Академический Документы
Профессиональный Документы
Культура Документы
09-SAMSS-080
Shop-Applied Baked Internal Coatings
29 April 2013
Scope............................................................. 2
References..................................................... 3
Definitions....................................................... 4
Materials......................................................... 4
Coating Application........................................ 8
Quality Requirements..................................... 9
10
Inspection Requirements............................... 9
11
Page 1 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
Scope
1.1
1.2
b)
c)
Custom coated items such as fittings, couplings, pipe spools, valves, and
the wetted portions of spectacle plates, blinds, and spacers.
a)
b)
Any conflicts between this specification and other Saudi Aramco Materials
System Specification (SAMSSs), Engineering Standards (SAESs), Standard
Drawings (SASDs) or industry standards, codes and forms shall be resolved in
writing by the Company or Buyer's 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's Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.
Page 2 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
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
SSPC SP 1
Solvent Cleaning
SSPC SP 5
SSPC SP10
NACE TM0384
Page 3 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
ASTM D516
ASTM E337
Definitions
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.
Manufacturer: Company which manufactures the required coatings.
Vendor: Pipe and/or custom coating applicator.
Pipe: For purposes of this specification pipe is used to refer to steel tubulars,
including line pipe and OCTG casing and tubing, and heat exchanger tubing.
Custom Coated Pieces: All spool pieces and fittings are not coated by automated inplant equipment, which are less than 40-foot in length.
Fitting: For purposes of this specification, fitting is used to refer to any custom
coated piece.
DFT: Dry film thickness.
RSA: Responsible Standardization Agency Representative - Coating Engineer
designated by the Manager, Consulting Services Department.
Materials
5.1
Coating
5.1.1
5.1.2
5.1.3
Manufacturer's name
b)
c)
Batch number
d)
Date of manufacture
e)
5.1.4
The Vendor shall keep samples of each batch for a period of 1 year.
The sample shall be of sufficient size to run duplicates of the
qualification tests in Appendix A, paragraph A3, if required.
5.1.5
5.1.6
The coating Manufacturer shall provide the coating Vendor with the
following:
5.1.7
5.2
09-SAMSS-080
a)
b)
Certification that each batch of coating material has passed all the
quality control tests, and met all inspection requirements
specified by the coating Manufacturer.
The Buyer's Representative may at any time 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. If the coating passes the tests, the
Buyer shall pay for the tests; otherwise the Vendor shall pay the costs.
Repair Materials
Touch-up or repairs shall be made with materials and procedures that have been
approved by the coating Manufacturer and that, in addition, have been tested in
accordance with, and meet the adhesion and autoclave performance
requirements of Appendix A of this specification. Repair materials shall be
marked with the information in paragraph 5.1.3. Repair materials are subject to
the retest provisions of paragraph 5.1.7.
5.3
Blast Abrasives
5.3.1
Abrasives for blast cleaning shall have less than 50 ppm sulfates and
less than 50 ppm chlorides. They shall be of a particle size that will
produce a clean, angular surface profile. The abrasives shall be stored
in a dry condition and kept dry during use.
Page 5 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
5.3.2
5.3.3
5.3.4
The use of reclaimed abrasives and the methods used for cleaning them
shall be according to the Manufacturer's recommendations.
The Vendor shall use suitable equipment for unloading, handling and temporary
storage of all items received for coating to avoid damage to the items or
obliteration of identification markings.
6.2
6.3
6.4
All products supplied to the Vendor for coating shall have all sharp edges, weld
fillets, and similar abrupt contours rounded by grinding or machining to produce
at least a 3 mm (0.12 in) radius on all surfaces where the internal coating is to be
applied. All weld spatter, metal laminations, pin holes, pits, blind holes and
other surface defects in the area to be coated shall be removed. Inaccessible
areas shall be sealed off (where possible) by welding. Weld seams shall be
inspected and all porosity and undercutting corrected before the product is
delivered to the coating Vendor.
6.5
Products received by the Vendor that do not meet the above criteria shall be
reported to the Buyer's Representative for disposition prior to coating.
6.6
Heat exchanger tube bundles: damaged and blocked tubes shall be retubed.
Extra length of tubes and tube overhang exceeds 3mm must be cut with the same
level of the tube sheet surface. The tube bundle assembly shall be hydrotested
prior to coating application by the vendor.
