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GAS Arabian

Coating System of external Girth Weld


Services Co. Ltd
for Buried Piping APCS 113C Dammam

TABLE OF CONTENTS

Pages

Issue / Revision Record 3

1.0 Scope ...................................................................................................................................4


2.0 Purpose ................................................................................................................................4
3.0 References ………………………………………………………………………………………….4

4.0 Definations……………………………………………………………………………………… 5

5.0 Resposibility ........................................................................................................................5


6.0 Procedure ...........................................................................................................................6
7.0 Safety Requirements ........................................................................................................10
8.0 Supporting Documents ………………………………………………................................................ 10

9.0 Attachement .....................................................................................................................10

Document No Issue Revision Page No


GAS-QCP-PAC-003 1 0 Page 2 of 10
GAS Arabian
Coating System of external Girth Weld
Services Co. Ltd
for Buried Piping APCS 113C Dammam

ISSUE / REVISION RECORD

Issue Revision Paragraph Description Date


1 0 All Issued for Approval 03-10-2017

NOTE: Where revisions affect the whole document, NO identification will be placed adjacent to the revised paragraph.

Document No Issue Revision Page No


GAS-QCP-PAC-003 1 0 Page 3 of 10
GAS Arabian
Coating System of external Girth Weld
Services Co. Ltd
for Buried Piping APCS 113C Dammam

1.0 Scope

This procedure covers the application of APCS 113C “STOPAQ” and applicable coating
system for buried field joint external girth welds, fitting in the new construction pipe lines and
applicable external girth weld Joints for the BI-21-00083 Fuel supply to YNP.

2.0 Purpose

This procedure explains production and Quality Control processes that will be adopted for
any Pipeline / piping structural apparatus which involves application of Coating APCS-113C
“STOPAQ”. This procedure also sets out function and responsibilities that are to be carried
out by personnel involved for this job. Operating temperature of the pipelines it should not
exceed 70 Deg C if you are utilizing the normal version of APCS-113C and shall not
exceed 80 Deg C if you are utilizing the high temperature version.

3.0 References

GAS Project Quality Plan


Saudi Aramco Construction Safety Manual
GAS Safety, Health and Environmental Program
GAS-QCP-PAC-001 Painting and Coating Procedure
SAEP-316 Performance qualification of coating personnel
SAES-H-001 Selection Requirements for Industrial Coating
SAES-H-002 Internal & External Coatings for Steel Pipelines & Piping
SAES-H-002V Approved Saudi Aramco Data Sheets for the Pipeline Maintenance External
Coatings
SAES-H-102 Safety Requirements for Painting
SATIP-H-002-09 Hand-Applied Tape Wrapping of Buried Piping
SATIP-H-002-11 Renovation and Repair of Coating submerge Services
Contract Codes, Standards, Specifications & Drawings.
Manufacturer’s Data Sheets and Recommendation Procedure (Attachment)

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GAS-QCP-PAC-003 1 0 Page 4 of 10
GAS Arabian
Coating System of external Girth Weld
Services Co. Ltd
for Buried Piping APCS 113C Dammam

4.0 Definitions

ITP - Inspection & Test Plan


GAS - GAS Arabian Services
QCP Quality Control Procedure
IFC Issued for Construction
SATIP Saudi Aramco Inspection Testing Plan
SAIC Saudi Aramco inspection Check List

5.0 Responsibility:

Project Manager

Ensures compliance by all parties to this procedure, the Quality Plan, Inspection & Test
Plan and relevant customer specifications, drawings and Industry Codes.

Construction Manager

Ensure compliance by all craftsmen to the content of this procedure, Project Quality Plan,
Inspection & Test Plan and Customers Specifications.

QC Manager

Ensure and responsible for the implementation of the procedure and overall monitor and
controlling the Quality control activities at site.

QC Supervisor
Ensure and supervise the under assigned QC Inspectors, ensure the implementation of the QCP,
IFC and inspection testing plan.

Quality Control Inspector

Monitors daily ongoing construction activities and verifies compliance with approved inspection and
test plans, procedures, specification and standard requirement. Prepares daily QC records and final
Inspection acceptance documentation where required, ensure the Procedure’s are being followed.

