CAT GROUP QUALITY ASSURANCE INSPECTION AND TESTING FOR PAINTING WORKS

REVISION 3 DATED 18-03-2013

REVISONHISTORY
Revision Prepared By Controlled By Date Approved By
0 QCManager QCManager 23.02.2012 ProjectManager
A QCManager QCManager 22.04.2012 ProjectManager
1 QA/QCManager QA/QCManager 17.02.2013 ProjectManager
2 QA/QCManager QA/QCManager 10.03.2013 ProjectManager
3 QA/QCManager QA/QCManager 18.03.2013 ProjectManager

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CAT GROUP QUALITY ASSURANCE INSPECTION AND TESTING FOR PAINTING WORKS
REVISION 3 DATED 18-03-2013

Table of Contents

1. PROCEDURE NO.

2. SCOPE AND PURPOSE

3. APPLICABILITY

4. RESPONSIBILITY

5. GENERAL

6. DEFINITIONS

7. PROCEDURE

7.1. Safety

7.2. Material

7.3. Personnel and Equipment

7.4. Process Control for Painting Works

7.4.1. Surface Preparation

7.4.2. Application of Coating

8. REPAIR OF COATING

9. INSPECTION OF FINAL COATING

10. HOLIDAY TEST

11. RECORDS

12. REFERENCES

13. ATTACHMENTS

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CAT GROUP QUALITY ASSURANCE INSPECTION AND TESTING FOR PAINTING WORKS
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1. PROCEDURE NO.

CAT-SHY 1- APCS 113A

2. SCOPE AND PURPOSE

The scope of this procedure is to define the criteria of workmanship for the proper
execution of the Painting works in accordance with Client requirements, IFC
drawings, specifications, Manufacturers instructions for storage mixing handling and
application and applicable codes and standards.

The purpose of this procedure is to detail the techniques to be applied on the

different activities relevant to the proper execution of the painting activities.

3. APPLICABILITY

Repair of damaged FBE, a well as, short runs of pipes (60 meters or less) that
will not require subsequent bending (as per SAES-H-002, section 5.4.1 dated
08 May 2011)

Coating of field girth weld joints of new construction tie-in welds and
occasional isolated welds (as per SAES-H-002, section 5.4.2 dated 08 May
2011)

Renovation of external coating of buried piping, pipelines and associated

fittings and appurtenances (as per SAES-H-002, APCS 113A, item II General
Data dated 08 May 2011)

Buried stainless steel lines (as per SAES-H-002, section 5.6.4 dated 02 June
2012).

A. Listed below are the data regarding the use of APCS 113A for
stainless steel lines.

i. Operating conditions (at flow condition)

1. For the 2 inch line:

Temperature = 72O F
Pressure = 15 psig
Specific Gravity = 0.095 lb/ft3
Viscosity = 0.0117 cp

2. For the 1 inch line:

The line will carry a mixture
of Fuel Gas and air from the
Flame Front Generator

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REVISION 3 DATED 18-03-2013

ii. Total length of buried stainless steel line

1. For the 2 inch line = 1,700 meters

2. For the 1 inch line = 19,000 meters

4. RESPONSIBILITY

Project Manager
Discipline Engineer
Discipline Foreman
QA/QC Manager
QC Personnel
Painting Crew Supervisor
Coating Applicators
Abrasive Blasters
Material Controller

5. GENERAL

The responsibility for the Process Control of the Painting Works rests primarily with
the QC Inspectors, the Discipline Engineer and the Discipline Foreman with the
Painting Crew Supervisor and audit by the QA & QC Manager.

The discipline Engineer and the Discipline Foreman as well as the Crew Supervisor
shall ensure the required work permits are available and in place on a daily basis.
Similarly they shall ensure that utilized drawings are latest revision

Surface preparation shall conform to the project specifications.

Client specifications and drawings, manufacturer instructions / recommendations
shall supersede the techniques detailed in this procedure when they differ.

The following procedure is a basic outline of requirements and in all cases

the relevant SATIP (if available) shall be reviewed by QC Manager or QC
Supervisor to ensure Inspectors are fully aware of tests and documentation
requirements prior to start of work.

