Materials System Specification

09-SAMSS-089 7 February 2017

Shop-Applied External Fusion Bonded Epoxy Coating for Steel Line Pipes
Document Responsibility: Paints and Coatings Standards Committee

Contents

1 Scope ................................................................ 2
2 Conflicts and Deviations .................................... 2
3 References ........................................................ 3
4 Definitions .......................................................... 5
5 Health, Safety, and Environment ....................... 6
6 Material .............................................................. 6
7 Handling of Pipe Before Coating ....................... 8
8 Cleaning and Surface Preparation ..................... 9
9 Coating Application .......................................... 11
10 Quality Requirements ...................................... 13
11 Inspection Requirements ................................. 13
12 Recheck on Coating Material Qualities ............ 19
13 Repairs ............................................................ 20
14 Pipe Storage and Preparation for Shipment .... 20
Revision Summary .................................................. 21

Appendix A - Qualification Procedure for Initial

Product Approval ........................................ 22

Previous Issue: 15 October 2011 Next Planned Update: 7 February 2020

Page 1 of 29
Contact: Salazar Vidal, Oscar Daniel (salazaox) on phone +966-3-8809563

Saudi Aramco 2017. All rights reserved.

Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

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 pipes, single or double joint, 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 APCS-104A for buried or immersed, with temperatures not exceeding

65C in Subkha soil or subsea, or up 93C in dry soil condition.

1.2.2 APCS-104B for buried or immersed, with temperatures not exceeding

90C in Subkha soil or subsea, or up to 125C in dry soil condition.

1.2.3 APCS-104C for buried or immersion with temperature up to 130C.

1.3 For projects reviews, all protective coating requirements, specifications and
coatings map as per SAEP-303, shall be consolidated in Index H.

1.4 This standard shall be attached to, and made part of, purchase orders when
required.

1.5 Information Required with the Quotation

1.5.1 Cost if burn-off is required to remove oily contaminants from the surface
prior to blast cleaning (see paragraph 8.1).

1.5.2 Cost of UV protection if coated pipes will be stacked in the vendors

yard more than six months.

2 Conflicts and Deviations

2.1 Any conflicts between this specification and other Saudi Aramco Materials
System Specifications (SAMSSs), Engineering Standards (SAESs), Standard
Drawings (SASDs), or industry standards, codes and forms shall be resolved in
writing by the Company or Buyer Representative through the Manager,
Consulting Services Department of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

and forward such requests to the Manager, Consulting Services Department of

Saudi Aramco, Dhahran.

3 References

Referenced standards and specifications shall be the latest edition, revision or

addendum in effect on the date of the purchase order, unless stated otherwise.

3.1 Saudi Aramco Documents

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standards

SAES-H-001 Coating Selection and Application Requirements for
Industrial Plants and Equipment
SAES-H-002 Internal and External Coatings for Steel Pipelines
and Piping
SAES-H-200 Storage, Handling, and Installation of Externally
Coated Pipe
SAES-H-201 General Specifications for Over-the-Ditch External
and Internal FBE Coating of Field Girth Welds
SAES-W-012 Welding Requirements for Pipelines

Saudi Aramco Inspection Requirements

Form 175-091300 Coating: Shop Applied, Internal or External

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 Abrader
ASTM D4940 Standard Test Method for Conductimetric Analysis
of Water Soluble Ionic Contamination of Blasting
Abrasives
ASTM D7393 Standard Practice for Indicating Oil in Abrasives
ASTM G8 Test for Cathodic Disbonding of Pipeline Coatings
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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

International Organization for Standardization

ISO 8501-1/SIS Pictorial Surface Preparation Standard for Painting
Steel Surfaces
ISO 8502-3 Preparation of Steel Substrates before Application
of Paint and Related Products - Tests for the
Assessment of Surface Cleanliness - Part 3:
Assessment of Dust on Steel Surface Prepared for
Painting
ISO 8502-6 Preparation of Steel Substrates before Application
of Paint and Related Products - Tests for the
Assessment of Surface Cleanliness - Part 6:
Extraction of Soluble Contaminants for Analysis
ISO 8503-4 Preparation of Steel Substrates before Application
of Paints and Related Products - Surface
Roughness Characteristics of Blast-cleaned Steel
Substrates Part 4: Method for the calibration of
ISO Surface Profile Comparators and for the
Determination of Surface Profile - Stylus
Instrument Procedure
ISO 8503-5 Preparation of Steel Substrates before Application
of paints and Related Products - Surface
Roughness Characteristics of Blast-cleaned Steel
Substrates - Part 5: Replica Tape Method for the
Determination of the Surface Profile
ISO 21809-2 Petroleum and Natural Gas Industries - External
Coatings for Buried or Submerged Pipelines Used
in Pipeline Transportation Systems - Part 2:
Single layer Fusion-bonded Epoxy Coatings

Swedish Standard Institute

SS 05 59 00 Pictorial Surface Preparation Standard for Painting
Steel Surfaces

The Society for Protective Coatings (SSPC)

