Professional Documents
Culture Documents
09-SAMSS-089
25 October 2011
Shop-Applied External Fusion
Bonded Epoxy Coating for Steel Line Pipes
Document Responsibility: Paints and Coatings Standards Committee
Scope............................................................. 2
References..................................................... 3
Materials......................................................... 5
Coating Application........................................ 8
Quality Requirements.................................... 9
Inspection Requirements............................. 10
10
11
Repairs......................................................... 14
12
Page 1 of 22
Scope
1.1
This Specification, together with the Purchase Order and appropriate Data
Sheets, defines the minimum mandatory requirements of shop-applied, heatcured external fusion-bonded epoxy (FBE) coating systems for the external
surfaces of steel tubular products and associated fittings and couplings.
1.2
1.3
1.2.1
1.2.2
1.2.3
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.
Page 2 of 22
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
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.
References
Material or equipment supplied to this specification shall comply with the latest edition
of the references listed below, unless otherwise noted.
3.1
Page 3 of 22
SAES-H-100
ASTM D4060
ASTM G8
ASTM G14
ASTM G42
SSPC SP 1
Solvent Cleaning
SSPC SP 10
Page 4 of 22
NACE International
NACE PR0394 - 94
Materials
4.1
Coating
4.1.1
4.1.2
4.1.3
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:
4.1.5
a)
b)
c)
d)
Date of manufacture
e)
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)
b)
Gel Time
c)
Moisture Content
d)
Bend tests
Page 5 of 22
e)
4.1.6
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.
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
5.4
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.
Page 6 of 22
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 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
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/m. 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 7 of 22
6.6
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
6.6.3
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
3C above the dew point.
6.8
Any metal surface showing evidence of flash rusting shall be re-blasted prior to
coating.
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
Page 8 of 22
7.3.1
7.3.2
7.3.3
575 to 750 microns (23 to 30 mils) for the service described in paragraph
1.2.3
7.3.4
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).
Quality Requirements
The Vendor's quality assurance system shall include, as a minimum, the following:
a)
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)
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)
Page 9 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)
k)
l)
m)
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
9.3
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.
Page 10 of 22
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)
b)
c)
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
9.4.1.2
9.4.1.3
9.6
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 80C.
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.
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
9.6.3
9.6.4
9.6.5
- Shoe radius
95.2 mm
- Chord
152 mm
- Arc
178 mm
9.6.6
9.6.7
9.6.8
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 13 of 22
10
9.8.2
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
11.3
total damaged area exceeds 1860 cm, 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.
b)
c)
The patch coating shall not be applied when the pipe surface
temperature is less than 3C above the dew point.
12
a.
b.
c.
d.
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 16 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
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.
25 October 2011
Revision Summary
Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with editorial revisions including removing the committee members list.
Page 17 of 22
General Requirements
1.1
b)
Certification by the Supplier that the proposed coating meets the following:
c)
1.2
2.
Has passed all the tests and met all the requirements of this
qualification procedure.
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.
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
2.2.2
2.2.3
2.3
2.4
Prior to each test the specimens shall be conditioned for 24 hours at 25C
and 50% relative humidity.
2.3.2
2.3.3
2.4.1.2
2.4.2
2.4.3
Bending
2.4.3.1
2.4.3.2
95.2 mm
Chord
152 mm
Arc
178 mm
Page 19 of 22
2.4.4
2.4.5
2.5
2.6
Acceptance Criteria
2.4.4.1
2.4.4.2
2.4.4.3
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
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
2.8
Three (3) specimens shall be half immersed for 30 days in each of the
following solutions at 80C:
a)
Distilled water
b)
5% Sodium Hydroxide
Page 20 of 22
c)
3.
5% Sodium Chloride
2.8.2
2.8.3
Tests for FBE Coatings to be used in Hot Subkha Service (up to 115C)
3.1
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
3.4
3.4.2
Page 21 of 22
Page 22 of 22