SAES-H-005 Thermal Spray Aluminium by Arc Spray Process

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Page 1 of 23 Page 1 of 23 Primary contact:

Primary contact: Al-Mansour, Mana Al-Mansour, Mana Hamad on Hamad on +966-13-880-9557+966-13-880-9557

Thermal Spray Aluminum Coating by Arc Spray Process

for Structure Materials against Atmospheric Environment (APCS-30TSA)

Document Respo

Document Responsibility:

nsibility: Paints and Coating

Paints and Coatings Standards Com

s Standards Committee

mittee

Saudi Aramco DeskTop Standards

Table of Contents Table of Contents 1

1 Scope....Scope... ... 22 2

2 Conflicts Conflicts and and Deviations...Deviations... 2 2 3

3 Applicable Applicable Documents...Documents... 22 4

4 Definitions Definitions and and Acronyms...Acronyms... ... 55 5

5 General Requirements………...General Requirements………... 6 6 6

6 Surface Preparation...Surface Preparation...……….……….…66 7

7 Thermal Thermal Spray Spray Application....Application... ... 88 8

8 Sealer Sealer Coat/Top-Coats...Coat/Top-Coats... ... 99 9

9 Coating Coating Repair...Repair... 1010 10 Inspection... 10 Inspection... 13 13 11

11 Qualification Qualification of of Materials Materials // Process / Equipment

Process / Equipment………...……….... 12. 12 12

12 Qualification Qualification ofof Operators………Operators……… 13 13 13

13 DocumentDocumentation...ation... ... 1414 14 Safety... 14 Safety... 1515 Table 1 - Abrasive Materials Suitable

Table 1 - Abrasive Materials Suitable

for TSA (Arc Wire Process)... 7

Table 2 - TSA Inspection and Test Plan... 12

Table 3 - Qualification Requirements Table 3 - Qualification Requirements of TSA Materials, Process of TSA Materials, Process and Equipment……….. and Equipment………..1313 Table 4 - Prequalification of Thermal Table 4 - Prequalification of Thermal Spray Spray OperatorOperators...s... 14 14 Appendix Appendix I - Testing I - Testing Method fMethod for Prequaor Prequalificationlification.. .. 2020 Appendix Appendix II - InspeII - Inspection Chction Checklist...ecklist... 25 25 Appendix Appendix III -III - APCS 30TSA Approved Data… APCS 30TSA Approved Data…... 27... 27

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1 Scope

1.1

1.1 This This standard standard establishes establishes the the minimum minimum mandatory mandatory requirements, requirements, principles,principles,

methods, and inspection to be employed for Thermal Sprayed Aluminum Coating methods, and inspection to be employed for Thermal Sprayed Aluminum Coating by Arc

by Arc Spray prSpray process (APocess (APCS-30TSACS-30TSA) appli) applied in shoed in shop or in p or in the fiethe field forld for

onshore/offshore structures exposed to atmospheric areas and/or under insulation. onshore/offshore structures exposed to atmospheric areas and/or under insulation. 1.2

1.2 Additional Additional requirements requirements may may be be contained contained in in Scopes Scopes of of Work, Work, Drawings, Drawings, oror other Instructions or Specifications pertaining to specific items of work. other Instructions or Specifications pertaining to specific items of work. 2

2 Conflicts Conflicts and and DeviationsDeviations

Conflicts between this Engineering Standard and an

Conflicts between this Engineering Standard and an y other Mandatory Saudi Aramcoy other Mandatory Saudi Aramco Engineering Requirements shall be resolved by the Consulting Services Department in Engineering Requirements shall be resolved by the Consulting Services Department in writing.

writing. 3

3 Applicable Applicable DocumentsDocuments

Unless stated otherwise, all Procedures, Specifications, and Codes referenced

Unless stated otherwise, all Procedures, Specifications, and Codes referenced in thisin this standard shall be of the latest issue (including revisions, addenda, and

standard shall be of the latest issue (including revisions, addenda, and supplements) andsupplements) and are considered part of this standard.