SSPC PA 2 Procedure for Determining Conformance to Dry
Coating Thickness
SSPC SP 1 Solvent Cleaning
SSPC SP 10 Very Thorough Blast Cleaning (near white metal
blast)

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

Canadian Standards Association

CAN/CSA-Z245.20-14 External Fusion Bond Epoxy Coating for Steel Pipe

NACE International
NACE SP0394-2013 Application, Performance, and Quality Control of
Plant-Applied Single-Layer Fusion Bonded
Epoxy External Pipe Coating

4 Definitions

Approved 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.
Approved Product: A coating material that has been approved by the RUS as meeting
the requirements of the applicable APCS or SAMSS. Only approved products are
allowed for use in Saudi Aramco jobs. These requirements apply to all coatings
referred to in all the SAES-H-series standards.
Batch: Specified quantity of material produced under the same uniform conditions
during a continuous production run by one Manufacturer.
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.
Corrosive Service: Generally, everything except treated seawater and refined products.
Custom Coated Pieces: All pipes not coated by automated in-plant equipment.
Generally, fittings, short spools and fabricated spools.
Cut-back: The length of pipe left uncoated at each end for joining purposes.
DFT: Dry film thickness
Fabricated Spools: Spools longer than 10 feet that cant be coated by the automated
process due to connection to flanges or other spools.
FBE: Fusion bond epoxy coating
Fitting: For purposes of this specification, fitting is used to refer to any custom
coated piece including valves and pumps.
Holiday: A discontinuity in applied coating that exhibits electrical conductivity when
exposed to a specific voltage.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

Manufacturer: Company which manufactures FBE powder coatings and corresponding

repair materials.
Maximum Operating Temperature: Maximum temperature that can be reached
during operation of pipeline.
Non-Corrosive Service: Treated Seawater or Refined Products
Overlap: Length of the field joint coating over the plant-applied coating including the
coating bevel.
Pipe: For purposes of this specification pipe is used to refer to steel tubular,
including line pipe and OCTG casing and tubing.
Responsible Unit Supervisor (RUS): The Engineering Consultant of Nonmetallic,
CP & Coatings Group who is designated by the Manager, Consulting Services
Department.
Test Ring: A sample taken from production-coated pipe or a pup piece pipe, having the
same specification of coated pipes, coated in the same production line.
Vendor: FBE coating applicator

5 Health, Safety, and Environment

Applicable safety requirements addressed in Section 5 of SAES-H-001 shall be followed.

6 Material

6.1 FBE External Coating

6.1.1 Material for the shop-applied external coating shall be in a form of

thermosetting resin powder suitable for application by the fusion bond
process as tested and approved by Saudi Aramco, and applied
according to the Manufacturer's recommendation.

6.1.2 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. If the reclaimed powder found contaminated at the
end of the production, reclaimed powder shall be stopped.

6.1.3 The Vendor shall use only Saudi Aramco approved products under
APCS-104A, APCS-104B or APCS-104C for the intended service.

6.1.4 Any approved coating that is subjected to modifications and/or

reformulations, or replacement including change of names or
re-branding shall be requalified.
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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

6.1.5 Powder coating materials supplied to the Vendor shall be certified by

Manufacturer with the following information, which must meet
initially approved material:
a) The Manufacturer's name
b) Product description
c) Mass of material
d) The material identification number
e) The batch number
f) Date of manufacture
g) Location of manufacturing
h) Temperature required for transportation and storage
i) The shelf life (or expiration date)
j) Material identification fingerprints

6.1.6 Each batch of FBE coating must be tested and certified by the
Manufacturer in accordance with the requirement of Table 1.
Vendor shall conduct the same tests to verify compliance with the
requirements.

Table 1 - Epoxy Powder Properties

Property Acceptance Criteria Test Method

Density Meets Manufacturer specification CSA Z245.20 Clause 12.6

3.0% maximum retained on 150 m
Particle Size mesh and 0.2% maximum
retained on 250 m mesh.
Gel Time Meets Manufacturer specification
Cure Time Meets Manufacturer specification
CSA Z245.20 Clause 12.5
CSA Z245.20 Clause 12.2
CSA Z245.20 Clause 12.1

Moisture Content 0.5% maximum CSA Z245.20 Clause 12.3

Thermal Meets Manufacturer specification

CSA Z245.20 Clause 12.7
Characteristics for Tg1 (C), Tg2 (C), H (J/g)

6.1.7 The Vendor shall retain samples of each powder batch for a period of
2 years or until the expiration date. The sample shall be of sufficient
size to run duplicates for the following tests if required:
a) Instrumental Analyses: FT-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-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

e) Cathodic disbondment tests

6.1.8 Coating material shall be stored and handled in accordance with the
coating manufacturer's recommendations. Expired material shall not
be used.

6.2 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 materials shall be marked with the information in
paragraph 6.1.5. Manufacturer should identify the repair material before starting
the qualification process to be included in the testing program, if needed.
Touch-up material shall be stored, handled, and applied in accordance with the
manufacturer's specifications.

