09-Samss-089 2018

Materials System Specification
09-SAMSS-091 17 January 2018

Qualification Requirements for Shop-Applied Internal FBE Coatings
Document Responsibility: Paints and Coatings Standards Committee
Contents
1 Scope ................................................................ 2
2 Conflicts and Deviations .................................... 2
3 References ........................................................ 2
4 Definitions .......................................................... 4
5 Health, Safety, and Environment ....................... 6
6 Material .............................................................. 6
7 Handling of Pipe ................................................ 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 ............ 21
13 Repairs ............................................................ 21
14 Pipe Storage and Preparation for Shipment .... 22
Revision Summary.................................................. 22
Appendix A - Qualification Procedure

for Initial Product Approval .......................... 23
Previous Issue: 6 February 2017 Next Planned Update: 17 January 2021

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Contact: Mansour, Mana H. (mansmh0c) on phone +966-13-8809557
©Saudi Aramco 2018. All rights reserved.

Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 17 January 2018
Next Planned Update: 17 January 2021 Qualification Requirements for Shop-Applied Internal FBE Coatings
1 Scope
1.1 This specification defines the minimum mandatory requirements of shop-applied
primed fusion bonded epoxy FBE powder coating systems for the internal
surfaces of steel pipes and associated fittings and couplings.
1.2 Unless stated otherwise in the Purchase Order, pieces coated in accordance with
this specification shall be suitable for continuous service at 3,000 psig pressure
and for exposure to hydro-testing at 5,575 psig.
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 7.1).
1.5.2 Procedure of the field girth weld internal coating application, quality
control, and coating defects repair.
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
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 Procedures
SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
Saudi Aramco: Company General Use

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SAEP-303 Engineering Reviews of Project Documentation

SAEP-1200 Qualification Procedures for Protective Coatings
and Abrasive Blasting Materials
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 External and Internal
FBE Coatings of Pipeline Field Girth Welds
SAES-W-012 Welding Requirements for Pipelines
Saudi Aramco Inspection Requirement

Form 175-091300 Coating: Shop Applied, Internal or External
3.2 Industry Codes and Standards
The Society for Protective Coatings

SSPC PA 2 Procedure for Determining Conformance to Dry
Coating Thickness Requirements
SSPC SP 1 Solvent Cleaning
SSPC-SP 5/NACE No. 1 - White Metal Blast Cleaning
SSPC-AB2 Cleanliness of Recycled Ferrous Metallic Abrasives
SSPC-AB3 Ferrous Metallic Abrasive
International Organization of Standardization

ISO 8501-1 Pictorial Surface Preparation
ISO 8502-3 Assessment of Dust on Steel Surface Prepared for
Painting
ISO 8502-6 Extraction of Soluble Contaminants for Analysis -
The Bresle Method
ISO 11124-3 Specifications for Metallic Blast-Cleaning
Abrasives- Part 3: High-Carbon Cast-Steel Shot
and Grit

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ISO 11125 Test Methods for Metallic Blast-Cleaning Abrasives

ISO 11126-10 Specification for Non-metallic Blast-Cleaning
Abrasives- Part 10: Almandite Garnet
ISO 11127 Test Methods for Non-metallic Blast-Cleaning
Abrasives
American Society for Testing and Materials

ASTM D4417 Field Measurement of Surface Profile of Blasted
Cleaned Steel
ASTM D6677 Standard Test Method for Evaluating Adhesion by
Knife
ASTM D7393 Standard Practice for Indicating Oil in Abrasives
NACE International
NACE SP0188 Discontinuity (Holiday) Testing of New Protective
Coatings on Conductive Substrates
NACE TM0185 Evaluation of Internal Plastic Coatings for
Corrosion Control of Tubular Goods by
Autoclave Testing
NACE SP0394 Application, Performance, and Quality Control of
Plant-Applied Single-Layer Fusion-Bonded
Epoxy External Pipe Coating
Canadian Standards Association

CSA Z245.20 Series-14 Plant-Applies External Coatings for Steel Pipe
America Petroleum Institute
API 5L7 Recommended Practice for Unprimed Internal
Fusion Bonded Epoxy Coating of Line Pipe
API 5L9 External Fusion Bonded Epoxy Coating of Line Pipe
4 Definitions
Approved Procedure: Procedure referred to in this specification that has been

approved by CSD/Paints and Coating Standards committee. Approved procedures do
not require re-approval in new purchase orders.
Approved Product: A coating material that has been approved by CSD/Paints and
Coating Standards committee as meeting the requirements of the applicable APCS,
SAMSS or relevant international standards. Only approved products are allowed for