are considered part of this standard. 3.1

3.1 Saudi Saudi Aramco Aramco ReferencesReferences

Saudi Aramco Engineering Procedures Saudi Aramco Engineering Procedures

SAEP-302

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering requirement

Saudi Aramco Engineering requirement SAEP-316

SAEP-316 Performance Qualifications of Coating Personnel Performance Qualifications of Coating Personnel SAEP-1200

SAEP-1200 Process Flow Requirements for Qualification Process Flow Requirements for Qualification Procedures of Industrial Coating and Abrasive Procedures of Industrial Coating and Abrasive Blasting and Abrasive Blasting Products

Blasting and Abrasive Blasting Products Saudi Aramco Engineering Standards

Saudi Aramco Engineering Standards SAES-H-001

SAES-H-001 Selection Requirements for Industrial CoatingsSelection Requirements for Industrial Coatings SAES-H-002

SAES-H-002 Internal and External Coating for Steel Pipelines Internal and External Coating for Steel Pipelines and Piping

and Piping SAES-H-004

SAES-H-004 Pro Protecttective Cive Coatioating Seng Selectilection anon and Appd Applicalicationtion Requ

Requiremirements ents for for OffOffshorshore Ste Structructures ures and Fand Facilacilitieitiess SAES-H-101V

SAES-H-101V Approved Saudi Aramco Data Sheets-Paints and Approved Saudi Aramco Data Sheets-Paints and Coatings

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SAES-L-133 Corrosion Protection Requirements for Pipelines, Piping and Process Equipment

SAES-H-102 Safety Requirements for Coating Applications

SAES-N-001 Basic Criteria, Industrial Insulation

Saudi Aramco Materials System Specification

12-SAMSS-007 Fabrication of Structural and Miscellaneous Steel

Saudi Aramco General Instructions

GI-0002.100 Work Permit System

GI-0006.021 Safety Requirements for Abrasive Blast Cleaning

3.2 Industry Codes and Standards

American Society of Materials (ASM)

ITSC 1103 The Application of Thermal Spray Technology in the

Oil and Gas Industry. American Society for Testing and Materials

ASTM D7091 Standard Test Methods for Nondestructive

Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Non-Magnetic, Non-Conductive

Coatings Applied to Non-Ferrous Metals

ASTM D4285 Standard Test Method for Indicating Oil or Water in

Compressed Air

ASTM D4541 Standard Test Method for Pull-Off Strength of

Coatings Using Portable Adhesion Testers

ASTM D 4940 Standard Test Method for Conductimetric Analysis

of Water Soluble Ionic Contamination of Blasting Abrasives

American Welding Society

ANSI/AWS C2.18 AWS Guide for the Protection of Steel with Thermal

Sprayed Coatings of Aluminum and Zinc and their Alloys Composites

AWS C2.25/C2.25M Specification for Thermal Spray Feedstock Solid and Composite Wire and Ceramic Rods

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International Organization for Standardization

ISO 209-1 Wrought Aluminum and Aluminum Alloys

-Chemical Composition and Forms of Products

ISO 11124 Preparation of Steel Substrates before Application

of Paints and Related Products -- Specifications for Metallic Blast-Cleaning Abrasives

of Paints and Related Products -- Test Methods for Metallic Blast-Cleaning Abrasives

of Paints and Related Products - Specifications for Non-Metallic Blast-Cleaning Abrasives

of Paints and Related Products - Test Methods for Non-Metallic Blast-Cleaning Abrasives

ISO 8501-1 Preparation of Steel Substrates before Application

of Paints and Related Products - Visual Assessment of Surface Cleanliness

ISO 8502-3 Preparation of Steel Substrates before Application

of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 3: Assessment of Dust on Steel Surfaces Prepared for Painting (Pressuresensitive Tape Method)