6.3 Blast Abrasives

6.3.1 Abrasives for blast cleaning shall be Garnet in accordance with the
requirement of paragraph 6.3 and 8.2 of SAES-H-001. Abrasives for
blast cleaning shall have less than 50 PPM sulfates and less than 50 PPM
chlorides. They shall be of a particle size that will produce a clean,
angular surface profile as specified in paragraph 8.4 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.

6.3.2 The Vendor shall furnish a chemical analysis for all batches of abrasives
to verify compliance with the requirements in paragraph 6.3.1.

7 Handling of Pipe before Coating

7.1 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.

7.2 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.

7.3 Vendor shall have an approved procedure (see paragraph 1.4) for handling,
loading, unloading, storage and preparation for shipment for pipe and fittings

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

prior to coating.

8 Cleaning and Surface Preparation

8.1 Prior to abrasive cleaning, all oil, grease and other deleterious materials shall be
removed by solvent cleaning in accordance with SSPC SP 1 or by detergent
washing or steam cleaning. No residue that will affect adhesion shall be left on
the surface.

Oven burn-off at a temperature of 370 - 400C may also be employed, if, in the
opinion of the Vendor, this is the only satisfactory method of insuring that the
steel is free of oily contaminants. The reported oily contamination shall be
investigated and confirmed by the Buyer's Representative and written approval
shall be obtained from the Buyer prior to burn-off. All pipe and fittings which
have been received with internal mill varnish or other deleterious coatings or
have been in previous oil service shall always be burned off.

8.2 The pipe or fitting surface temperature shall be at least 3C above the dew point
and humidity shall be less than 80% during abrasive blasting until the primer
application and until startup of pre-heating. If preheating is used, it shall be
carried out in a uniform manner to avoid distortion.

8.3 The surface to be coated shall be abrasive cleaned to a near white metal surface
finish equal to Sa 2- as described in ISO 8501-1 or SSPC- SP10/NACE No 2.
Internal coating shall be protected from damage by the blasting material at all
times.

8.4 The anchor profile shall be 50-100 micrometers. Anchor profile shall be
measured by Stylus type profile meter (ISO 8503-4). Replica tape (ISO 8503-5)
can be used in area where Stylus profile meter cant be used. Abrasives,
including recycled materials, shall be maintained clean, dry, and free from
contaminants in accordance with SSPC-AB2 and SSPC-AB3. Vendor should
have a written procedure for monitoring size, shape, dryness and cleanliness of
the blasting material. Oil contamination shall be checked twice per shift on the
re-circulated abrasives in accordance with ASTM D7393.

8.5 Dust level shall be less than Class 1, as per ISO 8502-3. Test the first 5 pipes
and/or fittings on any given day. After that, test one out of every 10 pipes or
10 fittings.

8.6 Defects

8.6.1 Weld spatter, rough weld surfaces, and sharp protrusions shall be
ground smooth.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

8.6.2 When serious defects such as mentioned in paragraph 7.2 are found
following the abrasive cleaning operation, the affected pipe or fitting
shall be set aside for disposition by the Buyer's Representative.

8.6.3 If these anomalies affect enough of the pipe or fitting to the extent that
the coating process is severely disrupted, the coating process shall be
stopped and the Buyer informed. The Vendor shall advise the Buyer of
any remedial measures that could be taken to achieve an acceptable
coating. The Vendor shall make the final decision, after consultation
with the Buyer's Representative, whether the affected pipe or fittings
can be coated.

8.7 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 or the relative humidity is above 80%.

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

8.8 Chloride Contamination

8.8.1 The blasted surface of pipes and fittings shall be tested for the presence
of residual chlorides after blasting using a test method that has been
prior-approved in writing by the RUS. Residual chlorides shall be no
greater than 20 mg/m.

8.8.2 Test a random location on the first pipe and/or fitting coated on any
given day. After that, test one pipe joint out of every 30 pipes or
20 fittings.

8.8.3 In the event of a failure, re-test the piece. If it fails the re-test, test all
pieces that were blast cleaned both before and after the contaminated
piece until five in a row pass the test. All pieces coated after the last
good test must be re-blasted, re-tested, and re-coated.

8.8.4 If the phosphoric acid/fresh water wash is needed prior to application

of the FBE powder, Vendor must use an approved procedure by RUS.
The procedure should include, at least, the following:

8.8.4.1 Required pH level after wash shall be controlled.

8.8.4.2 Description of the acid wash process and qualification shall

be provided.

8.8.4.3 Dwell time, pH, and minimum temperature controls.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

8.8.4.4 A thorough, clean, high-pressure water rinse at 500 to

1,000 psi (35 to 70 bar) tip pressure must follow to remove
any treatment residue.

8.8.4.5 Quality of water and control of total dissolved solids and

chlorides control.

8.8.4.6 Provisions and controls to avoid acid to dry on pipe with

residual heat or to avoid traces of acid or reactive products to
be left on surface.

8.8.5 Pipe or fittings treated in this manner may not require testing for
chloride contamination, provided that vendor has shown proof of
consistency in the process.