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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.
Cutback: The length of pipe left uncoated at each end for joining purposes.
DFT: Dry film thickness
Fabricated Spools: Spools longer than 10 feet that can’t 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.
Manufacturer: Company which manufactures FBE powder coatings and corresponding

repair materials.
Non-Corrosive Service: Treated Seawater or Refined Products
Pipe: For purposes of this specification “pipe” is used to refer to steel tubular,
including line pipe and OCTG casing and tubing.
Production pipes: Pipes coated using automated process.
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

Working shift: The maximum working shift shall be 12hrs.

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5 Health, Safety, and Environment
Applicable safety requirements addressed in SAES-H-102 shall be followed.
6 Material
6.1 FBE Internal Coating
6.1.1 Material for the shop-applied internal 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 The use of recycled powder may be permitted if adequate recovery and
screening equipment is used and maintained. In no cases shall such use
be greater than 10% by weight. If the reclaimed powder found
contaminated, reclaimed powder shall be stopped.
6.1.3 The Vendor shall use only Saudi Aramco approved products under
APCS-102A, APCS-102B or APCS-102C 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.
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.
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Table 1 - Epoxy Powder Properties

Property Acceptance Criteria Test Method
Density Meets Manufacturer specification CSA Z245 Clause 12.6

3.0% maximum retained on 150 μm
Particle Size mesh and 0.2% maximum retained on CSA Z245 Clause 12.5
250 μm mesh.
Gel Time Meets Manufacturer specification CSA Z245 Clause 12.2
Cure time Meets Manufacturer specification CSA Z245 Clause 12.1
Moisture Content 0.5% maximum CSA Z245 Clause 12.4

Thermal Meets Manufacturer specification for
CSA Z245 Clause 12.7
characteristics Tg1 (°C), Tg2 (°C), ΔH (J/g)
NACE SP0394-2013
Bend test No crack
(Appendix H)
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
e) Autoclave 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 Saudi Aramco-approved materials.

Touch-up material shall also be approved by the FBE coating manufacturer.
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 Steel abrasives and/or garnet shall be used for surface preparation. Only
Saudi Aramco approved abrasive materials are allowed to be used.

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6.3.2 Each batch of abrasive must be tested and certified by the Manufacturer in
accordance with the requirement of ISO 11124-3 or 11126-10.
6.3.3 The use of reclaimed slag abrasives is prohibited. The use of reclaimed
garnet is permitted for pre-blasting work, provide it meets the
requirements of ISO 11126-10 and ASTM D7393 for oil contamination.
6.3.4 The use of recycled steel abrasives is allowed, provide it meets the
requirements of SSPC-AB2.
6.3.5 After blast cleaning all pipes shall be blown out with clean, dry
presurized air (at least 100 psi) to remove any residual contaminants
from the blast cleaning operation. The quality of air must be tested twice
per shift using the blotter test.
6.3.6 The abrasives shall be stored in a dry condition and kept dry/clean during
use. For all abrasives, the sulfate content shall be less than 50 PPM, the
chloride content shall be less than 50 PPM, and calcium carbonate shall
be 1.0% by weight.
6.3.7 Garnet abrasives shall meet the requirements of ISO 11126-10 and
11127. The steel abrasives shall meet the requirements of ISO 11124-3
and 11125.
6.3.8 Abrasives shall be of a particle size that will produce a clean, angular
surface profile as specified in paragraph 8.4 of this specification.
6.3.9 Sand is prohibited as an abrasive for pre-cleaning, cleaning, and all other
abrasive blasting processes.
6.3.10 The Vendor shall furnish a chemical analysis for all batches of abrasives
to verify compliance with the requirements in paragraph 6.3.6.
7 Handling of Pipe
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.