ISO 14918 Thermal Spraying

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Approval Testing of Thermal

Sprayers

ISO 14231 Thermal Spraying

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Acceptance Inspection of

Thermal Spraying Equipment

ISO 9220 Metallic Coatings

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Measurement of Coating

Thickness

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Scanning Electron Microscopy Method

ISO 26946 Standard Method for Porosity Measurement of

Thermally Sprayed Coatings

ISO 12679 Thermal Spraying - Recommendations for Thermal

Spraying German Standard

DIN EN 573-3 Aluminum and Aluminum Alloys - Chemical

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National Association of Corrosion Engineers

NACE SP0198 Standard Practice Control of Corrosion under

Thermal Insulation and Fireproofing Materials-a System ApproMaterials-ach

Joint NACE 12 Specification for the Application of Thermal Spray

AWSC2.23M Coatings (Metallizing) of Aluminum, Zinc,

SSPC-CS 23.00 and Composites for Corrosion Protection of Steel

Steel Structures Painting Council

SSPC Vol. 1 & 2 Steel Structures Painting Council

SSPC-CS 23.00 Thermal Spray Coating for the Application of

Aluminum, Zinc, and their Alloys and Composites for the Corrosion Protection of Steel

DE-119889 Procedure for Painting of Offshore Platforms

American National Standard Institute

ANSI Z49.1 Safety in Welding, Cutting, and Allied Processes

ANSI Z88.2 American National Standard for Respiratory

Protection

4 Definitions and Acronyms

Adhesion Test: A test to determine the tensile strength of a thermal spray coating.

Bend Test: The bend test (180° bend on a mandrel diameter) is a qualitative test of the ductility and tensile bond of the TSC. The bend test is a macro-system test of surface preparation, equipment setup, spray parameters, and application procedures.

Companion Coupon: A small rectangular metal sample surface prepared and coated concurrently with the workpiece, used for inspection.

CSD: Consulting Services Department, Saudi Aramco

ID: Inspection Department Vendor, Operations or Project Inspector or Inspection Representative.

Monitor Activity: Random check by direct or indirect inspection to verify that there is conformance of the item or process.

MSDS: Material Safety Datasheet QC: Quality Control

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Rust Bloom: Discoloration indicating the beginning of rusting. For the purpose of this standard, rust bloom is rusting that occurs after specified surface preparation.

Sealer: The sealer is a thin coat that is absorbed into the pores of the TSC. Sealing is accomplished (a) naturally by the oxidation of the sprayed aluminum filling the pores with a tightly adherent oxide layer or (b) by applying thin paint sealer coatings that penetrate and are absorbed into the pores of the TSC.

Soluble-Salt Contaminants: These water-soluble salts are inorganic compounds (such as chlorides and sulfates) that contaminate a product. If soluble salts are present on a prepared steel surface, they may cause rust bloom and premature coating failure.

TSC: Thermal Spray Coating

TSA: Thermal Spray Aluminum

Topcoat: is a coat over the seal coat. Topcoats should never be applied over an unsealed TSC.

Witness Point: It is significant operation point requiring sighting and scrutinizing of the activity, however, the activity and any subsequent activity proceed as planned, notifications to witness these activities are advised informally.

5 General Requirements

5.1 TSA application shall be Arc Spray process.

5.2 The chemical composition of aluminum wires for thermal spray shall conform to the requirements of ISO 209-1, AWS C2.25/C2.25M, DIN EN 573-3.

Aluminum feed wire shall have a minimum purity of 99.5% aluminum.

5.3 Only prequalified brands or proprietary spray equipment shall be used. Spray equipment spare parts shall always be maintained in stock so as not to cause any operational delay during application.

5.4 Rolls of wires withdrawn for use shall be covered with polythene sheets to prevent being contaminated.

6 Surface Preparation

6.1 Prior to blasting it should be made sure that any surface imperfections such as laminations, weld spatters, rough welds shall be removed b y grinding or by appropriate means. Rough welds and sharp edges shall be ground to a minimum radius not less than 2 mm to ensure proper coating application.