8.9 Maximum time between blasting and coating shall be 4 hours and any metal
surface showing evidence of flash rusting shall be re-blasted prior to coating.
A minimum light intensity at the inspection site of 100 foot-candles (1,000 Lux)
is required for visual inspection of the surface.

Table 2 - Summary of Surface Preparation Tests

Test Test Method Acceptance Criteria Frequency
Surface Cleanliness Para. 8.3 Sa 2.5 All
Anchor Profile Para. 8.4 50~100 m All
First 5 pipes or fittings on
Dust grade Para. 8.5 Less than Class 1 any given day then every
10 pipes or 10 fittings
Free of weld spatter,
Defects Para. 8.6 rough weld surfaces All
and sharp protrusions
3C above steel
Dew Point Para. 8.7 Every 2 hours
temperature
Relative Humidity Para. 8.7 Less than 80% Every 2 hours
First pipe and/or fitting on
Residual Chloride Para. 8.8 Less than 20 mg/m any given day then every
30 pipes and 20 fittings

9 Coating Application

9.1 The FBE coating material shall be applied according to the Vendor's approved
application procedure, which incorporates the Manufacturer's recommendations.
The Vendor shall submit his application procedure to the RUS for Saudi Aramco
approval prior to application. Already approved procedures do not require RUS
review and approval on new purchase orders, unless otherwise it is required by
the Buyer's representative or any other standards documents.
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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
Next Planned Update: 7 February 2020 Epoxy Coating for Steel Line Pipes

9.2 Pipe surface temperature shall be maintained and monitored to be within coating
Manufacturer specified curing temperature until the coating is fully cured.
Surface temperature and interval time of each process shall be measured
immediately prior to coating application, after coating application and before
quenching.

9.3 In no case shall steel pipes and associated fittings and couplings, which have
been internally coated, be exposed to a temperature detrimental to the internal
coating. In all pipes, the lining shall be visually inspected after application of
external FBE and result must be reported in the inspection sheet.

9.4 The coating dry film thickness shall be as follows, unless otherwise agreed upon
in writing by the Buyer.

9.4.1 350 to 525 micrometers (14 to 21 mils) for the services described in
paragraph 1.2.1

9.4.2 575 to 750 micrometers (23 to 30 mils) for the service described in
paragraph 1.2.2

9.4.3 As recommended by coating manufacturer for the service described in

paragraph 1.2.3

9.4.4 Fittings and couplings are allowed a maximum DFT of 50 microns

above the values in 9.4.

9.5 Any pipes products and associated fittings and couplings having a thickness
outside the specified DFT range shall be re-blasted and coated at no cost to
Saudi Aramco.

9.6 The finished coating shall have a cut back at each end in the range of 50 to 75 mm
measured from end of pipe, on pipes of 6 diameter and above and in the range of
25 to 50 mm on pipes with less than 6 diameter. If longer cut-back is needed,
RUS shall be consulted.

9.7 The cured coating shall be of uniform color and gloss, and shall be free of blisters,
bubbles, sags, voids fish eyes and any other irregularity. The coated surface shall
be 100% visually inspected to ensure it is free of such irregularities.

9.8 In Double Jointed pipes at girth weld areas, the allowable DFT shall be in the in
accordance with 9.4.4.

9.9 The internal root reinforcement shall be 1.5 mm or less, as per SAES-W-012,
paragraph 16.10.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
Issue Date: 7 February 2017 Shop-Applied External Fusion Bonded
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10 Quality Requirements

The Vendor's quality assurance system during the coating application shall include the
following as minimum requirements:

10.1 Checking cleanliness of pipe and/or fittings immediately prior to blasting (see
paragraph 8.1).

10.2 Monitoring of size, shape, dryness and cleanliness of the blasting material and
process (see paragraph 6.3).

10.3 Checking visually, in good light, the inner surface for metal defects, dust and
surface debris (see paragraph 8.6).

10.4 Checking blasted surface profile (see paragraph 8.4).

10.5 Checking temperature control of the surface (see paragraph 8.2).

10.6 Checking thickness of cured coating (see paragraph 11.4).

10.7 Checking on the coating adhesion properties (see paragraph 11.5).

10.8 Holiday detection of 100% of the surface area of all pipes and fittings
(see paragraph 11.6).

10.9 Supervision of adequate and proper repair of all defects.

10.10 Checking of coating color, appearance and uniformity (see paragraph 9.7).

10.11 Cure Test - see paragraph 11.8.

10.12 Conduct required test on Production test Rings (see paragraph 11.9).

11 Inspection Requirements

11.1 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.

11.2 Responsibility for Inspection

11.2.1 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.

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Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-089
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11.2.2 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.

11.2.3 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.

11.3 Visual Inspection

The external 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.

11.4 Thickness Test

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 11.10.1. All results shall be as specified in paragraph 9.4
and shall be recorded.

11.5 Adhesion Test

11.5.1 General Requirements

11.5.1.1 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.

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11.5.1.2 For custom coated pieces test two samples per production
lot.

11.5.1.3 Failure of the adhesion test shall require lot narrowing by

testing the pipes or fittings until five 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.