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7.3 Vendor shall have an approved procedure for handling, loading, unloading,
storage and preparation for shipment of pipe and fittings 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 - 400ºC 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 Before and after blasting, pipes or fittings surface temperature shall be at least
3ºC above the dew point. 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 “white” metal surface
finish equal to Sa3 as described in ISO 8501-1, SSPC SP 5/NACE No. 1.
8.4 The anchor profile shall be 50 - 100 micrometers.
8.5 Dust level shall be Class 2 or less in accordance with ISO 8502-3. Test the first
5 pipes in each shift. After that, test one out of every 20 pipes or 2 fittings per
production lot.
8.6 Defects
8.6.1 Weld spatters shall be removed. Rough weld and sharp edges shall be
ground to a minimum radius of 3 mm.
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.

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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
3ºC above the dew point.
8.8 Chloride Contamination
8.8.1 The blasted surface of pipes and fittings shall be tested for the presence
of residual chlorides using ISO 8502-6. Residual chlorides shall be no
greater than 20 mg/m².
8.8.2 Test a random location on the first two blasted pipe and/or fitting on any
given day. After that, test one pipe joint out of every 50 pipes. For
fittings, test at least two pieces per production lot.
8.8.3 In the event of a failed test result, the piece shall be re-tested. If it fails
after 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.
8.9 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 50 foot-candles (500 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 3 All

1) First 5 pipes in
each shift and then
one pipe out of
Anchor Profile Para. 8.4 50~100 μm every 20 pipes.
2) Two fittings per
production lot.
1) First 5 pipes in
each shift and then
one pipe out of
Dust grade Para. 8.5 ≤ Class 2
every 20 pipes.
2) Two fittings per
production lot.
Free of weld spatter,
Defects Para. 8.6 rough weld surfaces All
and sharp protrusions

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Test Test Method Acceptance Criteria Frequency
3°C above steel

Dew Point Para. 8.7 Every 2 hours
temperature
1) First 2 pipes on
any given day and
then one pipe out
Residual Chloride Para. 8.8 Less than 20 mg/m²
of every 50 pipes.
2) Two fittings per
production lot
9 Coating Application
9.1 The dew point of air in the fuidized bed and powder feed lines shall be no higher
than -20°F (-29°C). A source of clean, dry air with instrumentation to monitor
dryness is required.
9.2 Adequate screens (80 mesh (180 micron) or finer) shall be present in the powder
handling system to ensure that large particles or agglomerates are not carried to
the application equipment.
9.3 The FBE and its primer 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
CSD/Paints and Coating Standards committee for Saudi Aramco approval prior
to application. Already approved procedures do not require CSD/Paints and
Coating Standards committee review and approval on new purchase orders,
unless otherwise is required by the Buyer's representative or any other standards
documents.
9.4 The phenolic primer shall be applied in accordance with the coating
manufacturer data sheet. The primer should be applied uniformly at dry film
thickness of 13-25 microns (0.5-1.0 mils) to just wetting the blasted surface and
keeps the surface profile peaks exposed to allow optimum adhesion for the FBE
coating. This low thickness can not be measured by the conventional DFT
gauges. Therefore, Vendor should describe in the coating application procedure
his method in achieving the required primer thickness.
9.5 The coating dry film thickness DFT for pipe joints shall be in the range of 375 to
625 microns (15-25 mils) for APCS-102A and APCS-102B and 500-750 microns
(20-30 mils) for APCS-102C unless otherwise agreed upon in writing by the
Buyer.
9.5.1 For girth weld areas (pipe and custom coated pieces), the allowable DFT
shall be in the range of 375 to 625 microns (15-25 mils) for APCS-102A

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and APCS-102B and 500-750 microns (20-30 mils) for APCS-102C.