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GAS-QCP-PAC-003 1 0 Page 5 of 10
GAS Arabian
Coating System of external Girth Weld
Services Co. Ltd
for Buried Piping APCS 113C Dammam

Safety Supervisor

Ensure work permits are obtained prior to commencement of any work. Checks personnel and
confirms compliance to safety requirements, such as wearing personnel protective equipment.
Check work areas for any unsafe conditions. Liaises with the field supervisors ensuring that work is
carried out in accordance with project safety plan/procedures.

Documentation made by QC Inspector shall be signed by QC supervisor.

6.0 Procedure
6.1 Material
GAS Arabian Services is using following Saudi Aramco certified and approved coating materials for
APCS-113C coating system:
Material handling, Storage and Preservation shall followed in accordance with the GAS-QAP-MHS-
009 Material handling, storage, preservation.
All Material shall be inspected in accordance with applicable ITP prior use for construction. The
coating product shall be APCS-113C
6.2 Coating Personnel’s
All coating personnel such as blasters, Coating applicators and supervisors shall be qualified and
shall possess valid certification cards in accordance with SAEP-316.

6.3 Equipment

Compressed air supply shall be free of oil, moisture and contamination, as a minimum, the
inspector shall check and ensure the air quality at the start and mid-point of each 8-hour
period. This shall be determined as follows:

All equipment that will be use for execution of this coating system shall confirm to the Client
specified standard requirements.

All equipments that will be use for this coating system shall be calibrated.

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GAS-QCP-PAC-003 1 0 Page 6 of 10
GAS Arabian
Coating System of external Girth Weld
Services Co. Ltd
for Buried Piping APCS 113C Dammam

6.4 Storage

The Coating material APCS 113C material Storage shall confirm the client specified requirement.
APCS-113C materials long term storage:
0
The coating material shall be stored in a closed warehouse at storage temperature below 30 C or
Storage in accordance with manufacturer technical data sheet.
Coating Material APCS-113C materials Short term storage / on site storage.
The coating system components are not recommended to store under direct sunlight for more than
eight hours.

6.5 Surface Preparation

6.5.1. Blast cleaning is recommended if the pipe length is more than one meter.
Surface profile is not critical but if blast cleaning is employed, commercial
blasting to achieve a profile Sa-2 is acceptable.

6.5.2. The type and particle size of the abrasive material are not critical. Recycled
abrasive can be used.

6.5.3. For a pipe length of less than one meter, tool cleaning (wire brushing)
according to SSPC SP 2 is acceptable.

6.5.4. Any sharp metal protrusions exceeding 0.8 mm in height should be ground to
prevent the possibility of the polyethylene layer being torn

6.6 Application of Coating System “STOPAQ”

6.6.1 Before starting the wrapping of the wrapping-band CZ H, the following items
should be ensured.

a) Allow proper accessibility to the pipeline from all directions for free movement of
labor during the application.

b) In "Subkha" areas, the bell hole should be drained properly and continuously for a
dry working condition during the application.

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GAS-QCP-PAC-003 1 0 Page 7 of 10
GAS Arabian
Coating System of external Girth Weld
Services Co. Ltd
for Buried Piping APCS 113C Dammam

c) Use CZ H paste in areas of significant transition in the pipeline such as the welds
on metal sleeves. This paste will enable a gradual transition from the higher edge of
the metal sleeve to the original pipe body.

d) Apply the wrapping-band CZ H over the CZ H paste immediately after the


adhesive application.

6.6.2 : The Wrapping-band shall be applied onto the steel pipe without tension.

a) The first wraparound of the wrapping-band is done without advancing the roll.
One complete circumferential wrapping around the pipe is made before starting the
next wrapping.

b) After the first wraparound is finished, successive wraps should be performed with
a minimum overlap of 10 mm or larger regardless of the width of the roll.

c) When a roll of the wrapping-band is finished, the next roll should be used starting
at a distance of at least 100 mm before the end of the finished roll.

d) After the pipe is completely wrapped, another circumferential wrap is done at the
pipe end. This acts as a "seal" to ensure that the end of the wrapping-band will not
be removed.

e) Any areas of blisters or slackening of the wrapping-band shall be pressed or


"massaged" by hand to improve the wrapping.