11.5.1.4 The weld cutback on selected pipe lengths or fittings (see

paragraph 9.5) 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
Section 12 of this specification.

11.5.2 Adhesion Test Procedure

11.5.2.1 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.

11.5.2.2 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
intersection of the X such that the blade point is on the
metal surface. Using a levering action, the flat point shall
be forced away from the steel in an attempt to pry off the
coating. Refusal of the coating to disband from the
substrate shall be recorded as a pass. A pass shall also
be recorded where the coating fails cohesively. Partial or
complete adhesive failure between the coating and the
substrate shall be recorded as a failure. Disbondment at the
point of the intersection is common due to the action of
marking the 'X' cut. Therefore, for 1 mm away from the tip
of the intersection any disbondment shall be ignored.

11.5.2.3 The pipe shall be allowed to cool to below 80C prior to

conducting the adhesion test. Failure of the test shall
require each piece coated on that day to be subjected to the
test until a total of three tests in a row (three done both
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before and after the piece which failed) are satisfactory.

11.6 Holiday Detection

11.6.1 100% of the internally coated surface area of the pipe shall be tested
with a hot spark, pulse-type DC holiday detector employing an audible
signaling device. The electrode used for locating holidays shall be
designed to ensure direct contact with the coating (with no visible gaps).

11.6.2 Travel rate of the detector electrode shall not exceed 30 cm/sec.
The electrode shall not be allowed to remain stationary while the
power is on.

11.6.3 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 2,400 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.

11.6.4 The allowable number of holidays rate that can be repaired before
other special measures are required, is as follows:

11.6.4.1 For pipe smaller than 14 inches OD, one holiday per meter
length, determined by dividing the total number of holidays
by the total pipe length, expressed in meters, for the
individual pipe tested.

11.6.4.2 For pipe of 14 inches OD or larger, 0.7 holidays per square

meter, determined by dividing the total number of holidays
by the total outside surface area, expressed in square
meters, for the individual pipe tested.

11.6.4.3 If the quantity of holidays exceeds the limit specified

above, the affected pipe shall be stripped and recoated.

11.7 Bend Test

11.7.1 Once per shift (or, for pipe, every one hundred pipe lengths, whichever
is the more frequent) and at the start of using a new batch of powder
the flexibility of the coating shall be determined by a bend test.
The powder utilized for the test shall be taken from the plant
application fluidizing bed.

11.7.2 Two test bars measuring approximately 25 mm x 192 mm x

(6.5-9.5) mm shall be coated at a dry film thickness specified for each
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coating system.

11.7.3 The coating thickness shall be measured at 5 locations 25 mm apart on

each sample, and the thickness recorded. The average of these
readings shall fall in the range in paragraph 11.7.2.

11.7.4 The test bars shall be holiday detected in accordance with paragraph
11.7.7 of this specification, and all holidays marked and recorded.

11.7.5 The specimens shall be at three different temperatures 5, 10,

and 25C 3C when clamped in the bender with the coated side up.
The specimens shall be bent flat wise at the angles of 3.0, 3.75 and
5.5, respectively.

11.7.6 Bending shall be accomplished in less than 30 seconds.

11.7.7 The coated specimens shall show no cracks to base metal when
examined at 10X magnification except where gripped or clamped.
If visual examination cannot determine whether a crack extends to base
metal, holiday testing using the hot spark detector method with a
conductive rubber electrode shall be used. Tests are to be carried out
as required in paragraph 11.6.3 of this specification. If no holidays are
signaled, the crack-like defect is acceptable.

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

11.7.8.1 If both bend retests are satisfactory, the bend test shall be
accepted.

11.7.8.2 If either (or both) of the retests fail, immediately

discontinue further coating with the suspect batch of
powder and proceed as follows:
a) Pipe: All pipes coated since the previous successful
bend test shall be set aside. Two specimens with the
same dimensions as given in paragraph 11.7.2 shall be
cold cut from the production coated pipes in question
and subjected to the bend test. The edges of the
specimens as necessary shall be chamfered to remove
stress raisers. As many specimens as necessary shall
be tested until the Buyer's Representative is satisfied
that all pipes with substandard coatings have been
identified. These pipes shall be rejected.
b) Fittings: All fittings coated with the suspect powder
shall be re-blasted and recoated.
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11.7.9 If deemed necessary in some critical applications or according to an

end-user request, the RUS shall request the Vendor to prepare the Bend
test samples from a coated pipe section. Samples shall be cut in both
radial and longitudinal directions from the pipe section to suit the Bend
test requirements. The procedure of the test shall be as shown above.

11.8 Cure Test

Twice per shift the coating on production pipes shall be tested by Differential
Scanning Calorimeter analysis in accordance with CSA Z245.20 Clause 12.7 for
cured coating. Custom coated fittings and spools shall be subjected to the same
test at a frequency of three 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 (Tg4-Tg3) must be in the range specified by the FBE Manufacturer,
within 3C. Any coated pipes, girth welds, or fittings fail the test within the
acceptable range shall be rejected.

