is severely

disrupted, the coating process shall be stopped and both the Buyer and

the Buyer's Representative shall be informed. The Vendor shall advise

them of any remedial measures that could be taken to achieve an

acceptable coating. The final decision, whether the affected pipe and

fittings can be coated, shall be made by the Vendor after consultation

with the Buyer's Representative.

6.7 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

3°C above the dew point.

6.8 Any metal surface showing evidence of flash rusting shall be re-blasted prior to

coating.

7 Coating Application

7.1 The coating material shall be applied according to the Vendor's approved written

application procedure (see paragraph 1.4) incorporated with the Manufacturer's

recommendations.

7.2 In no case shall steel tubular products and associated fittings and couplings,

which have been internally coated, be exposed to a temperature detrimental to

the internal coating.

7.3 The coating dry film thickness shall be as follows:




Page 9 of 22

7.3.1 350 to 525 micrometers (14 to 21 mils) for the services described in

paragraph 1.2.1

7.3.2 575 to 750 micrometers (23 to 30 mils) for the service described in

paragraph 1.2.2

7.3.3 575 to 750 microns (23 to 30 mils) for the service described in paragraph

1.2.3

7.3.4 Fittings and couplings are allowed a maximum DFT of 1000 micrometers

(40 mils) regardless of service.

7.4 Any steel tubular products and associated fittings and couplings having less than

the specified minimum dry film thickness shall be re-blasted and coated at no

cost to Saudi Aramco.

7.5 The finished coating shall have a cut back at each end in the range of 38 to

65 mm measured from end of pipe, dependant on the diameter of the pipes.

7.6 The cured coating shall be of uniform color and gloss, and 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 area affected is less than

0.5 % of the total coated area.

7.7 For girth weld areas the allowable DFT shall be in the range of 400 to

1000 micrometers (16 to 40 mils). Lower limit is determined by the service

(see paragraph 1.2).

8 Quality Requirements

The Vendor's quality assurance system shall include, as a minimum, the following:

a) Checking cleanliness of pipe immediately prior to blasting (see paragraph 6.1).

b) Monitoring of size, shape, dryness and cleanliness of the blasting material and

process (see paragraph 4.3).

c) Checking visually, in good light, the surface of the pipes for metal defects, dust

and surface debris (see paragraph 6.6.1).

d) Checking pipe surface blast profile (see paragraph 6.4).

e) Checking temperature control of the pipe surface (see paragraphs 6.2 and 7.2).

f) Checking coating thickness of cured FBE (see paragraphs 7.3 and 9.3).

g) Checking on the coating adhesion properties (see paragraph 9.4).




Page 10 of 22

h) Holiday detection of l00% of the coated surface area of all pipes (see paragraphs

9.5 and 11.4).

i) Supervision of adequate and proper repair of all defects (see paragraph 11).

j) Checking of coating color, appearances and uniformity (see paragraph 7.6).

k) Visual examination for damage to internal coating (see paragraph 5.2).

l) Cure Test - see paragraph 9.7

m) Checking for residual chloride contamination (see paragraph 6.5.1).

9 Inspection Requirements

9.1 Notice

The Vendor shall notify the Buyer's Representative 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 permit him to witness or

monitor all processing and testing phases.

9.2 Responsibility for Inspection

9.2.1 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.

9.2.2 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.

9.2.3 The Buyer's Representative shall have the right to halt this work pending

alterations or corrections to the process to correct all faults found in the

work that result in failure to conform to this specification.

9.3 Coating Thickness Test

Every pipe and spool piece shall be checked in accordance with SSPC (PA-2) in

at least five (5) equidistant places. Loose fittings shall be checked in at least

5 locations. All coating thickness measurements shall be made using a

non-destructive type of thickness gauge, which has been calibrated as required

in paragraph 9.8.1. All results shall be as specified in paragraph 7.3 of this

Specification, and shall be recorded.




Page 11 of 22

Exception:

Except that fittings 6-inch and smaller shall be checked in at least 3 locations.