The total dry film thickness in the overlap area between the girth weld
coating and the adjacent coating shall not exceed 1,250 microns for
APCS-102A and APCS-102B and 1,500 (60 mils) for APCS-102C.
9.5.2 For pipes with diameters less than 24” and/or too small to access the
girth weld area, the Vendor should describe in the coating application
procedure his method in controlling the DFT.
9.6 The coating thickness for custom coated pieces shall meet the requirement
specified in paragraph 9.5, additional 20% of the maximum thickness is
acceptable. However, the thickness at the end of the custom coated pieces, last 15
cm, should be within the specified thickness in paragraph 9.5 to maintain the same
thickness in the overlap area specified in paragraph 9.5.1 of this document.
9.7 Line pipe and ancillary piping products for subsequent welding shall have a
cut-back at each end in the range of 50 to 75 mm measured from the end of pipe
unless otherwise specified. In the case of fittings 6” diameter or less, the cutback
range of 25 to 50 mm. If longer cut-back is needed, CSD/Paints and Coating
Standards committee shall be consulted.
9.8 The internal root reinforcement shall be 1.5 mm or less, as per SAES-W-012,
paragraph 16.10.
9.9 The cured coating shall be of uniform color and gloss, and shall be free of blisters,
fish eyes, orange peel, sags and runs.
9.10 Pipe or fittings which have been primed and waiting for FBE coating application
must be covered to be protected against any dirt or other deleterious materials
and not to be hold more than 4 hours for FBE coating application. For pipes and
fittings, the final curing process of the FBE coated items must begin within two
hours of the FBE application.
9.11 Custom coated fittings are subject to a size limit of maximum 36” diameter and
10 feet in length. For fabricated spools that can not be coated through the
automated process, custom coating is acceptable with the following conditions:
9.11.1 During coating application, pipe temperature shall be within the

minimum and maximum limits recommended by the coating material
manufacturer.
9.11.2 Coating thickness shall meet the requirement of paragraph 9.6 of this
document.
9.11.3 Coating should pass the testing requirements in papagraph 10.

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9.11.4 Buyer’s Representative should attend, at least, the coating of the first
piece to ensure the above requirements are incorporated.
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). If blasting and primer applications are
taking place on the same vicinity, primer application shall be stopped while
blasting is in progress.
10.4 Checking blasted surface profile (see paragraph 8.4).
10.5 Checking temperature control of the surface (see paragraph 8.2).
10.6 Visual inspection of primer thickness. (see paragraph 9.4)
10.7 Checking thickness of cured coating (see paragraph 11.4).
10.8 Checking on the coating adhesion properties (see paragraph 11.5).
10.9 Holiday detection of 100% of the surface area of all pipes and fittings
(see paragraph 11.6).
10.10 Supervision of adequate and proper repair of all defects.
10.11 Checking of coating color, appearance and uniformity (see paragraph 9.9).
10.12 Cure Test (see paragraph 11.8).
10.13 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.

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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.
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 internal 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
Coating thickness for every pipe and fitting shall be checked in accordance with
SSPC PA 2 at accessible area 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 9.5 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,

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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.
11.5.1.2 For custom coated pieces, fittings and short spools, test one
sample per production lot.
11.5.1.3 For custom coated fabricated spools, test the first

production joint and once every ten joints.
11.5.1.4 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.
11.5.1.5 The weld cutback on selected pipe lengths or fittings

(see paragraph 9.7) 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 13 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
Page 15 of 27
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 80°C 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
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 The holiday test voltage of the hot spark detector shall be 125 volts DC
per 25 micrometers of maximum coating thickness. However, to
eliminate the need for continual adjustment during shop production, a
maximum voltage of 2,200 volts ± 50 volts shall be used for coating
thickness in the range from 375 to 750 micrometers.
11.6.4 All holidays in pipe coated above 24” diameter shall be repaired.
The maximum number allowed for repair is 10 holidays. They shall be
holiday free when re-tested after repair in accordance with paragraph 13.3.
If the number is more than 10 holidays, the pipe joint shall be rejected.
11.6.5 The number of holidays in a pipe joint with diameters up to 20” shall be
permitted a maximum of 3 holidays per 12.2 m length. Repair if these
holidays are accessible; otherwise, leave them unrepaired and inform the
Buyer's representative and log it in the quality control document.
11.6.6 Internal girth weld coatings on the double-joints pipe shall be tested in
accordance with the following:
11.6.6.1 Pipe diameters equal and greater than 24”: All holidays
shall be repaired. The coating on the girth weld area shall
be holiday free when tested in accordance with Section 13.
The maximum number allowed for repair is 3 holidays.
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11.6.6.2 Pipe diameters less than 24”, but large enough to allow
visual inspection of the girth weld area coating by remote
controlled crawling equipment; holiday(s) shall be marked
and repaired. Otherwise, the coating shall be rejected.
11.6.6.3 Pipe diameters too small to allow visual inspection of the