11.9 Production Test Ring

Vendor should obtain a test ring from the pipe end, at least 500 mm, to be
subjected to the tests listed in Table 3. The minimum test frequency, for each
production line, shall be one test ring per pipe diameter and specified wall
thickness every working shift, a minimum of once every 12 h.

Table 3 - Production Test Ring Requirements

Test
Test Acceptance Criteria Test Method
Specimens
Flexibility: (3.0 /PD, No cracks, tears, NACE SP0394-2013,
3
Test temperature: 0C) delamination, or disbondment (Appendix H)
5.5/Pipe Diameter Flexibility No cracks, tears, NACE SP0394-2013,
3
@ 25 Celsius delamination, or disbondment (Appendix H)
Hot-water soak
NACE SP0394-2013,
Hot-water adhesion: Rating of 1 1
(Appendix J)
(48 hours) 75 3C
CSA Z245.20,
Interface contamination 5% 1
Clause 12.9.3
Cathodic Disbondment CSA Z245.20,
10 mm 1
24 hours @ 65C, -3.5 V Clause 12.8
CSA Z245.20,
Cross-section porosity Rating of 1 1
Clause 12.10.3
Tg = -2, +3C, 95% CSA Z245.20,
Thermal characteristics 1
conversion Clause 12.7.3.2.2
DFT Para 9.4 1 SSPC-PA2

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11.10 Calibration of Inspection Equipment

11.10.1 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.

11.10.2 The holiday detector shall be calibrated at least twice per 8-hour shift
against a suitable calibrated voltmeter.

11.11 Internal coating shall not be subjected to double heating, in case the external
coating is rejected and recoating is required.

Table 4 - Summary of Coating Application Requirements

Test Acceptance
Test Frequency
Method Criteria
Dry Film Thickness Para. 11.4 As specified in Para. 11.4 All
25-50 mm (less than 6 inch dia.)
Cutback Para. 9.6 All
50-75 mm (larger than 6 inch)
Internal Root
Para 9.9 1.5 mm or less All
Reinforcement
First joint or once every hour or
every twenty pipe lengths.
If three tests successful, every
Adhesion Test Para. 11.5 Pass 2 hours or 50 pipe lengths for
pipe
One sample per production lot
for custom coated pieces
Holiday Detection Para. 11.6 Para. 11.6 All
Once per shift and at the start
Bend Test Para. 11.7 No crack of using a new batch of
powder
For pipe twice per shift
Cure Test Para. 11.8 (Tg4-Tg3) = -2, +3C For fittings three sample per
production lot
Production Test Ring Para. 11.9 Table 3 Once per shift

12 Recheck on Coating Material Qualities

The Buyer's Representative at any time may require that the Vendor prepare a set of test
specimens as defined in Appendix A, and arrange for the performance of any or all of
the tests covered by Appendix A at a laboratory agreeable to the Buyer. Provided the
coating on the specimens passes the tests, the Buyer shall pay for the tests; otherwise
the Vendor shall pay the costs.

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13 Repairs

13.1 Repair materials shall be as specified under paragraph 6.2 of this specification,
and repairs shall be in accordance with the approved procedure.

13.2 Abrasive blasting and patch repair work shall not be conducted when the metal
surface temperature is less than 3C above the dew point.

13.3 Repaired areas shall be retested for holidays per paragraph 11.6 and shall be
holiday free.

13.4 Each length of coated pipe leaving the Vendor's premises shall be free of
holidays and any visual coating defects.

13.5 Defects shall be repaired in accordance with the criteria and methods below:

13.5.1 Small Defects (Areas up to 2 mm diameter or 3.2 mm such as small

pinholes and metal slivers repair) shall be done with either hot melt
stick or two part liquid epoxy coating.

13.5.2 Large Defects (Areas greater than 2 mm in diameter and less

than 250 cm) repair shall be done with two part liquid coating.
Repairs shall be in accordance with the coating Manufacturer's
recommended procedure.

13.5.3 Areas exceeding 250 cm, the joint shall be rejected.

Exception:

Hot melt sticks shall not be used for the repair of FBE used for services described
in paragraphs 1.2.2 and 1.2.3.

14 Pipe Storage and Preparation for Shipment

14.1 Each coated length of pipe shall be externally stenciled at a point approximately
60 cm (2 ft) 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.

14.2 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
12.2 m length, 5 per 24.4 m length shall be used to separate the pipe for yard
transportation and storage.

14.3 Padding material and procedures shall be approved by the Buyer's Representative.

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14.4 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. Pipe shall not be stored directly on the ground.

14.5 End caps or any suitable end covers shall be used to prevent sand, water, and
other contaminants in getting in contact with the internal coating if applied.
End seal tapes shall be used to keep the end caps or end covers in place and to
protect the cut-back from corrosion and surrounding contaminants.

14.6 If FBE coated pipes are to be stored at Vendors yard for more than six (6)
month, the stacked pipes must be protected from UV exposure by using
tarpaulins or other approved means of protection as per SAES-H-200. If stored
pipes are not protected for a year or more, the coating must be requalified by
taking test rings from several pipes to be tested in accordance with Table 3.