9.4 Adhesion Test

The adhesion of the coating shall be determined at one location on a pipe 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 twenty pipe lengths, whichever is more frequent.

If 3 tests have been successful, the frequency may be reduced to once every

2 hours or 50 pipe lengths, whichever is sooner. Custom coated pieces shall

have one sample per production lot subjected to this test. Failure of the test shall

require lot narrowing by testing the pipes/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.

9.4.1 Test Procedure

9.4.1.1 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.

9.4.1.2 At the intersection of the X, an attempt shall be made to force

the coating from the steel substrate with the knife point.

The point of the knife shall be inserted horizontally i.e., the flat

of the blade under the coating at the point of intersection of the

X such that the blade point is on the metal surface. Using a

levering action, the flat point shall be forced away from the steel

in an attempt to pry off the coating. Refusal of the coating to

disbond 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.

9.4.1.3 The pipe or fitting shall be allowed to cool to below 80°C prior

to conducting the adhesion test. Failure of the test shall require




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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.

9.5 Holiday Detection

9.5.1 l00% of the coated pipe or fittings surface area shall be holiday detected

with a hot spark 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, (with no visible gaps). Holiday

detection shall not be conducted if the surface temperature of the pipe is

above 80°C.

9.5.2 Travel rate of the detectors electrode shall not exceed 75 cm/s and shall

not be allowed to remain stationary while the power is on.

9.5.3 Holiday test voltage shall be 125 volts DC per 25 micrometers (0.001 in)

of maximum coating thickness. However, to eliminate the need for

continual adjustment during shop production, a maximum voltage of

2400 volts ± 50 volts may be used for the coating thickness range 350 to

750 micrometers (14 to 30 mils). Holidays shall be clearly marked for

repair.

9.6 Bend Test

9.6.1 Once per shift or 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 fluid bed. (Bend testing

is not required for custom coated fittings.)

9.6.2 Two test bars measuring approximately 25 mm x 192 mm x 9.5 mm shall

be coated at a dry film thickness of 425 - 525 micrometers (17 - 21 mils)

for the services in paragraph 1.2.1 and 575 - 750 micrometers (23 to

30 mils) for the service in paragraph 1.2.2 and 1.2.3.

9.6.3 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 9.6.2.

9.6.4 Test bars shall be holiday detected in accordance with paragraph 9.5.3 of

this specification, and all holidays marked and recorded.

9.6.5 Specimens shall be at a temperature of 25°C ± 3°C when clamped in the

bender with the coated side up. The specimens shall be bent flatwise at

60 degrees over a 25.4 mm thick shoe of the following dimensions:




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- Shoe radius 95.2 mm

- Chord 152 mm

- Arc 178 mm

9.6.6 Bending shall be accomplished in less than 30 seconds.

9.6.7 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 9.5.3 of this specification.

9.6.8 If either of the bend tests fail, the tests shall be repeated.

9.6.8.1 If both bend re tests are satisfactory, the bend test shall be

accepted.

9.6.8.2 If either (or both) of the re tests fail, all pipes coated since the

previous successful bend test shall be set aside. Further

coating application with the suspect batch of powder shall be

immediately discontinued.

Two specimens with the same dimensions as given in

paragraph 9.6.2 shall be cold cut from the first coated pipe with

the suspect batch or since the last successful bend test,

whichever occurred later. The edges of the specimens as

necessary shall be chamfered to remove stress raisers.

If the samples fail the bend test, all pipe that has been coated

with the suspect material shall be blasted off and the pipes shall

be recoated. If the samples pass the bend test, lot narrowing

shall be used until the Buyer's Representative is satisfied that

all pipes with substandard coatings have been identified.

These pipes shall be blasted and recoated.

9.7 Cure Test

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




Page 14 of 22

difference (Tg2-Tg1) must be in the range specified by the FBE manufacturer to

be acceptable.

