09 Samss 091

Materials System Specification
09- SAMSS-091 6 February 2017

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................................5
6 Material.......................................................................5
7 Handling of Pipe.........................................................7
8 Cleaning and Surface Preparation..............................8
9 Coating Application..................................................10
10 Quality Requirements...............................................11
11 Inspection Requirements..........................................12
12 Recheck on Coating Material Qualities....................19
13 Repairs......................................................................19
14 Pipe Storage and Preparation for Shipment..............20
Revision Summary...........................................................20
Appendix A - Qualification Procedure

for Initial Product Approval................................21
Previous Issue: 15 October 2011 Next Planned Update: 6 February 2020
Contact: Mansour, Mana H. (mansmh0c) on phone +966-13-8809557
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©Saudi Aramco 2017. All rights reserved.
Document Responsibility: Paints and Coatings Standards Committee 09-SAMSS-091
Issue Date: 6 February 2017
Next Planned Update: 6 February 2020 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

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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 Over-the-Ditch External
and Internal FBE Coating of 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
International Organization of Standardization

ISO 8501-1/SIS Pictorial Surface Preparation
[SS 05 59 00 (1988)] Standard for Painting Steel Surfaces
ISO 8502-3 Assessment of Dust on Steel Surface Prepared for
Painting
ISO 8502-6 Extraction of Soluble Contaminants for Analysis -
The Bresle Method
American Society for Testing and Materials

ASTM D4417 Field Measurement of Surface Profile of Blasted
Cleaned Steel

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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
Canadian Standards Association

CSA Z245.20 Series-14 Plant-Applies External Coatings for Steel Pipe
4 Definitions
Approved Procedure: Procedure referred to in this specification that has been

approved in writing by the RSA. Approved procedures do not require re-qualification
in new purchase orders.
Approved Product: A coating material that has been approved by the RUS as meeting
the requirements of the applicable APCS or SAMSS. Only approved products are
allowed for 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.

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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.
Responsible Unit Supervisor (RUS): The Engineering Consultant of Nonmetallic, CP

& Coatings Group who is designated by the Manager, Consulting Services Department.
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
5 Health, Safety, and Environment
Applicable safety requirements addressed in Section 5 of SAES-H-001 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 Use of reclaimed powder shall not exceed the Manufacturer's

recommendation. In no cases shall such use be greater than a maximum
of 10% by weight. If the reclaimed powder found contaminated at the
end of the production, 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.

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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.
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 mesh
Particle Size and 0.2% maximum retained on 250 μm CSA Z245 Clause 12.5
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 12.3
Thermal Meets Manufacturer specification for
CSA Z245 Clause 12.7
characteristics Tg1 (°C), Tg2 (°C), ΔH (J/g)
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
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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 FBE or other Saudi Aramco-approved

materials tested in accordance with, and meeting the applicable requirements of,
Appendix A of this specification. Touch-up material shall also be approved by
the Manufacturer. Repair materials shall be marked with the information in
paragraph 6.1.6. 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 Abrasives for blast cleaning shall be Garnet in accordance with the
requirement of paragraphs 6.3 and 8.2 of SAES-H-001. 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 as specified in paragraph 8.4 of this specification.
The abrasives shall be stored in a dry condition and kept dry during use.
Sand is prohibited as an abrasive for pre-cleaning, cleaning, and all other
abrasive blasting processes.
6.3.2 The Vendor shall furnish a chemical analysis for all batches of abrasives
to verify compliance with the requirements in paragraph 6.3.1.
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 (see paragraph 1.4) for handling,
loading, unloading, storage and preparation for shipment for 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 The pipe or fitting surface temperature shall be at least 3ºC above the dew
point and humidity shall be less than 80% during abrasive blasting until the
primer application and until startup of pre-heating. 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/SIS SS 05 59 00 (1988) or
SSPC SP 5.
8.4 The anchor profile shall be 50 - 100 micrometers.
8.5 Dust level shall not exceed Class 1 as per ISO 8502-3. Test the first 5 pipes
and/or fittings on any given day. After that, test one out of every 10 pipes or
10 fittings.
8.6 Defects
8.6.1 Weld spatter, rough weld surfaces, and sharp protrusions shall be
ground smooth.
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
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any

Page 9 of 25
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.
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 or the relative humidity is above 80%.
8.8 Chloride Contamination
8.8.1 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 RUS. Residual chlorides
shall be no greater than 20 mg/m².
8.8.2 Test a random location on the first pipe and/or fitting coated on any
given day. After that, test one pipe joint out of every 30 pipes or
20 fittings.
8.8.3 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 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 100 foot-candles (1,000 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

Anchor Profile Para. 8.4 50~100 μm All
First 5 pipes or
fittings on any given
Dust grade Para. 8.5 Less than Class 1
day then every
10 pipes or 10 fittings
Free of weld spatter,
Defects Para. 8.6 rough weld surfaces All
and sharp protrusions
3°C above steel
Dew Point Para. 8.7 Every 2 hours
temperature

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Test Test Method Acceptance Criteria Frequency
Relative Humidity Para. 8.7 Less than 80% Every 2 hours