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6.2 All components shall be solvent cleaned as per SSPC-SP1. Do not use

kerosene, diesel or other degreasers that leave an oily film unless the surface is subsequently cleaned with a non-greasy solvent such as SAP m/n 1000186759 (s/n 26-854-642), m/n 1000022130 (s/n 45-605-875) and m/n 45-605-875/880 (s/n 1000022131). Oil residues will not be washed away with water. All oil and other liquid contamination should be removed before grit blasting. If not,

contaminated grit could re-contaminate the clean surface. The surface shall be free of all contaminants prior to blasting, to provide a mechanical key for TSA to the surface.

6.3 Abrasive materials shall comply with requirements established in SAES-H-001 sub-sections 6.3, 6.4, 6.5 and Section 8. Regardless of the type of abrasive, the sulfate content shall be less than 50 PPM, the chloride shall be less than 50 PPM, and calcium carbonate shall be 0.1 0% maximum by weight. Selection and evaluation shall also comply with ISO 11124 11126 and 11127 series. Table 1 indicates typical blasting media and mesh size suitable for TSA on steel substrates. Blasting media shall be free from harmful contaminants such as oil, grease.

6.4 Compressed air - The water and/or oil content of the compressed air for surface preparation and coating operations shall be measured in accordance with

ASTM D4285. The blast compressed air shall be oil and moisture free. 6.5 Avoid blasting when the relative humidity is greater than 85% or when the

substrate temperature is less than 3°C (5°F) above the dew point and during dusty condition, rain, and foggy weather.

Table 1

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Abrasive Materials Suitable for TSA (Arc Wire Process)

Type Generic

Name Characteristics Standard Size (a)

Metallic Iron grit > 1.7% carbon ISO 11124-2 G-16 to G-40 Steel grit 0.8% to 1.2% carbon ISO 11124-3 G-16 to G-40

Natural mineral

Garnet Calcium iron silicate ISO 11126-10 G-16 to 30/40

Aluminum oxide

Crystalline corundum

Brown Fused Alumina ISO 11126-7 10 to 46 mesh

Mesh size, mix and nature of abrasives will depend on the degree of cleanliness and surface profile requirements. Silica sand as abrasive material is prohibited in Saudi Aramco as per GI-0006.021 requirements.

6.6 The steel substrate shall be prepared to the minimum of near-white metal finish Sa 2 ½ / NACE2/SSPC-SP 10. The slow process of TSA application shall be considered so that only sufficient area of the structure is blast cleaned to allow

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application of TSA without deterioration of already cleaned surfaces.

After blasting, atmospheric conditions shall be monitored every 3 hou rs to make sure there is no condition for the onset of rust blooming. Areas found with rust blooming shall not be coated but shall be brought up to required standard of

cleanliness before coating. Surface finish and cleanliness shall be confirmed according to ISO 8501-1/SSPC-VIS-1.

6.7 Level of dust remaining on the blast cleaned surface shall also be checked as per ISO 8502-3. Acceptable level shall be maximum rating 2.

6.8 The blast profile should be in the range of 75 – 125 microns. The anchor profile shall be measured by Replica tape, ISO profile comparator or Stylus type profile meter.

6.9 Members that are already primed / coated in accordance with the approved project paint procedure but are included in the TSA application scope of work

mentioned in Section 1.1 are to be re-blasted.

6.10 Intended weld areas and items not requiring TSA shall be masked off before TSA application. (Follow AWS C2.18, Subsection 8.22.)

6.11 Residual chloride shall not exceed 30 mg/m². Wash down the surface with sweet water to remove chloride contamination. Chloride test shall follow the water wash down until the correct value is achieved.

7 Thermal Spray Application

7.1 TSA application shall commence immediately upon inspection of the prepared surface. The maximum allowable time between surface activation and

application of first TSA coating shall be not more than 4 hours with excursions to lower times depending on atmospheric conditions and presence of rust

blooming. No coating application shall proceed during inclement weather like rain, fog, or dust storm unless the area is tented. Before coating application, test the substrate for the chloride content.

