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COATINGANDPAINTING

Introduction
DocumentsAndSpecifications
StorageAndHandlingofpipe
PreCautionduringWelding
InternalCoating
ExternalCoating
Holidaytesting
ExternalFBERepair
LoweringandBackfilling
Introduction
AbuJifantrunklinesincludea12inchtrunkline,900#,6.562KMfromanewAbu
JifanmanifoldRH13AtoexistingAbuJifanmanifoldRH13(ABJF1).

18inchtrunkline,900#,24.642KMfromexistingAbuJifanmanifoldRH13tonew
intermediateGOSP(ABJF2).

Mazalijtrunklineincludesa16inchtrunkline,900#,and31.2KMfromexisting
MazalijmanifoldRH14tonewGOSP(MZLJ1).

OilandwaterwillthenbepumpedtoKHCPFviaasingle26inch,91.232KMlong
pipeline(KHT1).

GaswillbedehydratedinaTEGunitandwillthenfreeflowtoKhCPFviaa
separate16inch91.198KMlongpipeline(KHTG1).

Currently,thetotalproductionatKhuraisisapproximately1,200MBCD.
Schematicviewfo Mazalij andabu Jifan
Pipeline
Introduction
DocumentsAndSpecifications

Theapplicabledocumentsandproceduresfor
thisprojectsareasfollows
SATIP,SAIC,SATAR Rev.8
ProjectSaudiAramcoDeskTopStandardscut
offdateshallbeMarch2014.
ApprovedProceduresandapprovedchecklist
forinternalcoating.
DocumentsAndSpecifications(cont..)
WorkProcedure Personnel
Approval(A)or Qualification
SpecialProcess Review(R) Approval
Required Required
PerformanceQualificationofCoating NA YES
Personnel
InternalcoatingAPCS120Procedure A YES

ExternalcoatingAPCS104AProcedure A YES

ExternalFBERepairandtouchupProcedure A YES

RenovationandRepairofBuriedPipeline A YES
(APCS113A)
Liquidpaintingandcoating A YES

NonCuring(ViscoElastic)APCS113C A YES

AROforThrustBoringpipes A YES
ApplicableAramcostandardforCoating
SAESH001CoatingSelectionandApplicationRequirementsforIndustrial
PlantsandEquipment
SAESH002Internal&ExternalCoatingsforSteelPipelinesandPiping
SAESH002VApprovedSaudiAramcoDataSheetsforthePipelineand
PipingCoatings
SAESH003ProtectiveCoatingsforIndustrialConcreteStructures
SAESH101VApprovedSaudiAramcoDataSheetsPaintsandCoatings
SAESH102SafetyRequirementsforCoatingApplications
SAESH200Storage,HandlingandInstallationofExternallyCoatedPipe
SAESH201ExternalandInternalFBECoatingofFieldGirthWelds
09SAMSS089ShopAppliedExternalFusionBondedEpoxyCoatingfor
SteelLinePipes
09SAMSS091QualificationRequirementsforShopappliedinternalFBE
Coating
SABPH004RoboticCoatingApplicationonInternalGirthWelds
PerformanceQualificationofCoatingPersonnel
SAEP316
Allprotectivecoatingsapplicatorpersonnelshallbeissuedacoating
certificationcard
ThecoatingcertificationCard,whenproperlysignedandissued,
shallbevalidforprotectivecoatingworkthroughoutSaudiAramco
untiloneofthefollowingoccurs:
a)Thecard'sexpirationdateisreached,
b)Thecardholderisnolongeremployedbythecompanyindicted
onthecard,or
c)Thecardholderfailsarenewcertification
StorageAndHandlingofpipe

LinepipecoatedwithFBEcorrosionprotectioncoating
shallbehandledinaccordancewithSAESH200.
Coatedpipesshallnotberolledordraggedonthe
ground
Duringbendingofexternalcoatedpipe,cradlesthat
contactthecoatedsurfaceofthepipeshallbepadded.
Slingsshallbenylonorequivalent;steelcablesshall
notbeused.
Duringstoragethecoatedpipesshallbeplacedatleast
150mmoffthegroundoneitherrockfreesandberms
coveredwithpolyethylenesheetingoronpadded
skids.
StorageAndHandlingofpipeCont.
FBEcoatedpipesduringstorage
ortransportationshallbeseparatedby
fullencirclement,noncompressible
rubberpaddingatleast10mmthick.
12mjointsofpipeshallhaveatleast3
fullencirclementseparationpads&24m
doublejointedpipelengthsshallhaveat
least5fullencirclementseparationpads.