First pipe and/or fitting
on any given day; then,
Residual Chloride Para. 8.8 Less than 20 mg/m²
every 30 pipes and 20
fittings
9 Coating Application
9.1 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 the
RUS for Saudi Aramco approval prior to application. Already approved
procedures do not require RUS review and approval on new purchase orders,
unless otherwise it is required by the Buyer's representative or any other
standards documents.
9.2 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’t be measured by the conventional DFT gauges.
Therefore, Vendor should describe in the coating application procedure his
method in achieving the required primer thickness.
9.3 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.
9.3.1 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
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.
9.3.2 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.
9.4 The coating thickness for custom coated pieces shall meet the
requirement specified in paragraph 9.3, additional 50 microns (2 mils) in
the maximum
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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 9.3 to
maintain the same thickness in the overlap area specified in paragraph 9.3.1 of
this document.
9.5 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, RUS shall be
consulted.
9.6 The internal root reinforcement shall be 1.5 mm or less, as per SAES-W-012,
paragraph 16.10.
9.7 The cured coating shall be of uniform color and gloss, and shall be free of
blisters, fish eyes, orange peel, sags and runs.
9.8 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.
9.9 Custom coated fittings are subject to a size limit of maximum 36” diameter and
10 feet in length. For fabricated spools that can’t be coated through the
automated process, custom coating is acceptable with the following conditions:
9.9.1 Pipe temperature shall not drop below the specified curing temperature
during the coating application.
9.9.2 Coating thickness shall meet the requirement of paragraph 9.4 of this
document.
9.9.3 Coating should pass the below testing requirements.
9.9.4 Bayer’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).

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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. (9.2)
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 9.7).
10.12 Cure Test - see paragraph 11.8.
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.
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

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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
Every pipe and fitting shall be checked in accordance with SSPC PA 2 at each
end 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 9.3
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,
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 two
samples per production lot.

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11.5.1.3 For custom coated fabricated spools, test the first

production joint and once every five 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 9.5) 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 12 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
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
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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 625 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 excessive 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.
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.
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11.6.6.3 Pipe diameters too small to allow visual inspection of the
girth weld area coating: The holiday test shall be made.

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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 Once per shift (or, for pipe, every one hundred pipe lengths,
whichever is the more frequent) and at the start of using a new batch
of powder the flexibility of the coating shall be determined by a bend
test.
The powder utilized for the test shall be taken from the plant
application fluidizing bed.
11.7.2 Two test bars measuring approximately 25 mm x 192 mm x (6.5-9.5)

mm shall be coated at a dry film thickness specified for each coating
system.
11.7.3 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 11.7.2.
11.7.4 The test bars shall be holiday detected in accordance with paragraph
11.7.7 of this specification, and all holidays marked and recorded.
11.7.5 The specimens shall be at three different temperatures 5, 10,

and 25°C ± 3°C when clamped in the bender with the coated side up.
The specimens shall be bent flat wise at the angles of 3.0°, 3.75°, and
5.5° per pipe diameter, respectively.
11.7.6 Bending shall be accomplished in less than 30 seconds.
11.7.7 The coated specimens shall show no cracks to base metal when
examined at 10X magnification except where gripped or
clamped.
If visual examination cannot determine whether a crack extends to base
metal, holiday testing using the hot spark detector method with a
conductive rubber electrode shall be used.
11.7.8 If either of the bend tests fail, the tests shall be repeated.
11.7.8.1 If both bend retests are satisfactory, the bend test shall be
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accepted.

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11.7.8.2 If either (or both) of the retests fail, immediately

discontinue further coating with the suspect batch of
powder and proceed as follows:
a) Pipe: All pipes coated since the previous successful
bend test shall be set aside. Two specimens with the
same dimensions as given in paragraph 10.7.2 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.
b) Fittings: All fittings coated with the suspect powder
shall be re-blasted and recoated.
11.7.9 If deemed necessary in some critical applications or according to an

end-user request, the RUS shall request the Vendor to prepare the
Bend test samples from a coated pipe section. Samples shall be cut in
both radial and longitudinal directions from the pipe section to suit the
Bend test requirements. The procedure of the test shall be as shown
above.
11.7.10 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 three sample per production lot. Girth welds 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
difference (Tg4-Tg3) must be in the range specified by the FBE Manufacturer,
within -2, +3°C. Any coated pipes, girth welds, or fittings fail the test within the
acceptable range shall be rejected.
11.9 Production Test Ring
Vendor should obtain a test ring from the pipe end, at least 500 mm, to be
subjected to the tests listed in Table 3. The minimum test frequency, for each
production line, shall be one test ring per pipe diameter and specified wall
thickness every working shift, a minimum of once every 12 h.
Page 20 of
Table 3 - Production Test Ring Requirements

