Critical Coating System

Internal Grith Weld Coating Syatem Requirments (SAES-H-002)

SAUDI ARAMCO ID/PID - 31-March-13 - REV 7 (Standards Cutoff - March 2013) Rev 7 31-Mar-13
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Receiving Inspection of Internal Coating Materials for Over-
SAIC-H-2058 30-Apr-13 COAT-H-
the-Ditch Field Girth Welds
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

A General Requirements

Only approved products shall be used. If the approved coating is

manufactured in a different manufacturing facility, it should be requalified SAES-H-002,
A1
even when it is manufactured by the same company. If its name or Para. 6.2
reference number is changed, it should also be requalified.

FBE coating material conforms to the requirements of SAES-H-002, SAES-H-201,

A2
APCS-102A/102B/102C Para. 6.1

The coating system for specific service are selected from the
SAES-H-002,
A3 various SAP Material Numbers specified in APCS-117 and APCS-118. In
Para. 5.2.11
this regard, CSD/Coatings Team shall be contacted.

For potable water service, the coating are certified by FDA, NSF or
SAES-H-002,
A4 equivalent.
Para. 5.2.14
Note: The certificate shall be renewed every 24 months.

Chemical analyses reports for all batches of blasting abrasives are SAES-H-201,
A5
verified and contain less than 100 ppm chlorides and sulfates. Para. 7.2.5

Material for Patch / Repair coating shall be supplied or approved by the

SAES-H-201,
A6 manufacturer of the powder epoxy coating and conform to CSD
Para. 8.5.3
approved Coating Procedure.

B Specific Requirements

FBE coating powder and repair materials shall be checked for the
SAES-H-201,
B1 manufacturer's name, product identification number, batch number, date
Para. 5.3
of manufacture, and the shelf life or the expiry date.

Safety measures shall be in place while handling the coating materials to

SAES-H-201,
B2 prevent inhalation of the powder dust and to prevent contact with the
Para. 5.2
eyes.
FBE Coating material shall be stored and handled in accordance with the
SAES-H-201,
B3 Manufacturer's recommendations & as per the CSD approved
Para. 5.1
procedures.

FBE Powder shall be kept away from moisture, direct sunlight and SAES-H-201,
B4
source of ignition at all times during its storage. Para. 5.2

Abrasives used for surface preparation shall be maintained dry during its SAES-H-201,
B5
storage and use Para. 7.2.5
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Surface Preparation of Pipe Joints for Field Internal Coating SAIC-H-2059 30-Apr-13 COAT-

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
A General Requirements

Coating application procedure incorporates all the mandatory SAES-H-201,

A1
requirements of SAES-H-201 and is approved by CSD Section 1

Internal cleaning & FBE coating of line pipes with diameter from 10" to
SAES-H-201,
A2 20" shall be conducted by the fully remote controlled crawling machine
Para. 7.1.5
fitted with 2 cameras to monitor the work.

Crawler Equipment for surface prep & FBE coating is verified for correct
functioning / calibration on a test spool. SAES-H-201,
A3
Note: The Length & diameter of the test spool shall be decided & agreed Para. 7.1.6
by contractor, CSD & SA inspector before work begins.

Page 1 of 5
 Chemical analyses reports of blasting abrasives are verified and contain
SAES-H-201,
A4 less than 100 ppm chlorides and sulfates. Sand shall not be used as an
Para. 7.2.5
abrasive.

Coating personnel hold a valid certification as follows :

A) Abrasive blaster (per SAEP-316, Para. 1.3) Sch. Q,
A5 B) Equipment operator (trained & certified by Coating Contractor) Attachment IV,
C) Crew supervisor (trained & certified by Coating Contractor) Para. 2.1
Note: Not required if qualifications are addressed in Quality Plan.

Pipe Girth Weld Preparation NOTE: The following inspection checkpoints shall be verified and modified in accordance with the
B
contractor's internal coating procedure approved by RSA of Saudi Aramco CSD.)

Maximum dimensions of pipeline sections welded do not exceed its

Approved
dimensions as detailed in the Contractor Coating Procedure.
B1 Coating
Length:_______________ , Bend Radius:________________ ,
Procedure
Minimum ID for 12" Dia. Pipe: __________________

All Welding & PWHT is completed before start of surface preparation

and FBE Coating Application. SAES-H-201
B2
Note 1: Thermite weld is located as close as possible to girth weld. Para. 7.1.3
Refer to Attachment 1 for Coating Sequence.

Pipe sections of 500 mm wide band centered on weld are solvent

cleaned to SSPC SP-1 using acceptable degreaser (SA solvents SAP #
SAES-H-201
B3 1000186759 & SAP # 01000198575).
Para. 7.2.1
Note: For pipe diameters not accessible, the solvent cleaning shall be
performed before joint fit up for welding.