6.6.2 : Overlapping

the visco-elastic layer, the overlap shall be 20% of the width of the tape for pipes
with diameters up to 10", and 15 mm for pipes with diameters larger than 10". For
the outer wrap, the overlap shall be 50% of outer wrap width.

a) For girth weld application:

For pipe diameter up to 12”, the overall bandwidth of the visco-elastic coating
system shall be 3 times the bandwidth of the girth weld bare area (if the bandwidth
of the girth weld is 4” (2 cutbacks), the total visco-elastic coating is 12”). For pipe
diameter more than 12”, the overall bandwidth of the visco-elastic coating system

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GAS-QCP-PAC-003 1 0 Page 8 of 10
GAS Arabian
Coating System of external Girth Weld
Services Co. Ltd
for Buried Piping APCS 113C Dammam

shall be 4 times the bandwidth of the girth weld bare area, in this case the total
visco-elastic coating will be 16” based on a bandwidth of 4” as an example.

6.6.3 : The outer wrap over the wrapping-band shall be applied with tension.

a. The wrapping of the outer wrap shall start 5 mm from the start of the wrapping of
the wrapping-band. This will enable a 5 mm of the wrapping-band to remain
exposed.

b) The first wrap of the outer wrap over the wrapping-band CZ H is done without
advancing the roll.

c) Subsequent wraps with 50% longitudinal overlap should be maintained regardless


of the width of the roll.

d) If a roll of outer wrap is finished, the succeeding roll should be initiated at a


distance of at least 25 cm before the end of the finished outer wrap roll.

e) When the entire length of visco-elastic coated pipe has been over-wrapped with
an outer wrap, a final wrapping similar to the first wrap as in (4.6.b, c, and d) must be
repeated.

f) Any areas showing blisters or irregularities as a result of entrapped air should be


removed with by using roller. The rolling action should be done longitudinally along
the pipe, starting from the blister toward the edge of the outer wrap.

g) Backfilling can be performed immediately after the applied coating system has
been checked, inspected, and approved by the inspector

6.7 Patch Repair

6.7.1 Patch repair is done when the coating is removed for “window” inspection or if
it is damaged by heavy earth moving equipment. The patch repair procedure shall
be as follows

a) Cut out the damaged area using a sharp blade cutter. Chamfer the surrounding
coating.

b) Use new patch of wrapping band to cover the area where the coating is removed.
Do not overlap the patch on the sound coating. Use several strips of the wrapping

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GAS-QCP-PAC-003 1 0 Page 9 of 10
GAS Arabian
Coating System of external Girth Weld
Services Co. Ltd
for Buried Piping APCS 113C Dammam

and if necessary to b applied next to each another (minimum 10 mm overlap with


one another).

d) Make several wraparounds over the new patch of wrapping band until it is
completely covered, and the outer wrap is at least 100 mm away from the edges of
the Wrapping-band.

6.8 Holiday Testing for Coated Piping:

Holiday detection test is not normally recommended, but if required the following
procedure is followed to determine inadequately coated areas

a) Use a high-voltage, "spark" holiday detector at a voltage ranging from 10,000 to 15,000
volts. Use a full-circle coiled spring electrode.

b) Move the probing electrode over the pipe surface in one direction at a rate approximately
0.3 m/second. Mark defective areas.

7.0 Safety Requirements

All Safety requirements shall be in accordance with the GAS Construction Safety Manual.

GAS shall comply and shall be responsible for ensuring that all sub-contractors comply in all
respects with Aramco safety regulations which shall be strictly adhered to.

GAS shall provide and maintain all temporary lights, guards, and warning signs and tapes when
and where necessary for protection of the work.

GAS shall provide and maintain sufficient and adequate first aid equipment at the site and ensure
that a sufficient number of personnel are trained in the performance of first aid techniques.

As required a work permit will be received by an approved work permit receiver prior to start of any
activity as per GI 2.100.

8.0 Supporting Document.

All Quality Control Records shall be in accordance with the applicable Inspection and
testing Plan SATIP’s and the relevant Check list SAIC’s, SATR.

9.0 Attachment

Vendor / Manufacturer Recommended Procedure.

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