6. DEFINITIONS

SATIP: Saudi Aramco Typical Inspection Plan

SAIC: Saudi Aramco Inspection Checklists.
SATR: Saudi Aramco Test Reports

7. PROCEDURE

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REVISION 3 DATED 18-03-2013

7.1. Safety

Safety during abrasive blasting and application of coating shall meet the
requirements of SAES-H-102, section 4; GI 0002. 100 (Work Permit System)
& GI 0006. 021 (Safety Requirement for Abrasive Blasting).

All the areas shall be barricaded prior to start of abrasive blasting and
coating; and necessary sign boards to be made visible near the area of
work. All the personnel involved in this process must wear proper personal
protective equipment.

The painting crew supervisor is responsible to ensure all relevant safety

standard sections are complied with prior to, during and after all activities.
Some specific requirements and precautions include:
Fire and Explosion Prevention

Smoking and/or the use of open flames shall be permitted only in

designated safe areas and never inside vessels.
Welding and the use of heating coils are prohibited in areas where
coating is in progress.
All electrical lighting equipment and connections shall conform to the
National electric Code, Class 1, Division 1, Group D explosion proof
requirements (NEC Article 500).
Solvents and paints shall not be applied to surfaces warmer than 80O C if
practical alternatives exist.
Work permits for hot work, cold work and confined space entry shall be
obtained in accordance with GI 0002. 100.

Ventilation

Forced ventilation shall be used in confined spaces whenever abrasive

blasting, solvent cleaning, and/or painting are in progress.
Air fed respirator hoods or helmet shall be worn by all personnel inside
confined spaces whenever:
Blasting or spray painting is in progress.
Solvent cleaning or brush painting is in progress in a confined
space having a volume of less than 16 m3.

Health Hazards

The appropriate personal protective equipment shall be worn. In addition,

safety belts and lines shall always be used by personnel working from
unguarded platforms or in confined spaces where a manhole accessed
by a ladder is the only exit.
Adequate washing facilities shall be readily available so that paints and
solvents splashed on the body or in the eyes can be immediately
removed.
Safety shoes and coveralls shall always be worn and safety hats shall be
worn as required by proponent organizations.

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Air hoses shall not be used by personnel for cleaning or cooling

themselves.
Solvents shall not be used by personnel for wash.

Abrasive Blasting

Blasting shall be equipped with remote control shut-off or a deadmans

switch.
The blast nozzle shall be electrically connected to an external ground in
order to prevent static electrical discharges or shocks to operating
personnel. Grounding wire shall be 4 AWG or larger.
The blasting hose shall be the static dissipating type with external
couplings.
Air fed respirator hoods for abrasive blasting and OSHA approved in-line
respirator air filters shall be utilized at all times by abrasive blasting
personnel.
Compressor hoses, air lines, and blast hoses shall be safety wired at
each coupling using proper safety pins.
Hearing protection shall be worn in confined spaces where abrasive
blasting is in progress.

7.2. Material

Material shall be in accordance with Client requirements and specifications,

material receiving inspection shall be in accordance with relevant SATIP and
SAIC, SAES-H-001, SAES-H-002 and SAES-H-002V.

International Protective Coatings Interzone 485 Ultra High Build Epoxy 99 %

Solid Epoxy according to APCS 113A; Saudi Aramco SAP Material No.
1000686070 (SAMS Serial No. 09-000-497)

Paint and Thinners shall be stored in well ventilated buildings/containers

clearly marked in accordance with 09-SAMSS-060.

Date of manufacture shall be clearly visible on container. Paints which have

exceeded shelf life given in Saudi Aramco data sheet shall be discarded.

Paint shall not be used from the container which shows signs of leakage.

7.3. Personnel and Equipment

All Abrasive Blasters, Painting / Coating Applicators and Crew Supervisors

shall be qualified, approved and possess valid certification in accordance
with Saudi Aramco SAEP - 316.

All compressed air used for abrasive blasting or coating operations shall be
free of oil moisture and contamination. The QC Inspector shall as a minimum
check air quality at the start and mid points of each 8 hour period.

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CAT GROUP QUALITY ASSURANCE INSPECTION AND TESTING FOR PAINTING WORKS
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All Blasting equipment shall have an operational dead-man control fitted.

Minimum nozzle pressure for blasting of steel shall be 90 psig.

Quality Control Equipment shall be available as required by project scope

and SAES-H-001.