All weld joints including adjacent areas to be FBE coated Internally are
ground smooth and free from. burrs, weld spatter, sharp edges. Weld
toes are merged and rounded with no sharp undercuts. The weld cap or SAES-H-201
B4
internal root protrusion is not more than 1.5 mm. Para. 7.2.2
Note: Refer to the recommendations in Attachment -1 for pipe diameters
not accessible for internal cleaning.

Maximum total length for FBE coating and surface preparation on girth
welds is 280 mm. SAES-H-201,
B5
Note 1: CSD shall approve extensions over 280 mm for adjacent coating Para. 7.1.4
damages.

Field weld number is marked inside of the pipe at 12" (300mm) from the Approved
B6 field joint. Coating
This unique ID is per the SAEP-1160 Reqmts Procedure

C Visual Inspection & Inside Surface Preparation verified as specified in Approved Procedure

Abrasive blasting shall be carried out only when the steel surface is at SAES-H-001,
C1
least 3°C above the Dew Point. Para. 6.4.3

Cleaning and coating operations are only allowed to proceed during bad
SAES-H-201,
C2 weather (rain, high winds, etc.) if protective canopies are used to the
Para. 7.3.6
satisfaction of the SA Inspector.

Blasting abrasives are stored in a dry condition & maintained dry during SAES-H-201,
C3
use. Para. 7.2.5

Quality of compressed air used for blasting is checked at the start and
SAES-H-001
C4 mid point of 8 hour shift by blotter test. It shall be free of oil , moisture
Para. 6.5.1
and other contaminants.

Page 2 of 5
 SAES-H-201,
In subkhas and areas where chloride contamination is possible. The
Para. 7.3.2.1
C5 blasted surface is tested for the presence of residual chloride as
&
specified in SAES-H-201 Para 7.3.2.1 & 7.3.2.2.
Para. 7.3.2.2

The gloss is removed from the shop-applied FBE pipe coating that will
SAES-H-201,
C6 be overlapped by the field coating by light abrasive (sweep) blasting or
Para. 7.2.4
sanding. Wire brushes shall not be used for this purpose

Surface Preparation / Degree of cleanliness meets the following: SAES-H-002,

C7 APCS-102A, 102B, 102C & APCS-28 - Sa 3 (White Metal Finish). SAES-H-001
APCS-117, 118, 119, 120 - SA 21/2 (Near white Metal Finish) APCS-Sheet

Surface Preparation / Anchor Profile meets the following:

APCS-28.......................................65-100 Microns Min-Max
APCS-102A, 102B, 102C ............50-100 Microns Min-Max SAES-H-002,
C8 APCS-117 & APCS- 120..............50-125 Microns Min-Max SAES-H-001
APCS-118.....................................75-175 Microns Min-Max APCS-Sheet
APCS-119.....................................20-40 Microns Min-Max
APCS-118.....................................75-175 Microns Min-Max

Spent abrasive and debris are removed from the blast cleaned internal SAES-H-001
C9
surfaces by dry brushing and vacuum cleaning Para. 6.6.1

SATR-H-2011 was completed in accordance with this checklist for Applicable

C10
production runs as identified. SATIP step

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
In-Process & Final Inspection of Internal coating
SAIC-H-2060 30-Apr-13 COAT-
Application on Field Girth Welds

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
A General Requirements

Coating application procedure incorporates all the mandatory

SAES-H-201,
A1 requirements of SAES-H-201 and is approved by CSD
Section 1

FBE Powder material, Batch Number, Date of Manufacture, expiry date SAES-H-201,
A2
meets with the requirements of APCS-102A, 102B & 102C Para. 5.3 & 6.1

FBE Coating Repair Material is supplied or approved by the

SAES-H-201,
A3 manufacturer of the powder epoxy coating and conform to CSD
Para. 8.5.3
approved Coating Procedure.

Internal coatings for potable water service are certified by FDA, NSF or
SAES-H-002,
A4 equivalent.
Para. 5.2.14
Note: The certificate shall be renewed every 24 months.

The coating system has been selected for specific service from the
SAES-H-002,
A5 various SAP Material Numbers specified in APCS-117 and approved by
Para. 5.2.11
CSD/Coatings Team . (Refer to Attachment #1)

Robotic crawler (consisting of blasting and coating equipment, dry film

thickness gauge and holiday detector) are used for onshore application
for internal field girth welds of pipe strings with diameters ranging from 8 SAES-H-002,
A6
to 36". Para. 5.2.4
Note: If isotope is used as the girth weld locator, it should be backed up
with a video camera for real time inspection.

Page 3 of 5
 For pipe diameters larger than 36", the coating application is done
SAES-H-002,
A7 manually by qualified contractors with the approval of CSD/Coatings
Para. 5.2.4
Team.

A semi-robotic system is used for offshore applications of specialty liquid

SAES-H-002,
A8 coating on internal girth welds with diameters ranging from 8" and above
Para. 5.2.5
qualified and experienced contractors shall be utilized.