girth weld area coating: The holiday test shall be made.
If there is a holiday in the girth weld, the coating shall be
rejected.
11.6.7 Custom coated fittings and short spools shall be free of holidays.
11.6.8 For custom coated fabricated spools, more than 3 meters and up to
6 meters, the maximum number allowed is one holiday. For more than
6 meters, follow the requirement addressed in sections 11.6.3, 11.6.4,
and 11.6.5.
11.7 Bend Test
11.7.1 Two test bars measuring approximately 25 mm x 192 mm x (6.0-10.0)

mm shall be coated at a dry film thickness specified for each coating
system.
11.7.2 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 9.5.
11.7.3 The test bars shall be holiday detected in accordance with paragraph
11.6 of this specification, and all holidays marked and recorded.
11.7.4 The specimens shall be clamped in the bender with the coated side up.
The specimens shall be bent flat wise.
11.7.5 The bend angles and temperatures are specified in table 3.
Table 3 – Bend test condition
Test Temperature Test Angle
5°C 3.0°/PD
10°C 3.75°/PD
25°C 5.5°/PD
11.7.6 Bending shall be accomplished in less than 30 seconds.

Page 17 of 27
11.7.7 The coated specimens shall show no cracks, tears, delamination, or

disbondment. The presence of strain marks alone does not constitute a
failure.
11.7.8 At the start of using a new batch of powder, the flexibility of the
coating shall be determined by bend test. The test should be conducted
on test bars at 5, 10 and 25ºC.
11.7.9 The bend test shall be conducted on test bars once per shift at 25ºC for
custom coating. The powder utilized for the test shall be taken from the
plant application fluidizing bed.
11.7.10 For production pipes, the bend test shall be conducted in accordance
with table 4.
11.7.11 For production pipes not covered in table 4, the bend test shall be
conducted on test bars once per shift at 25ºC. The powder utilized for
the test shall be taken from the plant application fluidizing bed.
11.7.12 FBE coating of valves and pumps do not require bend test during
application.
11.7.13 If any of specimen fail the bend tests, the test shall be repeated for that
temperature.
11.7.13.1 If the result of the retest is satisfactory, the bend test shall
be accepted.
11.7.13.2 If any of the specimen fail the retest, immediately

discontinue further coating with the suspect batch of
powder and proceed as follows:
a) Powder : If any specimen fails the retest, the suspected

batch of powder shall not be used.
b) Pipe: All pipes coated since the previous successful
bend test shall be set aside. Two specimens with the
same dimensions as given in paragraph 11.7.1 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.

Page 18 of 27
11.7.14 If deemed necessary in some critical applications or according to an

end-user request, CSD/Paints and Coating Standards committee may
request the Vendor to prepare the Bend test samples from a coated pipe
section.
11.7.15 Bend test is not required for girth weld coating.
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 Clause 12.7 for
cured coating. Custom coated fittings and spools shall be subjected to the same
test at a frequency of two samples per production lot. For double joint girth
welds, it 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 temperature difference (Tg4-Tg3) must be in the range
specified by the FBE Manufacturer, within ±3°C. Any coated pipes, girth welds,
or fittings fail the test within the acceptable range shall be rejected.
11.9 Production Test Ring
11.9.1 The vendor should obtain a test ring from the pipe end, at least 500 mm,
to be subjected to the tests listed in Table 4.
11.9.2 The minimum test frequency, for each production line, shall be one test
ring per pipe diameter and specified wall thickness every working shift.
11.9.3 Test ring is not required for valves, pumps and custom coatings.
11.9.4 If the coating failed any of following test, the tests shall be repeated for
that specific test. If the result of the retest is acceptable, the production
test shall be accepted. If the coating failed the retest, immediately
discontinue further coating with the suspect batch of powder and proceed
as follows:
11.9.5 All pipes coated since the previous successful tests shall be set aside.
Three pipes before/after the tested pipes shall be subjected to the tests
listed in table 4. If the coating continue to fail, the tests should continue
until consecutive three pipes are passed test.
11.9.6 Test ring is required for 4 inch and above diameter pipes.
11.9.7 Test ring is only required for a daily production of more than 25 pipes,
provided the total project pipes are more than 100 pipes.