9.8 Calibration of Inspection Equipment

9.8.1 Coating thickness gauge (reference paragraph 10.3) shall be calibrated at

the start of production and every 3 hours during production, at

approximately the mid-range of the coating thickness against a certified

or known standard.

9.8.2 Holiday detector shall be calibrated at least twice per 8 hours shift

against a suitable calibrated voltmeter and adjusted to ensure that voltage

is sufficiently high to detect an intentional pinhole holiday through the

coating on the pipe.

10 Recheck on Coating Material Quality

The Buyer's Representative at any time may require that the Vendor to 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 third-party laboratory. Provided the coating on

the specimens passes the tests, the Buyer shall pay for the tests; otherwise the Vendor

shall pay the costs.

11 Repairs

11.1 General

11.1.1 Each length of coated pipe leaving the Vendor's premises shall be free

of holidays and visual coating defects.

11.1.2 Defects shall be repaired in accordance with the criteria and methods

below.

11.2 Small Defects (Areas of damage up to 1450 mm²)

11.2.1 For small pinholes, metal slivers, or minor damage repair materials shall

be as specified under paragraph 4.2, and repairs shall be in accordance

with the coating Manufacturer's recommended procedure.

11.2.2 Repaired areas shall be tested in accordance with paragraph 9.5, and

shall be holiday free.

11.3 Large Defects (Areas of damage exceeding 1450 mm²)

When the Buyer's Representative approves large repairs, the following

procedure shall be followed using material outlined under paragraph 4.2. If the




Page 15 of 22

total damaged area exceeds 1860 cm², the joint shall be totally recoated.

Exception:

Hot melt sticks shall not be used for the repair of FBE used for services described in paragraph 1.2.3.

11.3.1 Preparation of Surface

The pipe surface to be recoated shall be cleaned to remove all dirt and

damaged or disbonded coating using abrasive blasting or other approved

and suitable means. The edges of the original coatings shall be

“feathered out” approximately 50 mm around the specific area to be

coated, and all dust cleaned off before applying the patch coating.

11.3.2 Patch Coating

The preferred method for patching large defects shall be to heat the area

locally with induction heating or other heating means and blow on

(flock) the same type powder used on the production coating line.

11.3.3 Alternative Patch Coating

When equipment is not available for patching by the method covered in

11.3.2, the following procedures shall be used:

a) The material for patch coating in the shop shall be catalytically

two-part cured epoxy coating supplied or approved by the

Manufacturer of the powder coating or by the RSA.

b) The repair coating shall be applied by spatula, brush, roller or spray

depending on the size and nature of the damaged area being repaired.

c) The patch coating shall not be applied when the pipe surface

temperature is less than 3°C above the dew point.

11.3.4 Curing Patched Area

Freshly patched coated areas shall be allowed to cure according to the

coating Manufacturer's recommendations prior to handling, and the

repaired area shall be holiday tested in accordance with paragraph 9.5.

11.4 Defect Acceptance Criteria

11.4.1 Mechanical Damage

Any coated joint with mechanically damaged coating exceeding

1860 cm², shall be rejected, blasted and coated at the expense of the




Page 16 of 22

Vendor. Mechanical damage repairs shall be per paragraphs 11.2 and

11.3 of this Specification.

11.4.2 Holidays

11.4.2.1 The allowable number of holidays rate that can be repaired

before other special measures are required, is 1 per 1.0 m² of

coated pipe surface.

11.4.2.2 If the cause of holidays is determined to be improper coating

application or defective coating materials, the joint shall be

rejected and totally recoated at the Vendor's expense.