7.2 Thermal spray equipment shall be set up and operated according to the instructions and technical manuals of the Manufacturer or TSC Applicator. 7.3 The coating shall be applied in multiple crossing passes with a standoff distance

between 100 and 200 mm. Each pass shall overlap the previous pass in order to achieve an even coating thickness as much as possible. The spray shall be maintained as close to perpendicular as possible and the spray angle should be within ±45º to the substrate from perpendicular. In no case can less than two passes be applied in any surface.

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7.4 The coating tensile-bond strength is greater if the spray passes are kept thin. Laying down an excessively thick spray pass increases the internal stresses in the TSA and decreases the ultimate tensile-bond strength of the total TSA. The suitability of the crossing-pass thickness shall be confirmed with appropriate inspection tests as depicted in sections 10 and 11.

7.5 Other methods such as “cross-hatch” method whereby each series of spray passes is followed (where possible) by another series of overlapping passes at 90° to the first. This method radically reduces the amount of inherent variations in the sprayed coating thickness. Oscillatory overlapping method, for small areas, can also be used provided that it conforms in principle to this specification with multiple thin passes being executed.

7.6 The deposited TSC shall be checked continuously and it shall be uniform without blisters, cracks, loose particles, or exposed steel.

7.7 The applied TSA thickness shall be between 250 to 600 microns, with no single reading below 250 microns. In complex geometries or areas of difficult access a maximum thickness of 800 microns is allowed provided that their area does not exceed 10% of the total area to be sprayed. The thickness measurement,

frequency and calculation shall be in accordance with NACE No 12/AWS C2.23/SSP-CS 23.00; Paragraph 6.3. The thickness gauges shall be calibrated before any coating application.

7.8 The final surface of unsealed TSA shall be visually inspected and should be uniform and free from coarse areas and loosely adherent particles.

7.9 Completed TSA coatings shall be coated with sealer as soon as possible or within 24 hours to avoid oxidation. Coatings that cannot be immediately over coated shall be protected from contamination by covering with clean plastic sheeting.

7.10 For items that will be welded after coating, 5 cm to 10 cm measured from the bevel area shall be left uncoated and 30 cm to 40 cm measured from the bevel

area shall be left without coating on top of the metal coating. After welding, the area should be prepared and coating as per the above requirement.

7.11 For complex geometries where some of the above requirements cannot be implemented, CSD shall be informed and documented procedure shall be submitted for approval.

8 Sealer Coat/Top-Coats

8.1 Sealers are intended to fill the porosity of the TSA and not to build film

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the amount of sealer applied must fit the porosity. Once the sealer does not soak into the coating anymore the application can be stopped. To facilitate sealer penetration into the pores, the sealer may be thinned with approved thinners and

sprayed on two to three coats.

8.2 In rough TSA surface, a sealer thickness slightly over 100 microns is the normal case although in flat surfaces the sealer can reach 40 microns DFT depending on the intended use. In any case, sealer thickness shall comply with manufacturer’s technical datasheet.

8.3 Selected approved sealer coat shall be immediately applied upon acceptance of TSA coating by QC Inspector. All application parameters including storage of paint materials, mixing, drying and curing shall be in accordance with

manufacturer’s technical data sheet.

8.4 Sealer coats shall not be used in TSA for corrosion under insulation (CUI). 8.5 Two component epoxy sealers shall be used for operating temperatures below

120̊ C and aluminum silicone sealers between 120 and 500°C.

8.6 Approved epoxy/silicone sealer coat shall be applied at the required DFT and aliphatic polyurethane top coat shall be in Yellow RAL 1021 at 50 microns DFT.