Page 19 of 27
Table 4 - Production Test Ring Requirements

Acceptance Test
Test Test Method
Criteria Specimens
No cracks, tears,
Flexibility: 5.5°/ PD at NACE SP0394-2013
delamination, or 2
25°C (Appendix H)
disbondment
Hot-water soak
NACE SP0394-2013,
Hot-water adhesion: Rating of 2 1
(Appendix J)
( 24 hours) 75 ± 3°C
CSA Z245
Interface contamination 20% 1
Clause 12.9.3
CSA Z245
Cross-section porosity Rating of 1-3 1
Clause 12.10.3
ΔTg of ±3°C, or 95% CSA Z245
Thermal characteristics 1
conversion Clause 12.7.3.2.2
DFT Para 9.5 1 SSPC-PA2
11.10 Calibration of Inspection Equipment
11.10.1 The coating thickness gauge (see paragraph 11.4) 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 Visual inspection is required for internally coated pipes subjected to external
FBE coating to ensure the internal coating is not affected. Inspection result must
be reported in the inspection sheet.
11.12 Internal coating shall not be subjected to double heating, in case the external
coating is rejected and recoating is required.
Table 5 - Summary of Coating Application Requirements

Acceptance
Test Test Method Frequency
Criteria
Dry Film Thickness Para. 11.4 As specified in Para. 9.5 All
25-50 mm
(less than 6 inch dia.)
Cutback Para. 9.7 All
50-75 mm
(larger than 6 inch)

Page 20 of 27
Acceptance
Test Test Method Frequency
Criteria
Internal Root
Para 9.8 1.5 mm or less All
Reinforcement
Adhesion Test Para. 11.5 Pass Para. 11.5
a) Pipe (≥ 24 inch)
Max. 10 holidays
Holiday Detection Para. 11.6 b) Pipe joint (≤ 20 inch) All
Max. 3 holidays per
12.2 m
Bend Test Para. 11.7 No crack Para. 11.7
For pipe twice per
shift*
Cure Test Para. 11.8 (Tg4-Tg3) = ±3°C For fittings two
samples per
production lot
Powder Moisture CSA Z245 Once per shift
0.5% maximum
Content Clause 12.4 from fluidized bed
Production Test
Para. 11.9 Table 4 Once per shift
Ring
* One shift is maximum twelve hours.
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.
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, written procedures.
13.2 Abrasive blasting and patch repair work shall not be conducted when the metal
surface temperature is less than 3ºC above the dew point.
13.3 Repaired areas shall be retested for holidays per paragraph 11.6 and shall be
holiday free.

Page 21 of 27
14 Pipe Storage and Preparation for Shipment
14.1 Each coated length of pipe or fitting shall be externally or internally stenciled to
identify the type of coating applied, coating Purchase Order number, original
pipe or fitting Purchase Order number (if known), pipe size, pipe grade, fitting
size, fitting class and date coated.
14.1.1 Pipe diameters of 16 inches and less shall be stenciled externally

starting at a point approximately 60 cm from the end. Size permitting,
fittings of these diameters shall be stenciled externally at any
convenient location.
14.1.2 Pipe diameters greater than 16 inches shall be stenciled internally

starting at a point approximately 15 cm from the end. Size permitting;
fittings of these diameters shall be stenciled internally at any
convenient location.
14.1.3 Fittings that cannot be stenciled as required above shall be marked in

accordance with the Buyer's written instructions.
14.2 All pipes shall be stored on polyethylene-sheathed sand berms until time for
delivery. Fittings shall be stored on pallets or padded elevated racks.
14.3 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.
14.4 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
30 March 2005 Revised the “Next Planned Update”. Reaffirmed the contents of the document, and reissued
with minor revisions.
15 October 2011 Editorial revision to remove the committee members list.
6 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, this revision resolved some of the challenges faced
in previous projects to eliminate conflicts and support project schedule.
17 January 2018 Major revision to clarify some test requirements, revise production test frequency to enhance
productivity, and be align with international standards. In addition, steel abrasives were
accepted for internal surface preparation.