Acceptance Test
Test Test Method
Criteria Specimens
No cracks, tears,
Flexibility: (3.75°/PD, NACE SP0394-2013
delamination, or 3
Test temperature: 5°C) (Appendix H)
disbondment
No cracks, tears,
5.5°/Pipe Diam NACE SP0394-2013
delamination, or 3
Flexibility @ 25 Celsius (Appendix H)
disbondment
Hot-water soak
NACE SP0394-2013,
Hot-water adhesion: Rating of 1 1
(Appendix J)
(48 hours) 75 ± 3°C
CSA Z245
Interface contamination 5% 1 Clause 12.9.3
CSA Z245
Cross-section porosity Rating of 1 1 Clause 12.10.3
ΔTg of -2, +3°C, or CSA Z245
Thermal characteristics 1 Clause 12.7.3.2.2
95% conversion
DFT Para 9.3 1 ASTM D4541
11.10 Calibration of Inspection Equipment
11.10.1 The coating thickness gauge (see paragraph 10.4) 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 4 - Summary of Coating Application Requirements

Acceptance
Test Test Method Criteria Frequency
Dry Film Thickness Para. 9.3 As specified in Para. 9.3 All

25-50 mm
(less than 6 inch dia.)
Cutback Para. 9.5 All
50-75 mm
(larger than 6 inch)

Page 21 of
Acceptance
Test Test Method Criteria Frequency
Internal Root
Para 9.6 1.5 mm or less All
Reinforcement
First joint or once
every hour or every
twenty pipe lengths.
If three tests
successful, every 2
Adhesion Test Para. 11.5 Pass
hours or 50 pipe
lengths for pipe
One sample per
production lot for
custom coated pieces
a) Pipe (≥ 24 inch)
Max. 20 holidays
Holiday Detection Para. 11.6 b) Pipe joint (≤ 20 inch) All
Max. 4 holidays per
12.2 m
Once per shift and at
Bend Test Para. 11.7 No crack the start of using a
new batch of powder
For pipe twice per
shift
Cure Test Para. 11.8 (Tg4-Tg3) = -2, +3°C For fittings three
sample per
production lot
Production Test Once per shift
Para. 11.9 Table 3
Ring (12 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 22 of
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.
14.5 End caps or any suitable end covers shall be used to prevent sand, water, and
other contaminants in getting in contact with the internal coating if applied.
End seal tapes shall be used to keep the end caps or end covers in place and
to protect the cut-back from corrosion and surrounding contaminants.
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.

Page 23 of
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 the RUS 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

Page 24 of
of coatings used and product data sheet.

Page 25 of
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 5,
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 11.7.2 of this specification

shall be tested and evaluated in accordance with paragraphs 11.7.3 through
11.7.7 of this specification.

Page 26 of
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 1010 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 should be more than 90% of the
initial reading.
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 2.
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 150 mm (4” X 6”).
3.8.3 The test chamber shall be heated to the test temperature specified in
Table 5 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
Page 27 of
discontinued.

Page 28 of
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 than

90% of the initial reading.
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 5 - 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 Stock Solution 2 (3,000 psig)
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 100% CO2 95ºC One week
(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
87 mole% Methane (3,000 psig)
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 29 of
Wasia Water Composition (mg/l):

Na = 2,500; Ca = 600; Mg = 120; Cl = 4,000; SO4 = 1,000;
HCO3 = 200; pH = 6.8 - 7.2
Table 6 - 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 1010 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 1-2 (Cross section)
Porosity Test Para. 3.7
Rate 1-2 (Interface)
Density Para. 3.9 Manufacturer specification
Thermal characteristics
CSA Z245 Manufacturer specification,
Tg1, Tg2, Tg3, Tg4,
Clause 12.7 ΔTg = -2, +3
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.

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Materials System Specification

09- SAMSS-091 6 February 2017

Appendix A - Qualification Procedure

Previous Issue: 15 October 2011 Next Planned Update: 6 February 2020

Contact: Mansour, Mana H. (mansmh0c) on phone +966-13-8809557

2 Conflicts and Deviations

Saudi Aramco: Company General

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

American Society for Testing and Materials

Saudi Aramco: Company General

ASTM D6677 Standard Test Method for Evaluating Adhesion by

Canadian Standards Association

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

Buyer: Saudi Aramco Purchasing Department representative.

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

DFT: Dry film thickness

Saudi Aramco: Company General

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

Responsible Unit Supervisor (RUS): The Engineering Consultant of Nonmetallic, CP

Vendor: FBE coating applicator

5 Health, Safety, and Environment

Applicable safety requirements addressed in Section 5 of SAES-H-001 shall be followed.

6.1 FBE Internal Coating

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

6.1.2 Use of reclaimed powder shall not exceed the Manufacturer's

Saudi Aramco: Company General

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

6.2 Repair Material

Touch-up or repairs shall be made with FBE or other Saudi Aramco-approved

6.3 Blast Abrasives

Saudi Aramco: Company General

8 Cleaning and Surface Preparation

8.4 The anchor profile shall be 50 - 100 micrometers.

Saudi Aramco: Company General

remedial measures that could be taken to achieve an acceptable coating.

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

Test Test Method Acceptance Criteria Frequency

Relative Humidity Para. 8.7 Less than 80% Every 2 hours

9.9.3 Coating should pass the below testing requirements.

9.9.4 Bayer’s Representative should attend, at least, the coating of the

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

Saudi Aramco: Company General

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. (9.2)