TheFBEcoatedpipesshallbeprotectedfromdirectsunlightinorderto
preventUVdegradation.
IncaseFBEcoatedpipesarestoredoutdoorswithoutappropriatecover
formorethansixmonths,FBEcoatedfilmmustbecheckedfor
prematuredeterioration
Whencoatedpipesaretransported,thebottomtierofpipeshallbe
supportedbypaddedcradles
STORAGEANDHANDLINGOF
COATINGMATERIALS
Theblastcleaningmaterialandthefieldjointcoating
materialpackages
shallcontain,asminimum,thefollowinginformation:
Materialstradename;
MaterialMANUFACTURERS
name;
Batchnumber;
Quantitycontainedineach
package;
Productsexpirydate.
STORAGEANDHANDLINGOFCOATINGMATERIALS
Theblastcleaningmaterialandthefieldjoint
coatingmaterialpackagesshallbeaccompanied
withthefollowingdocuments:
Technicaldatasheets;
MaterialSafetyDataSheets(MSDS)andother
relevantsafetyinstructionssuchas,
Storageinstructions;
Applicationinstructions.
Contaminatedmaterialsshallalsoberemoved
fromtheworksite;theirpackagesshallbe
markedasREJECTEDorUNACCEPTABLEand
shallnotbeusedintheproject.
PreCautionduringWelding
Protectivesleevesmade
fromweldingblanketsor
similarnonflammable
materialatleast0.5mwide
shallbewrappedsnugly
aroundthecoatedendsof
thepipesadjacenttothe
girthweldareawhilefield
weldingistakingplacein
ordertopreventweld
spatterfromburning
throughthecoating.
BlastCleaning
BlastingEquipmentsetup
BlastCleaningCont..
Compressedairsupplyshallbefreeof
oil,moistureandcontamination.
Theinspectorshallcheckandapprove
theairqualityat thestartandmid
pointofeach8hourperiod.Thisshall
bedetermined
asfollows:
Attachapieceofblotterorabsorbent
papertoaclipboard,thenholdit
approximately4560cminfrontof
theblastnozzleduringairflowonly,
withanozzlepressureof388kPa (50
psig)forapproximatelyoneminute.
Satisfactoryresultsshallbenowater
oroilcontaminationontheblotter.
Spentabrasiveshallberemovedfrom
cleanedexternalsurfacesbydry
brushingandblowingdownwith
clean,drycompressedair.
BlastCleaningCont..
DRYABRASIVEBLASTING
MEASURINGPRESSUREATTHENOZZLE

Minimumnozzle
pressureacceptablefor
blastingsteelshallbe
620kPa (90psig)
measuredatthenozzle
side.
Inserttheneedlethrough
thehosewiththeneedle
towardsthenozzle,atan
HYPODERMICNEEDLE
angleofapp.45degrees
GAUGE
BlastCleaningCont..
SolventcleaningperSSPCSP1willbeusedtoremove
oil,greaseandlubricantfromthesteelsurface.
Surfacepreparationcannotbeperformedwhenthe
relativehumidityisgreaterthan85%orthesurfaceto
becoatedislessthan3C(37.4F)abovethedewpoint.
Theblastmedia(abrasives)shallcontainlessthan50
ppmsulphates&chloridesandlessthan1%
carbonates.
Residualchlorideonthesurfaceshallnotexceed40
mg/m intheblastedgirthweldjoints.
Failuretomeettheresidualchloridelimitationrequires
thatthegirthweldbesweetwaterwashedandre
tested.
BlastCleaningCont..
BLASTINGGRADES Sa2.5andSa3
PREBLASTING(CLEANINGPRIORTOWELDING)
Theinternalsurfaceofthepipewillbeinspectedfor
contaminationbydirt,oil,grease,orotherforeign
material,andchlorides.
Useapipebungtoexpeditetheprecleaningofthe
cutbackareatokeeptheabrasiveoutofthepipeand
maintainacleanenvironment
Thedustcontaminationoftheblastedsurfaceareashallbe
testedasperISO85023
PREBLASTING(CLEANINGPRIORTOWELDING)

Positionthepipebungsothefirst6.5mm(inch)ofthe
factoryappliedcoatingcanbecompletelyremoved
leavingataperedEdge.
Oncethe50mm(2inches)cutback
hasbeencleaned,shiftthepipe
bungmeasuringfrompipeendat
approximately100mm(4inches).
Thentheremaining50mm(2
inches)factoryinternalFBEcoating
shallberoughed(feathering
out/brushblasted)toprovidea
keyfortheFieldWeldcoating
overlap.
InternalcleaningandFBEcoatingoflinepipeswith
diameterfrom10"to20"shallbecommencedbythefully
remotecontrolledcrawlingmachinefittedwith2cameras
tomonitorthework.
ThicknesschecksshallbemadeinaccordancewithSSPC
PA2.Aminimumnumberof6readingsshallbetakenon
eachfieldjointrootreinforcementshallnotexceed1.5mm
TheareatobecoatedshallbeblastcleantoSa2thenbe
immediatelyheatedtoatemperatureinaccordancewith
thePowderManufacturer'srecommendationusing
inductionheatingcoil.
DFTShallbe500to1000micronsforInternalCoatingAPCS
120
Pipesections(strings)shouldbeweldedtoamaximumof
500metersinlength.
InternalCoatingDemonstration
ThedustlevelshallbeClass2orbetter
Anychloridescontentequalorhigherthan40
mg/m2requiressweetwaterpressurewashing.
cutbackhasbeencleaned,shiftthepipebung
measuringfrompipeendincludingfeatherarea
totally305mmshouldcovetthegirthjoint.
Atrackingnumberistobeinsideoftheinternal
girthweldfieldjointareaapproximately305mm
(12inches)fromthepipeend.
InternalCoatingCont..
ExternalCoating
Thebaremetaljointshallbeabrasiveblastedto
nearwhitemetalcleanliness,Sa2.Thesurface
profileshallbe40to75micrometres.
Allweldjointsshallbegroundsmoothandfree
fromburrs,weldspatter,sharpedges.
Theweldcaporinternalrootprotrusionshallnot
bemorethan1.5m.