Page 22 of 27
Appendix A - Qualification Procedure for Initial Product Approval

1. General Requirements
1.1 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 CSD/Paints and Coating Standards committee 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.
1.2 Laboratory Report
1.2.1 Testing can only be considered if conducted at a third party laboratory

that is accepted by Saudi Aramco.
1.2.2 The third party test report shall include all the tests mentioned in this
specification, unless otherwise specified by CSD approved test protocol.
1.2.3 The final report shall include illustrative photos of all panels before and
after testing.
1.2.4 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.
1.2.5 All initial product qualification tests shall be carried out at no cost to
Saudi Aramco.
1.2.6 All coating systems supplied for use in potable water service as in
(APCS-102A) or any other systems shall have been tested to meet Food
and Drugs Administration (FDA), National Sanitation Foundation (NSF)
or Saudi Aramco-considered equivalent requirements for suitability for
use in contact with drinking/potable water. The certification shall be
valid for 4 years from the date of issuance, and thereafter, it shall be
renewed every 4 years to maintain the approval consecutively.
1.2.7 Along with any coated sample supplied for testing, the coating
manufacturer/vendor shall submit the following documents: coating
manufacturer’s location, date of manufacturing, batch/lot numbers of
coatings used and product data sheet.
Page 23 of 27
1.3 Test specimens shall be coated using electrostatic flocking method.
1.4 If the operating conditions for a certain project are not addressed in Table 6,
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
ASTM D4541 Pull Off Strength of Coatings
ASTM D4060 Standard Test Method for Abrasion Resistance of
Organic Coatings by the Taber Abraser
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 analyses of the coating powder and its primer shall be conducted by
the infrared (IR) approved method, and FBE differential scanning calorimetric
(DSC) analysis.
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.
3.3 Flexibility/Bending Test
Three (3) test specimens as detailed in paragraph 11.7.1 of this specification

shall be tested and evaluated in accordance with paragraphs 11.7.2 through
11.7.6 of this specification.

Page 24 of 27
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 3.8 below.
A pull-off value of not less than 2,000 psi is required.
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
than 24 hours, to obtain initial electrochemical impedance values. The initial
values must be greater than 1 x 108 ohm·cm² 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 shall be more than 1 x 108
ohm·cm2.
3.6 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.
3.7 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 1-3.
3.8 Chemical Resistance
3.8.1 The test should be conducted using high pressure (autoclave) in

accordance with NACE TM0185 with the following modification.
3.8.2 Three test panels shall be Carbon Steel plates, which are of a size at least
100 mm x 100 mm x 6 mm (4” x 4” x 0.25”).
3.8.3 The test chamber shall be heated to the test temperature specified in
Table 6 below.
3.8.4 The specimens should be immersed half-way in the specified test

solutions in the autoclave.
3.8.5 The pressurizing gas shall be Nitrogen (N2) unless otherwise specified.
3.8.6 Stable condition (temperature/pressure) shall be maintained for a

minimum of one week, after which the heat shall be discontinued.
Page 25 of 27
The unit shall be cooled to 90ºC and the pressure released over a time
period of a minimum of one minute and a maximum of three minutes.
3.8.7 The specimens shall be conditioned for one hour at 25ºC prior to being
assessed.
3.8.8 The test results shall not show blistering, cracking, swelling, or
softening. Slight discoloration is acceptable.
3.8.9 The pull off adhesion shall be more than 90% of the initial adhesion.
3.8.10 Electrochemical Impedance Spectroscopy (EIS) shall be more 1 x 108

ohm·cm2.
3.9 Density Test
3.9.1 The test shall be conducted in accordance with CSA Z245.20-14,

Method A. The density of the coating should be reported in grams per
liter.
Table 6 - Chemical Resistance Test Parameters

Service Test Medium Test Temp. Test Pressure Test Time
ASTM D1141, Stock
a) Treated 20.68 MPa
Solution 1 plus 90ºC One week
Seawater (3,000 psig)
Stock Solution 2
b) Brine Formation Water Brine
Reinjection Wet, 3 mole% CO2 20.68 MPa
95ºC One week
Sour Gas or 3 mole% H2S (3,000 psig)
Crude 94 mole% Methane
Wasia Water 20.68 MPa
c) Wasia Water 95ºC One week
100% CO2 (3,000 psig)
Covered Vented
d) Acid 10 vol. % HCl 70ºC One month
Container
8 mole% CO2
20.68 MPa
e) Sour gas 5 mole% H2S 95ºC One week
(3,000 psig)
87 mole% Methane
70% Formation Water
30% MEG
f) Sour gas with 20.68 MPa
8 mole% CO2 60ºC One week
dehydrator (3,000 psig)
5 mole% H2S
87 mole% Methane
Formation Water Brine Composition (mg/l):