8.7 Allow sealers to firm dry at ambient temperature. Sealer shall be inspected at 30X power magnification to ensure that all the pores have been sealed by the sealer coat. The sealer shall leave no voids or missed areas in coverage. 8.8 TSA should be topcoated with a compatible coating system only when:

a) The environment is very acidic or very alkaline (when pH is outside the range of or 4 to 9).

b) The metal is subject to direct attack by specific chemicals.

c) The required decorative finish can be obtained only with a topcoat. d) Additional abrasion resistance is required.

8.9 Apply sealer/top coat per manufacturer’s instructions.

9 Coating Repair

9.1 Areas of thin coating shall be over coated with additional thermal sprayed metallic coating within two hours of the initial application while the surface is clean and dry. Preheating may be required to comply with the adhesion

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9.2 If the TSA has been damaged and bare substrate metal may be exposed or the size of a damage or worn area is greater than 0.1 m2 [1 ft2] the coating repair shall follow the procedures outlined in AWS C2.18 as follows:

9.2.1 Solvent cleaning – All oil and grease contamination shall be removed by solvent cleaning. Solvents to be used shall be of the approved type

and shall not cause detrimental effects on the substrate material and shall not leave any residue film on the substrate.

9.2.2 Scrape off loosely adherent paint/TSA – A paint scraper blade shall be pushed underneath the loose TSA to push and scrape away all loosely

adherent paint and TSA until reaching a well-bonded TSA area. 9.2.3 Abrasive blasting – The surface to be repaired shall be abrasive

blasted to a white metal finish with an anchor profile of 75 - 125 µm. The blasting nozzle shall be kept perpendicular to the work surface. Angle blasting into the TSA-steel interface may separate the bonded TSA from the substrate.

9.2.4 Feathering – A 5.0 cm to 7.5 cm border shall be feathered by angle blasting into the undamaged TSA area.

9.2.5 Apply TSA – The TSA shall be applied using equipment in accordance with Section 7. Do not apply arc-spray TSA over flame-spray coatings because the greater energy of arc spraying may detach the marginal

flame sprayed coatings.

9.2.6 Sealer and top coat – Sealer and top coat shall be applied in accordance with Section 8.

9.2.7 Coating repairs shall be re-inspected to ensure compliance with the requirements of this standard.

9.2.8 Where only the sealer or top coat have been damaged, the surface shall be prepared with #60 abrasive paper until a clean bright surface is evident.

All edges of existing coatings shall be feathered. The appropriate sealer/top coat system shall then be reapplied to the damaged areas. 9.2.9 For areas smaller than 0.1 m2 [1 ft2] follow AWS C2.18, Section 9.

10 Inspection

10.1 The Supervisor in-charge shall conduct and/or organize all front line inspection on all stages of blast cleaning, thermal sprayed aluminum application, and final inspection.

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10.2 Companion coupon – A companion coupon made of similar material as that of the item to be coated measuring 3”x 6”x 5 mm. It shall be blast cleaned and TSA at the same time with the assembly. Pull-off adhesion test can all be evaluated on these coupons which shall be left unsealed.

10.3 All required checks inspection and hold points shall be in accordance with the TSA Inspection and Test Plan in Table 2.

11 Qualification of Materials / Process / Equipment

11.1 Prior to permanent use in Saudi Aramco installations, the Contractor’s

materials/process/equipment shall be qualified and approved by CSD as p er SAEP-1200. The Contractor shall submit detailed coating procedures, materials datasheets and samples for qualification and testing. The documentation,

coatings properties, test methods, sampling, acceptance criteria and reference standards for qualification are depicted in Table 3.

11.2 Samples submitted for qualification tests shall be representative of materials, process and equipment intended for use. Contractor shall submit written letter or

affidavit indicating compliance with this requirement. Qualification shall be conducted by third party labs or agents approved by CSD. (Refer to SAEP-1200).