11.4.2.3 If the holiday repair exceeds 1 holiday per 1.0 m² of coated

pipe surface, and the cause is determined to be defects in the

pipe surface, such as slivers, cold-laps or pitting, the

following procedure shall apply:

a. Any coated joint having a holiday rate of 2 holidays per

1.0 m² or less shall be 100% repaired.

b. If the holiday rate exceeds 2 holidays per 1.0 m², the

Vendor, in consultation with the Buyer's Representative

(and the Buyer, if needed), shall either reject the affected

pipes as “not coatable” or shall increase the coating

thickness to the maximum specified in paragraph 7.3 in

order to reduce the holiday rate to 1 per 1.0 m² or less.

c. After increasing the coating thickness, if the holiday rate

is still excessive, the Vendor shall advise the Buyer and

the coating operation shall be stopped.

d. The Vendor shall advise the Buyer of remedial measures

that could be taken to achieve an acceptable coating for

the Buyer's approval.

12 Pipe Storage and Preparation for Shipment

12.1 Each coated length of pipe shall be externally Stenciled at a point approximately

60 cm (2 feet) from the end to reproduce the original marking and to identify the

type of coating applied, Purchase Order number, pipe size, pipe grade and date

coated. For pipe double-jointed at the Vendor's shop, the shop weld number

shall be included in the stencil.

12.2 All pipes shall be stored on padded elevated racks or polyethylene sheathed sand

berms until time for delivery. Non-compressible rubber pads 10 mm thick 3 per




Page 17 of 22

12.2 m length, 5 per 24.4 m length shall be used to separate the pipe for yard

transportation and storage.

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

Representative.

12.4 All booms, hooks, forks, supports and skids used in handling or storing coated

pipe shall be designed and maintained in such a manner as to prevent any

damage to the pipe or to the coating, and shall be approved by Buyer's

Representative.

12.5 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

25 October 2011 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with editorial revisions including removing the committee members list.




Page 18 of 22

Appendix A – Qualification Procedure for Initial Product Approval

1. General Requirements

1.1 In order to qualify FBE powder coating material as acceptable under this

Specification, the Supplier of the coating material must submit the following

certification in writing to the Buyer's Representative, who for materials

prequalification purposes is hereafter referred to as 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 meets 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-104, “Shop or

Field-applied Fusion-Bonded Epoxy (External).”

c) A record of all test results.

1.2 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. Qualification Tests

2.1 Instrumental Analysis

Instrumental analysis of the coating powder material shall be conducted by the

infra red (IR) and differential thermal analysis (DTA) techniques, in a laboratory

acceptable to the RSA.

2.2 Preparation of Test Specimens

2.2.1 Test specimens shall be as outlined in the applicable test Specification

unless otherwise stated.

2.2.2 Surface preparation, application, dry film thickness and curing

parameters for the test specimens shall be identical to that used in this

coating Specification for the intended service.





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2.2.3 Prior to each test the specimens shall be conditioned for 24 hours at 25°C

and 50% relative humidity.

2.3 Glass Transition Temperature and Degree of Cure (CAN/CSA Z 245.20 - 02)

2.3.1 The glass transition temperature shall equal or exceed 93°C as minimum

requirement for all FBE powder coatings.

2.3.2 High Temperature FBE powder, the glass transition temperature shall

equal or exceed 115°C.

2.3.3 When determining the degree of cure, the difference in glass transition

temperatures (Tg2 – Tg1) shall be in accordance with the powder

manufacturer's specification.

2.4 Flexibility and Bending Test

2.4.1 Selection and Measurement

2.4.1.1 Three (3) test specimens of approximately 25 mm x 192 mm x

9.5 mm shall be cold cut from a coated pipe section in the

longitudinal direction, or test bars of this size coated in

accordance with 09-SAMSS-089 can also be used for this test.

2.4.1.2 The coating thickness shall be measured at 5 locations 25 mm

apart on each specimen, and the thickness recorded.

2.4.2 The specimens shall be holiday detected in accordance with paragraph 9.5

of this Specification, and all holidays shall be marked and recorded.

2.4.3 Bending

2.4.3.1 The specimens shall be placed in a freezer at 0°C for 30 minutes,

then removed and clamped in the bender with the coated side up.

The test 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

2.4.3.2 Bending shall be accomplished in less than 30 seconds. Allow

the coated specimens to return to ambient temperature and

inspect.