7.4. Process Control for coating Works

All painting must conform to the applicable approved project painting

specifications. A thorough review of these specifications at the beginning of
the project will help to assure quality workmanship and avoid rework.

7.4.1. Surface Preparation

7.4.1.1. Surface preparation for application of APCS-113A shall

meet the requirements of SAES-H-001, Section 8 and
SAIC-H-2048 shall be applied.

7.4.1.2. Visual inspection shall be carried out in order to decide if

substrate requires solvent or detergent cleaning prior to
abrasive blasting. Cleaning shall be done in accordance
with specifications.

7.4.1.3. Surface preparation should be carried out after necessary

covering is done on the Girth weld areas and only
approved abrasives will be used for the Surface
preparation

7.4.1.4. Blast Standard should be as per ISO 8501-1 Sa 2 and

surface profile should be in between 50 - 100 microns.

7.4.1.5. For surface preparation of stainless steel pipes shall meet

the requirement listed below. However, the listed items
below are not limited to it.

7.4.1.5.1. Use non-chlorinated solvent to remove oil,

grease and soil.

7.4.1.5.2. Use non-metallic grit such as an approved

garnet or aluminum oxide to perform the
sweep blasting.

7.4.2. Application of Coating

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CAT GROUP QUALITY ASSURANCE INSPECTION AND TESTING FOR PAINTING WORKS
REVISION 3 DATED 18-03-2013

7.4.2.1. Before commencing with the application of the coating of

paint a thorough review of the painting specifications and
APCS must be made. (SAES-H-001, Section 9)
7.4.2.2. Paints which have gelled shall not be used. Paints skin
shall be cut and removed before application on recently
opened and partially used containers.

7.4.2.3. Prior to application, all paint shall be thoroughly mixed

until homogeneous and then strained. For quantities over
5 liters, a power stirrer shall be used. The paint should be
mechanically agitated at all times.
Coating shall commence after meeting the Induction
period and paint to be applied within the pot life given in
the manufacturers Technical Data Sheet. Dry film
thickness of 600 1,000 microns (24 40 mils) applied in
wet-on-wet single coat application, as per SAES-H-002,
APCS-113A.

Drying and Recoating Time

Substrate Recoat Interval To Immersion

To Handle
Temperature Minimum Maximum Water Dry Soil
10O C 72 Hours 72 Hours 21 Days 2 Days 2 Days
25O C 24 Hours 24 Hours 10 Days 1 Day 1 Day
40O C 12 Hours 12 Hours 7 Days 1 Day 1 Day

7.4.2.4. Dry film thickness of coating shall be in accordance with

specification or manufacturers recommendations,
whichever is greater.

7.4.2.5. The Painting Crew Supervisor/ QC Inspector shall ensure

that that the total dry film thickness is as called for in the
painting specifications.

8. REPAIR OF COATING

This procedure is also applicable for repairing of the APCS-113A coatings, i.e.
APCS-113A is compatible repair coating for APCS-113A.

Unless specified otherwise, the sound coating adjacent to the defect being repaired
shall be roughened for a distance of at least 50 mm using at least the equivalent of
80 grit emery papers. Exposed pipe surfaces shall be cleaned to near white metal,
Sa 2.5.
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CAT GROUP QUALITY ASSURANCE INSPECTION AND TESTING FOR PAINTING WORKS
REVISION 3 DATED 18-03-2013

Areas smaller than 1450 mm2 use an epoxy patching compound approved by the
RSA.

Areas larger than 1450 mm2 use fast curing solvent free epoxy systems only as
per aPCS-113A or other RSA approved products.

The repair coating shall overlap the adjacent sound coating by at least 10 mm to
maximum 20 mm. Coating application shall meet the minimum required DFT with 2
or more coats.

After meeting the minimum & maximum re-coating interval as per manufacturer
data sheet, once the paint is dry, the area of the patch repair will be holiday tested
& released for backfilling.

9. INSPECTION OF FINAL COATING

Inspection of the final coating application shall be in accordance with the SAES-H-
001, APCS-113A and inspection checklist SAIC-H-2050.

Total DRY Film Thickness (DFT) of APCS-113A shall be 600 1,000 microns for
the coatings with solids greater than 85 %. Reference: SAES-H-002V, APCS-113A,
Interzone 485 dated 30 May 2009.