Crawler Equipment for internal coating is verified for correct functioning

and calibration on a test spool. SAES-H-201,
A9
Note: The Length & diameter of the test spool shall be decided & agreed Para. 7.1.6
by contractor, CSD & SA inspector before work begins.

Coating personnel hold a valid certification as follows :

SAEP-316
B) Equipment operator (trained & certified by Coating Contractor)
A10 Para 1.1 & Para.
C) Crew supervisor (trained & certified by Coating Contractor)
1.3

B In-Process Inspection of Internal FBE Coating

Coating operations are only allowed to proceed in bad weather

SAES-H-201,
B1 conditions (rain, high winds, etc.)if protective canopies approved by SA
Para. 7.3.6
Inspector are used.

Coating is applied with in 4 hrs, of blast cleaning before any rust

SAES-H-201,
blooming of the prepared metal surface occurs..
Para. 7.3.2
B2 Any flash rusting observed shall be re-blasted prior to coating.
SAES-H-002
Refer to the surface preparation and coating application requirements
APCS-Sheets
given in APCS Data sheets

Application of phenolic primer prior to the application of FBE is carried

out using a machine to ensure that the travel of application is constant
SAES-H-002,
B3 and that the DFT will not exceed 25 microns (One mil) in all areas.
Para. 5.2.3
Note : One mil thickness is exceeded if the “peaks” of steel substrate are
no longer visible.

Approved
Substrate Pre-Heat Temperature meets the temperature specified in the
Procedure SAES-
procedure. * Required Pre-heat Temp = ___________
H-201,
B4 1 . Preheating shall be accomplished by induction heating coils.
Para. 7.3.1
2. Preheating temperatures shall be measured with contact pyrometers.
&
Temperature crayons shall not be used.
Para. 7.3.4

The powder application is started immediately after correct metal temp is SAES-H-201,
B5
reached. Para. 7.3.5

Coating Machine applies the powder uniformly to correct width centered

SAES-H-201,
B6 on girth weld to achieve a target dry film thickness of 325 to 625 microns
Para. 7.3.5.1
in least number of passes possible.

Coated areas are protected from contamination of dirt or deleterious SAES-H-201,

B7
materials during application & curing. Para. 7.3.5.2

C Final Inspection Visual Check or Video Camera:

Internally coated pipeline with diameters from 10" to 20" shall be SAES-H-201,
C1
inspected by the cameras fitted on the crawling machine. Para 8.2.5

SAES-H-201,
Finished coating has a uniform, glossy appearance free of defects such
C2 Para 8.2.4
as holidays, fish eyes, lumps, dry spray, sags, and runs.

SAES-H-201,
Coating overlap shall be within the thickness specified in SAES-H-200
C3 Para 8.2.4
and / or as per the applicator's procedure approved.

Cure Test is performed on first five joints coated and twice each day
SAES-H-201,
C4 there after, and found acceptable the results are recorded using SATR-H-
Para 8.2.3
2009.

Page 4 of 5
 Adhesion Test is conducted as per the frequency specified in SAES-H-
201 found acceptable and test result recorded on SATR-H-2010. SAES-H-201,
C5
Note: Coatings failing the adhesion test criteria shall be completely Section 8.4
removed and areas recoated.

D Dry Film Thickness (DFT) measurement & Holiday Testing

Thickness measurements made on each coated weld joint using an
approved, correctly calibrated dry film thickness gauge (per SSPC PA-2). SAES-H-201,
A minimum of 6 readings shall be taken on each field joint including weld Para. 8.2.2
D1
seam. &
Refer to attachment # 1 for Coating thickness specified for Various Para. 7.3.5.1
Coating Systems.

Holiday test applied on 100% of the joints coated, at test voltage of 125 SAES-H-201,
volts DC per 25 microns of maximum coating thickness. Para. 8.3
D2
(Surface temp of pipe shall not exceed 88). 09-SAMSS-091
Test results are recorded on SATR-H-2008 Para 10.6.3

All holidays, imperfections, and damaged areas are carefully SAES-H-201,

D3
identified as required by the procedure. (Joint ID Number) Para 8.3.2

E Repairs

Girth welds with more than 3 holidays are completely blasted off and the SAES-H-201,
E1
area recoated Para 8.5.1

Pipe surface to be repaired are cleaned of all dirt and damaged or

disbonded coating using abrasive blasting or other suitable means. The
SAES-H-201,
E2 edges of the original coatings are "feathered out" approximately 50 mm
Para 8.5.2
around the specific area to be coated, and all dust wiped off before
applying the patch coating.

Approved
Patch-up coating is applied using materials & methods specified in the
E3 Coating
approved Repair Procedure.
Procedure

Patch Repair areas are 100% holiday tested applying procedures used
SAES-H-201,
E4 for original coating (Refer to D2 above) and found acceptable, results
Para 8.5.4
recorded on SATR-H-008

Page 5 of 5