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2.4.4 Acceptance Criteria

2.4.4.1 The coated specimens shall show no cracks when examined at

10 X magnification, except where clamped or gripped.

2.4.4.2 Holiday test on the bent specimens will show no holidays in

addition to those already marked and recorded prior to bending.

2.4.4.3 Flexibility at 25°C is 5.5° / pipe diameter, at 0°C 3.75° / pipe

diameter.

2.4.5 The flexibility and bending qualification tests must be carried out at

thickness 575 -750 microns (23-30 mils) DFT.

2.5 Impact Resistance (ASTM G14)

2.5.1 Seven (7) specimens shall be tested for impact resistance at a

temperature of 10°C in accordance with ASTM G14.

2.5.2 Impact resistance of all seven specimens shall be 6.8 J (60 inch lbs) or

more. Freedom from penetration shall be verified using a low voltage

(67.5 volts DC) wet sponge holiday detector.

2.5.3 Minimum requirements for the impact resistance for coatings approved

for service in the higher temperature range shall be 11.3 J (100 inch lbs)

2.6 Adhesion Test

Three adhesion tests shall be conducted on a section from the production coated

pipe. The test procedure and evaluation shall be in accordance with paragraph

9.4.1

2.7 Cathodic Disbonding (ASTM G8)

Three specimens shall be tested by the procedure given in ASTM G8. The cured

powder coating when subjected to an impressed current at 1.5 volts shall not

disbond more than 12 mm radius from the edge of the intentional holiday in

30 days, at a test temperature of 25°C.

2.8 Chemical Resistance, Immersion Test

2.8.1 Three (3) specimens shall be half immersed for 30 days in each of the

following solutions at 80°C:

a) Distilled water

b) 5% Sodium Hydroxide




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c) 5% Sodium Chloride

2.8.2 Specimens shall also be tested in synthetic seawater at 93°C for 90 days.

Longer period test may be required if the specimens showed

irreproducible results.

2.8.3 None of the coated specimens shall show evidence of cracking, softening,

loss of adhesion, swelling, and discoloration. Blisters shall be not more

than (#6) or less in size as determined and defined by ASTM D714.

3. Tests for FBE Coatings to be used in Hot Subkha Service (up to 115°C)

3.1 Cathodic Disbonding ASTM G42 (Modified for higher temperature)

Three specimens shall be tested by the procedure given in ASTM G42.

The cured powder coating when subjected to an impressed current at 1.5 volts

shall not disbond more than 15 mm radius from the edge of the intentional

holiday in 30 days, at a test temperature of 82°C.

For High Temperature FBE powder coating, repeat the same test for the duration

of 60 days, at a temperature of 93°C. Coating shall not disbond more than

10 mm radius from the edge of the holiday.

3.2 The cathodic disbonding tests shall be carried out on panels with dry film

thickness not exceeding 625 microns (25 mils).

Commentary Note:

Should a coating pass the tests below this thickness, it would be considered satisfactory at the specified thickness.

3.3 Cross-Section and Interface Porosity

To determine the degree or porosity and voids in the applied coating cross

section and interface. The coating manufacturer shall consult with the RSA to

determine which test and acceptance criteria shall be considered in accordance

with international standard that shall be used.

3.4 Electrochemical Impedance Spectroscopy (EIS)

3.4.1 Prepare three (3) steel panels in accordance with Section 4.1.

3.4.2 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 1x108 ohm.cm². Coatings with




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recommended film thickness exhibiting lower electrochemical

impedance values shall be rejected.

3.5 Fingerprinting for Coating Identification

As part of the qualification procedure of a coating system, the supplier shall

submit to the RSA, a fingerprint of the coating obtained in accordance with

ISO 20340 (Annex B). The fingerprint shall be used in subsequent routine batch

testing of coating supplied for use in the field, to confirm that the supplied

coating is similar to the coating tested in the qualification stage.

09-SAMSS-089

Documents

fresh water

applied external

steel tubular

dry film thickness

steel line

consulting

glass transition

custom coated