Na = 65,000; Ca = 23,000; Mg = 3,000; Cl = 150,000;
SO4 = 100; HCO3 = 300

Page 26 of 27
Wasia Water Composition (mg/l):

Na = 2,500; Ca = 600; Mg = 120; Cl = 50,000; SO4 = 1,000;
HCO3 = 200; pH = 6.8 - 7.2
Table 7 - Summary of the FBE Qualification Tests

Test Test Method Acceptance Criteria
Flexibility/Bending Test Para. 3.3 No crack
Adhesion Test Para. 3.4 More than 2,000 psi
Electrochemical Impedance
Para. 3.5 Greater than 1 x 108 ohm·cm²
Spectroscopy (EIS)
Abrasion resistance Test Para. 3.6 Below 100 mg
No blistering, cracking, swelling
Chemical Resistance Test Para. 3.8
or softening or loss of adhesion
Rate 1-3 (Cross section)
Porosity Test Para. 3.7
Rate 1-3 (Interface)
Density Para. 3.9 Manufacturer specification
Thermal characteristics
CSA Z245 Manufacturer specification,
Tg1, Tg2, Tg3, Tg4,
Clause 12.7 ΔTg = ±3°C
ΔTg (Tg4-Tg3), ΔH
Note: In order for full and unrestricted approval of a coating system it must pass all
above tests and also pass the bending tests. However, it is possible to get
limited approval by passing the individual tests in a specific service.
All systems shall pass (d) as well as be bendable in order to qualify except as
otherwise noted in this SAMSS.

Page 27 of 27

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Materials System Specification

09-SAMSS-091 17 January 2018

Appendix A - Qualification Procedure

Previous Issue: 6 February 2017 Next Planned Update: 17 January 2021

©Saudi Aramco 2018. All rights reserved.

2 Conflicts and Deviations

Saudi Aramco: Company General Use

SAEP-303 Engineering Reviews of Project Documentation

Saudi Aramco Engineering Standards

Saudi Aramco Inspection Requirement

3.2 Industry Codes and Standards

The Society for Protective Coatings

International Organization of Standardization

Saudi Aramco: Company General Use

ISO 11125 Test Methods for Metallic Blast-Cleaning Abrasives

American Society for Testing and Materials

Canadian Standards Association

Approved Procedure: Procedure referred to in this specification that has been

Saudi Aramco: Company General Use

Buyer: Saudi Aramco Purchasing Department representative.

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

DFT: Dry film thickness

FBE: Fusion bond epoxy coating

Holiday: A discontinuity in applied coating that exhibits electrical conductivity when

Manufacturer: Company which manufactures FBE powder coatings and corresponding

Non-Corrosive Service: Treated Seawater or Refined Products

Production pipes: Pipes coated using automated process.

Vendor: FBE coating applicator

Saudi Aramco: Company General Use

5 Health, Safety, and Environment

Applicable safety requirements addressed in SAES-H-102 shall be followed.

6.1 FBE Internal Coating

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

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

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

Table 1 - Epoxy Powder Properties

Density Meets Manufacturer specification CSA Z245 Clause 12.6

Cure time Meets Manufacturer specification CSA Z245 Clause 12.1

Moisture Content 0.5% maximum CSA Z245 Clause 12.4

6.2 Repair Material

Touch-up or repairs shall be made with Saudi Aramco-approved materials.

6.3 Blast Abrasives

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

8 Cleaning and Surface Preparation

8.4 The anchor profile shall be 50 - 100 micrometers.

Saudi Aramco: Company General Use

8.8 Chloride Contamination

Table 2 - Summary of Surface Preparation Tests

Test Test Method Acceptance Criteria Frequency

Surface Cleanliness Para. 8.3 Sa 3 All

Saudi Aramco: Company General Use

Test Test Method Acceptance Criteria Frequency

3°C above steel

Saudi Aramco: Company General Use

and APCS-102B and 500-750 microns (20-30 mils) for APCS-102C.

9.11.1 During coating application, pipe temperature shall be within the

9.11.3 Coating should pass the testing requirements in papagraph 10.

Saudi Aramco: Company General Use

10.1 Checking cleanliness of pipe and/or fittings immediately prior to blasting

10.4 Checking blasted surface profile (see paragraph 8.4).

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

10.6 Visual inspection of primer thickness. (see paragraph 9.4)