6.7
Vendor shall submit his handling, loading, unloading, storage and preparation
for shipment procedures for pipe and fittings for Saudi Aramco approval to the
Buyer's Representative prior to coating.
Page 6 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
Prior to abrasive cleaning, all oil, grease and other deleterious materials shall be
removed by solvent cleaning in accordance with SSPC SP 1 or by detergent
washing or steam cleaning. No residue that will affect adhesion shall be left on
the surface.
Oven burn-off at a temperature of 370-400C (700-750F) may also be employed,
if, in the opinion of the Vendor, this is the only satisfactory method of ensuring
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.
7.2
The pipe or fitting surface temperature shall be at least 3C (5F) above the dew
point before and during abrasive blasting until the primer application (if
required) or until start up of pre-heating. If preheating is used, it shall be carried
out in a uniform manner to avoid distortion.
7.3
The surface to be coated shall be abrasive cleaned to a white metal surface finish
equal to Sa3 as described in ISO 8501-1/SIS SS 05 59 00 (1988) or SSPC SP 5.
In case of internal coating of heat exchanger tubes, surface finish shall be
cleaned to Sa2.5 as described in the above standard or SSPC SP10.
7.4
7.5
7.4.1
7.4.2
Failure to meet the anchor profile requirement shall require lot narrowing
using the procedure given in paragraph 10.5.1.3.
When defects such as scabs, metal slivers, gouges or laminations are found
following the abrasive cleaning operation, and these defects cannot be repaired
by simple filing or grinding, the affected pipe or fitting shall be set aside for
disposition by the Buyer's Representative.
If this anomaly affects enough of the pipe or fittings so that the coating process
is severely disrupted, the coating process shall be stopped. The Vendor shall
advise the Buyer's Representative of the problem and of any remedial measures
that could be taken to achieve an acceptable coating. The final decision as to
Page 7 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
whether the affected pipe or fittings can be coated shall be made by the Vendor
after consultation with the Buyer's Representative.
7.6
Dew Point readings measured in accordance with ASTM E337 shall be recorded
at the start and every 2 hours during the blasting operation in the immediate
vicinity of the operation. Blasting and coating operations shall be suspended if
the substrate temperature is less than 3C above the dew point.
7.7
Any metal surface showing evidence of flash rusting shall be re-blasted prior to
coating.
7.8
The blasted surface of pipes and fittings shall be tested for the presence of
residual chlorides after blasting using a test method that has been prior-approved
in writing by the RSA. Residual chlorides shall be no greater than 40 mg/m.
7.8.1
Test a random location on the first pipe and/or fitting coated on any
given day. After that, test one out of every 50 pipes or 50 fittings.
7.8.2
In the event of a failure, re-test the piece. If it fails the re-test, test all
pieces that were blast cleaned both before and after the contaminated
piece until three in a row pass the test. All pieces coated after the last
good test must be re-blasted, re-tested, and re-coated.
Coating Application
8.1
8.2
The total dry film thickness of the coating system shall be defined in accordance
with the Manufacturer's recommendations for each particular service and
operating conditions.
8.3
The range of acceptable shades of color for the cured coating shall be
established prior to production coating. The color and gloss of the cured coating
shall be within the approved range and the cured coating shall be free of blisters
and fish eyes as defined in SSPC Vol. 1. Cosmetic sags, runs, and other noninjurious irregularities are acceptable.
8.4
Pipe and fittings for subsequent welding shall have a cut-back at each welding
end in the range of 50 to 75 mm (2.0 to 3.0 in) measured from the end of the
piece. In the case of fittings 6" diameter or less, the minimum cutback may be
reduced to 25 mm (1 in).
Page 8 of 17
8.5
09-SAMSS-080
Shop-Applied Baked Internal Coatings
Quality Requirements
The Vendor's quality assurance system shall include, as a minimum, the following:
10
a)
b)
c)
Checking the relative humidity, dew point, and the temperature of the pipe or
fittings prior to blasting
d)
Monitoring of size, shape, dryness and cleanliness of the blasting material and
process
e)
Checking visually, in good light, the inner surface for metal defects, dust and
surface debris
f)
g)
Checking visually the primed pipe or fittings for coating defects and for coverage
h)
i)
j)
k)
Holiday detection of 100% of the coated surface area of all pipes and fittings
including checking calibration of the holiday detectors.
l)
m)
n)
o)
Inspection Requirements
10.1
Notice
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 with a detailed time
schedule to permit him to witness or monitor all processing and testing phases.