10. HOLIDAY TEST

Holiday Test of liquid type coating in accordance with APCS-113A shall be

performed at 2,400 50 volts DC prior to backfill and results recorded in SATR-H-
2008.

11. RECORDS

Requirements for quality control records shall be in accordance with SAES-H-001,

Section 10 and SATIP-H-002-06.

All records relevant to above procedure shall be kept by the QC Manager in the site
office for the duration of the project and transferred to the Area Head Office, at the
achievement of the Project, to be filed, archived and kept for a period of Three
years

12. REFERENCES

Relevant APCS Documentation

SAES-H-001
SAES-H-002
SAES-H-002V

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REVISION 3 DATED 18-03-2013

SAES-H-102
SAEP 316

13. ATTACHMENTS

Technical Data Sheet of International Protective Coatings Interzone 485

SATIP-H-002-06
SAIC-H-2010
SAIC-H-2016
SAIC-H-2023
SAIC-H-2024
SAIC-H-2025
SAIC-H-2026
SAIC-H-2048
SAIC-H-2049
SAIC-H-2050
SAIC-H-2051
SATR-H-2004
SATR-H-2005
SATR-H-2008

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Document Responsibility: Paints and Coatings SAES-H-002V
Issue Date: 30 May 2009 Approved Saudi Aramco Data Sheets
Next Planned Update: 5 August 2010 for the Pipeline and Piping Coatings

3 International Paint - Approved Materials

APCS-113A Interzone 485 99% Solids Epoxy

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Document Responsibility: Paints and Coatings SAES-H-002V
Issue Date: 30 May 2009 Approved Saudi Aramco Data Sheets
Next Planned Update: 5 August 2010 for the Pipeline and Piping Coatings

Manufacturer - Approved Saudi Aramco Data Sheet

APCS-113A
Type of Coating : Ultra High Volume Solids Epoxy

Manufacturer : International Paint Saudi Arabia Ltd.

Product Name : Interzone 485

SAP M/N (SAMS S/N) : 1000686070 (09-000-497)

1. Storage

1.1 Shelf life, sheltered storage at 35C maximum : 12 months

2. Mixing

2.1 No. of Components : 2

2.2 Mixing Ratio : 4 PARTS EAA485:

1 PART EAA486

2.3 Thinner : GTA203

SAP M/N (SAMS S/N) : 09-000-498

2.4 Thinning Requirements : Up to 3%

2.5 Induction Time : N/A

2.6 Pot Life : 45 minutes at 25C

30 minutes at 40C

3. Application

3.1 Maximum Allowable Substrate Temperature : 100C

3.2 Typical Wet Film Thickness Per Coat : 600 - 1000 micrometers

3.3 Typical Dry Film Thickness Per Coat : 600 - 1000 micrometers

3.4 Theoretical Coverage at 25 Micrometers : 39.6 M/L

Dry Film Thickness

3.5 Minimum Number of Coats : 1

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Document Responsibility: Paints and Coatings SAES-H-002V
Issue Date: 30 May 2009 Approved Saudi Aramco Data Sheets
Next Planned Update: 5 August 2010 for the Pipeline and Piping Coatings

Manufacturer - Approved Saudi Aramco Data Sheet

APCS-113A Interzone 485 (Cont'd)

3.6 Drying Time

Substrate Recoat Interval Burial

Temperature To Handle Minimum Maximum* Water Dry Soil

10C 72 Hours 72 Hours 21 Days 2 days 2 days

25C 24 Hours 24 Hours 10 Days 1 day 1 day

40C 12 Hours 12 Hours 7 Days 1 day 1 day

* Before overcoating after exposure in a contaminated environment, clean thoroughly by high pressure
fresh water hosing and allow to dry.

3.7 Recommended Equipment

Airless spray : 0.030 in. tip; Remove all filters

45:1 ratio pump preferred
4,000 psi

Conventional spray : Not recommended

Brush and Roller : Not recommended

4. Technical Properties

4.1 Volume Solids (ASTM D2697) : 99%

4.2 Product Weight (ASTM D1475) : 1.10 Kg/L

4.3 Viscosity (ASTM D562) : 40-50 poise (BRT)

4.4 Flash Point (ASTM D93 or D56) : 63C (base)

Approval Date: March 31, 2004

Replaces: New

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