Theglossshallberemovedfrom
theshopappliedFBEpipecoating
thatwillbeoverlappedbythefield
coatingbylightabrasive(sweep)
blasting.Wirebrushesshallnotbe
usedforthispurpose.
ExternalCoatingCont..
Coatingmaterialshallbestoredandhandledin
accordancewiththeManufacturer's
recommendations.
Powdershallbekeptdryatalltimesandnot
exposedtodirectsunlightorusedwithin15mof
any
Minimumacceptablewidthofthestripareatobe
coatedshallbe:280mmcanteredontheweld.
Butinpracticeitmustby300mm.
Theareatobecoatedshallthenbeimmediately
heatedtoatemperatureinaccordancewiththe
PowderManufacturer'srecommendationusing
inductionheatingcoil.
ExternalCoatingCont..
DryfilmthicknessShallbe625mtoamaximumof1000
mforExternal.
TheDFTGaugeshallbecalibratedinaccordancewithSSPC
PA2.
CureshallbecheckedbymaintainingaMEKsoakedpadin
contactwiththecoatingsurfaceforoneminuteandthen
rubbingvigorouslyfor15seconds.Thereshallbeno
softeningofthecoatingorsubstantialcolourremovalfrom
thecoating.
Thefinishedcoatingshallhaveauniform,glossy
appearanceandbefreeofdefectssuchasholidays,fish
eyes,lumps,dryspray,sagsandruns.
100%ofthecoatedgirthweldsurfaceareashallbeholiday
detected,inspected,andrepaired.
Ifthenumberofdefectismorethanthree(3)holidayson
anygirthweld,thecoatingshallbecompletelyblastedoff.
Holidaytesting
Thecoatedpipelineshallbe100%inspectedwithapulsetypeDCholiday
detectoremployinganaudiblesignallingdeviceimmediatelypriortoburial
Holidaydetectionshallnotbeconductedifthesurfacetemperatureofthe
coatedgirthweldareaexceeds88C.
Holidaytestinginthefieldshallbedoneatthefollowingvoltages:
FBE1500to2000 50voltsDC
PEandPP25,000 1000voltsDC
Thetravelrateofthedetector's
electrodeshallnotexceed300mm/s
norshallitbeallowedtoremain
stationarywhilethepowerison.
Fieldcalibrationoftheholiday
detectorshallbecheckedatleast
twiceper8hourshiftagainsta
calibratedvoltmeterandadjustedas
necessary.
Holidaytesting
Thefunctionaloperationoftheholiday
detectormaybecheckedinthefieldby
makinganartificialholidayinthecoating
notmorethan1.6mmdiameter.
Theholidaydetectorshallbegroundeddirectly
tothepipebeinginspected.
Ifthepipeitselfisgrounded,itispermissibleto
groundtheholidaydetectordirectlytothe
earth.
TheInspectorshallkeepadailyrecordofthenumberofcoating
repairsperjointrequiredpriortoburial.
Defectivelocationsshallbeclearly
markedwithacrayonimmediately
upondiscovery.TheInspectorshall
certifythatthedefectiveareashave
beenrepairedpriortoburial.
HolidaytestingEquipments
ExternalFBERepair
Thesoundcoatingadjacenttothedefectbeing
repairedshallberoughenedforadistanceofat
least50mmusingatleasttheequivalentof80
gritemerypaper.
Patchrepairareasshallbe100%holidaytested
ExternalFBERepair
DamagedFBEcoatingshallberepairedasfollows:
Areassmallerthan1450mm usethermalmeltsticksor
anepoxypatchingcompound
Areaslargerthan1450mmandsmallerthan0.2m use
anepoxypatchingcompoundapprovedbytheRSA.
Areaslargerthan0.2m usefastcuringsolventfree
epoxysystemsonlyasperAPCS113AorotherRSA
approvedproducts.
LoweringandBackfilling
Thecoatedpipelineshallbe100%inspectedwith
apulsetypeDCholidaydetectoremployingan
audiblesignallingdeviceimmediatelypriorto
burial,i.e.,afterthelastboom.
Priortobackfillingandduringlowering,the
pipelineshallbesupportedinsidethetrenchwith
amaximumallowableunsupportedlengthof3
meters(m).
Thetrenchshallbewideenoughtoallow
loweringthepipewithoutdamagingthepipeor
thecoating
Thebottomofthetrenchshallbefreeofrockor
othermaterialthatcoulddamagethepipeor
pipecoating.
Lowering
InspectionKit
THANK YOU

Any Questions?