Page 9 of 17
10.2
10.3
09-SAMSS-080
Shop-Applied Baked Internal Coatings
10.2.2
10.2.3
The Buyer's Representative shall have the right to halt the work and to
request alterations or corrections to the application process in order to
correct all faults found in the work which constitute failure to conform
to this Specification.
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.
10.4
Thickness Test
Every pipe and fitting shall be checked in accordance with SSPC PA 2 using a
non-destructive type of thickness gauge which has been calibrated as required in
paragraph 10.7.1. (These measurements may be confined to the ends of small
diameter items whose inner surfaces cannot be reached.) All results shall be as
specified in paragraph 8.2 and shall be recorded.
10.5
Adhesion Test
10.5.1
Frequency
10.5.1.1
Page 10 of 17
10.5.2
09-SAMSS-080
Shop-Applied Baked Internal Coatings
10.5.1.2
10.5.1.3
10.5.1.4
Test area
The weld cutback on selected pipe lengths or fittings (see paragraph
8.4) 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 repaired.
10.5.3
10.5.3.2
10.5.3.3
10.5.3.4
Page 11 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
Holiday Testing
10.6.1
10.6.2
For pipe, holidays shall not exceed an average of 1 per 3 m (32 ft) of
total coated surface in any given order, and shall not exceed more than
5 holidays in any single length. If more than 10 holidays have to be
repaired on any single length to meet the holiday requirement, the pipe
length shall be reblasted and recoated.
10.6.3
10.6.3.2
10.6.3.3
Page 12 of 17
10.7
11
09-SAMSS-080
Shop-Applied Baked Internal Coatings
10.7.2
The holiday detector used for production line holiday detection shall be
calibrated in accordance with NACE TM0384 or TM0186 as
appropriate.
11.1.2
11.1.3
11.2
11.3
All booms, hooks, forks, supports and skids used in handling or storing coated
items shall be designed and maintained in such a manner as to prevent any
damage to the item or to the coating, and shall be approved by Buyer's
Representative.
11.4
The Buyer's Representative shall 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.
29 April 2013
Revision Summary
Revised the Next Planned Update. Reaffirmed the content of the document, and reissued
with editorial revision to change the primary contact person.
Page 13 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
General Requirements
A1.1
b)
c)
A1.2
A2
Passed all the tests and met all the requirements of this qualification
procedure.
All qualification tests shall be carried out at no cost to Saudi Aramco. The RSA
shall decide if the data presented by the Supplier satisfy the requirements of the
tests outlined below.
References
Industry Codes and Standards
American Society for Testing and Materials
ASTM D714
ASTM D235
Page 14 of 17
A3
09-SAMSS-080
Shop-Applied Baked Internal Coatings
Qualification Tests
A3.1
A3.2
Specimen Preparation
A3.1.1
A3.1.2
A3.1.3
Adhesion
The test procedure and evaluation shall be in accordance with paragraph 10.5.3
of this Specification. The adhesion shall be measured both on as-coated
specimens and on specimens after immersion in the chemical resistance test in
paragraph A3.3.
A3.3
A3.3.2
Page 15 of 17
09-SAMSS-080
Shop-Applied Baked Internal Coatings
Test Solution
Test Temp.
C (F)
Test
Pressure
Test
Duration
a) Treated Seawater
120 (250)
34.5 MPa
(5000 psig)
24 Hrs
b) Brine Reinjection;
Wet, Sour Gas;
Wet, Sour Crude
120 (250)
34.5 MPa
(5000 psig)
24 Hrs
c) Wasia Water
Wasia Water
100% CO2
120 (250)
34.5 MPa
(5000 psig)
24 Hrs
d) Acid
10 Volume % HCl
50 (120)
Covered Vented
Container
24 Hrs
Commentary Notes:
To obtain approval for use in all the listed services, a coating system must pass
all above tests.
Alternatively, coatings may be approved for specific services by passing the
individual tests in those specific services.
All systems shall pass the acid test (d) in order to be qualified in accordance with
this specification.
A3.4
A3.4.2
A3.4.3
Page 16 of 17
A3.4.4
09-SAMSS-080
Shop-Applied Baked Internal Coatings
Chord
152 mm (6 in)
Arc
178 mm (7 in)
A3.4.5
A3.4.6
Page 17 of 17