14.7 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.
7 February 2017 Major revision to clarify some of the requirements, summarize required tests in tables,
specify coating thickness for each system, revise acceptance criteria, highlight safety
requirements, add new tests to be in line with international standards such as dust level,
porosity, abrasion, EIS and production test ring. In addition, qualification requirements of
high temperature FBE coatings (APCS 104C) were added and addressed the provisions for
the long term storage of FBE coated pipe in applicator yard.

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Appendix A - Qualification Procedure for Initial Product Approval

1. General Requirements
Qualification of any product under this specification shall be in strict compliance with
SAEP-1200. In order to qualify a coating system as acceptable under this specification,
the coating supplier must submit a certified test report documenting to the RUS that the
proposed coating system meets the qualification tests and requirements of this SAMSS.
Preparation and testing shall be performed and/or witnessed by an independent laboratory
or inspection agency. This report shall be submitted to Saudi Aramco Coating / CSD for
review and approval.

Laboratory Report
Testing can only be considered if conducted at a third party laboratory that is accepted
by Saudi Aramco.
The third party test report shall include all the tests mentioned in this specification,
unless otherwise specified by CSD approved test protocol.
The final report shall include illustrative photos of all panels before and after testing.
The third party laboratory shall report the results of the tests to Saudi Aramco, first.
Upon approval, the report can be then released to the Manufacturer. The third party
laboratory can only report the results. However, interpretation of the results and
making the final conclusion is solely the role and responsibility of CSD.
All initial product qualification tests shall be carried out at no cost to Saudi Aramco.
Along with any coated sample supplied for testing, the coating manufacturer/vendor
shall submit the following documents: coating manufacturers location, date of
manufacturing, batch/lot numbers of coatings used and product data sheet.
Test specimens shall be coated using electrostatic flocking method.
If the operating conditions for a certain project are not addressed in Tables 6 and 7,
re-qualification test is required at the R&DC.

2. References
2.1 Saudi Aramco Engineering Standard
SAES-H-002 Internal and External Coating for Steel Pipelines and Piping
2.2 Industry Codes and Standards
ASTM D714 Evaluating the Degree of Blistering of Paints

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ASTM D4541 Pull Off Strength of Coatings

ASTM D4060 Standard Test Method for Abrasion Resistance of Organic
Coatings by the Taber Abrader
ISO 8501-1 Preparation of Steel Substrates Before Application of Paints
and Related Products - Visual Assessment of Surface
Cleanliness

3. Qualification Tests

3.1 Instrumental Analysis

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

Fourier transform infrared spectroscopy (FT-IR) and Differential scanning
calorimetry (DSC) techniques in a laboratory approved by the RUS.

3.2 Preparation of Test Specimens

3.2.1 Test specimens shall be as outlined in the applicable test specification

unless otherwise stated.

3.2.2 Surface preparation, application, dry film thickness, and curing parameters
for the test specimens shall be identical to that used in this coating
specification.

3.2.3 Prior to each test the specimens shall be conditioned for 24 hours at 25C
and 50% relative humidity.

3.3 Flexibility/Bending Test

Three (3) test specimens as detailed in paragraph 11.7.2 of this specification shall
be tested and evaluated in accordance with paragraphs 11.7.3 through 11.7.7 of
this specification.

3.4 Adhesion Test (ASTM D4541)

An adhesion test shall be conducted on specimens after exposure (up to 24 hours

recovery time allowed) to the chemical resistance tests in paragraph 3.6 below
using an Elcometer or Hate Adhesion Tester. A pull-off value of not less than
2,000 psi is required. Tester must be run and a pull-off value of not less than
2,000 psi confirmed.

3.5 Electrochemical Impedance Spectroscopy (EIS)

At ambient temperature, conduct electrochemical impedance spectroscopy (EIS)

measurements, after exposing the coated panels to 3% NaCl solution for no less

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than 24 hours, to obtain initial electrochemical impedance values. The initial values
must be greater than 1 x 1010 ohmcm2 at an applied signal frequency of 0.01 Hz.
Coatings with the recommended film thickness exhibiting lower electrochemical
impedance values shall be rejected. EIS shall be conducted after the chemical
resistance test and the value should be more than 90% of the initial reading.

3.6 Cathodic Disbondment Tests

Cathodic disbondment shall be performed according to CSA Z245.20 -2014

(clause 12.8) with the following modification: the sodium chloride solution and
the coated sample shall be heated separately and temperature shall be as follows:

Table 5 - Cathodic Disbondment Tests Temperature

Sodium Chloride Solution
Coating System Sample Temperature (C)
Temperature (C)
APCS 104A 75 65
APCS 104B 95 80-90
APCS 104C 130 85-95

3.7 Abrasion Resistance Test

The test should be conducted in accordance with ASTM D4060. The abrasive
wheels shall be CS-17 with a load of 1,000 grams on each wheel and for
1,000 cycles. The mass lose should be below 100 milligrams.

3.8 Porosity of the Coating

The test should be conducted in accordance with CAS Z245.20, Clause 12.10.
The acceptance criteria for both cross-section porosity and interface porosity is
Rating 1-2.

3.9 Impact Resistance

3.9.1 The test should be conducted in accordance with CAS Z245.20,

Clause 12.12 with the following modification:
3.9.1.1 Testing temperature is 10C.
3.9.1.2 Impact energy is 4.0 Joules.

3.10 Chemical Resistance Chemical Resistance, Immersion Test

3.10.1 Chemical resistance test shall be conducted in glass beakers covered with
watch glass to prevent evaporation. The glass beaker was filled with
enough medium to immerse half the length of the test specimen securely
held in the non-conducting sample holder. Electrochemical Impedance
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Spectroscopy (EIS) before and after immersion shall be conducted to

assure the coating maintain the barrier property after chemical exposure.

3.10.2 Three (3) specimens of all side coated test specimen of 2 6 0.25
shall be half immersed for 30 days in each of the following solutions at
80C for APCS 104A and 95C for APCS 104B and APCS 104C:
a) Distilled water
b) 5% Sodium Hydroxide
c) 5% Sodium Chloride

3.10.3 Specimens shall also be tested in synthetic seawater at 65C for

APCS-104A, 95C for APCS-104B and APCS-104C for 90 days.
Longer period test may be required if the specimens showed
irreproducible results.

3.10.4 None of the coated specimens shall show evidence of cracking,

softening, swelling, blistering, and discoloration. Loss of adhesion
(as per EIS measurements) shall not be equal or greater than specified
impedance value of 1.0 108 ohmcm at 0.1 Hz, characteristic of good
barrier properties for coating performance.

Table 6 - Coating System Qualification Requirements for APCS-104A and APCS- 104B

Acceptance Criteria
No. of
Test APCS-104A APCS-104B Test Method
Specimens
5.5/Pipe Diameter No cracks, tears, No cracks, tears,
NACE SP0394-2013
Flexibility delamination, delamination, 3
(Appendix H)
@ 23 Celsius or disbondment or disbondment
No cracks, tears, No cracks, tears,
3.75/Pipe Diameter NACE SP0394-2013
delamination, delamination, 3
Flexibility @ 0 Celsius (Appendix H)
or disbondment or disbondment
Impact Resistance 4.0 Joules 4.0 Joules CSA Z245.20,
3
@ 10 Celsius minimum minimum Clause 12.12
Cathodic Disbondment
10 mm N/A CSA Z245.20 3
30 days @ 75C, -1.5 V
Cathodic Disbondment
N/A 10 mm CSA Z245.20 3
30 days @ 95C, -1.5 V
Chemical Resistance:
(Para. 3.10) (Para. 3.10) (Para. 3.10) 3
Distilled Water
Chemical Resistance:
(Para. 3.10) (Para. 3.10) (Para. 3.10) 3
5% NaOH
Chemical Resistance:
(Para. 3.10) (Para. 3.10) (Para. 3.10) 3
5% NaCl
Chemical Resistance:
(Para. 3.10) (Para. 3.10) (Para. 3.10) 3
Synthetic Sea Water

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Acceptance Criteria
No. of
Test APCS-104A APCS-104B Test Method
Specimens
Interfacial Porosity Rating 1-2 Rating 1-2 CSA Z245.20 3
Cross Section Porosity Rating 1-2 Rating 1-2 CSA Z245.20 3
Electrochemical
(Para. 3.5) (Para. 3.5) (Para. 3.5) 3
Impedance - as per 3.5

Table 7 - Coating System Qualification Requirements for APCS-104C

No. of
Test Acceptance Criteria Test Method
Specimens
Tg Greater than 145C 1
Cure Delta Tg Less than -2, +3C 2
5.5/Pipe Diameter Flexibility No cracks, tears, delamination, NACE SP0394-2013
3
@ 23 Celsius or disbondment (Appendix H)
3.75/Pipe Diameter Flexibility No cracks, tears, delamination, NACE SP0394-2013
3
@ 0 Celsius or disbondment (Appendix H)
Impact Resistance
3.0 Joules minimum (Para. 3.9) 3
@ 10 Celsius
Cathodic Disbondment
10 mm (Para. 3.6) 3
30 days @ 95C, -1.5 V
Chemical Resistance:
(Para. 3.10) (Para. 3.10) 3
Distilled Water
Chemical Resistance:
(Para. 3.10) (Para. 3.10) 3
5% NaOH
Chemical Resistance:
(Para. 3.10) (Para. 3.10) 3
5% NaCl
Chemical Resistance:
(Para. 3.10) (Para. 3.10) 3
Synthetic Sea Water
Interfacial Porosity Rating 1-2 (Para. 3.8) 3
Cross Section Porosity Rating 1-2 (Para. 3.8) 3
Electrochemical
(Para. 3.5) (Para. 3.5) (See 3.5)
Impedance - as per 2.8.2

3.11 Fingerprinting for Coating Identification

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

submit to the RUS, 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.

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