Table 2

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TSA Inspection and Test Plan

Property Test Method Sampling Test Frequency Acceptance Criteria

Compressed air ASTM D4285

(See 6.4) NA

Once per shift after start, when compressor

restarts or changes in compressed air source

Per the standard (No visible contamination)

Blast abrasives Visual NA Every batch (See 6.3)

Ambient conditions Ambient and steel temperature Relative humidity Dew point NA

Once on shift start and every 3 hours thereafter. Every hour when sudden weather changes

(See 6.5)

Surface Cleanliness ISO8501 or

SSPCVIS-1 All surfaces Continuously (See 6.6) Surface Cleanliness

(for Dust) ISO8502-3 All surfaces Continuously (See 6.7) Surface Profile (See 6.8) All surfaces Twice per shift (See 6.8)

Soluble Salts ISO8502-6 and-9 All surfaces

100 m² of blasted surface (automated blasting)

Minimum two r the first 50 m², and one for every

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Property Test Method Sampling Test Frequency Acceptance Criteria 50 m² thereafter for

manual blasting.

TSA finish Visual inspection All surfaces Continuously (See 7.4 to 7.7) Coating Thickness (See 7.7) All surfaces Continuously (See 7.7)

Sealer Visual

(See 8.7) All surfaces Continuously (See 8.7)

Pull-off adhesion ASTM D4541 Test coupon Once per shift (See Appendix 1)

Table 3

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Qualification Requirements of TSA Materials, Process and Equipment

Attribute Test Method Sample Acceptance Criteria

Reference Standard

Documentation Review/Approval N/A Completed

documentation (See Section 12) Equipment Acceptance Visual verification N/A As per STD ISO 14231

TSC finish Visual at 10x

magnification 3 samples (See 7.4 to 7.7) N/A

Coating thickness See 7.8

3 samples, 5 readings per sample 250 to 400 microns NACE No 12/AWS C2.23/SSPC 23.00 Adhesion in Bending Bend test (Refer to Appendix I) 4 samples Refer to Appendix I SSPC-CS 23.00 (Engineering Manual EM1110-2-3401 Pull-off Adhesion ASTM D4541 3 samples 1500 psi

(10.3 Mpa) ASTM D4541 Thickness by SEM (on

Metallographic sample) SEM – Image (400X) 1 sample 250 to 400 microns ISO 9220 or ASTM B748 Porosity by SEM (on

Metallographic sample) SEM - Image (400X)- see Appendix I (3) 3 samples < 10% At magnification of 400x ISO/TR 26946 (porosity evaluation)

Resistance to salt spray

Salt Spray (1500 Hours) with scribe 3 samples No signs of cracks, rust, blisters or corrosion ASTM B117 ISO 7253

Note: _{Other qualification tests might be required depending on specific application.}

12 Qualification of Operators

12.1 Contractor’s TSA operators shall demonstrate adequate practical experience and job knowledge of thermal spraying processes, materials and safety requirements

for which they are to be approved in compliance with ISO 14198.

12.2 Prior to commencement of work in accordance with this standard, the operator shall pass the pre-qualification tests described in Table 4. The results from the

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qualification tests are valid for maximum 12 months without regular coating work. 12.3 Contractor shall keep individual records of each operator qualifications tests and

provide up-to-date documentation to Saudi Aramco inspection personnel during qualification and/or inspection.

Table 4

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Prequalification of Thermal Spray Operators

Attribute Evaluation Method Acceptance Criteria Thermal spray Equipment Written exam Pass mark 70%

Thermal Spraying Process Written exam Pass mark 70% Substrate Materials Written exam Pass mark 70% Safety and accident Prevention Written exam Pass mark 70%

Visual examination of Coating Practical application (see 7.7)

Thickness and shape Test

(see NOTE 1) Practical application

Operator able to use device and perform thickness measurements.

Thickness within 250 and 400 microns. Adhesion in Bending Practical application,

see Appendix I (1) Results shall comply with Appendix I (1) Pull-off Adhesion Practical application

see Appendix I (2)

3 samples, results shall comply with Appendix I (2)

Note 1: _{One 1500 mm sample with “T” shaped profile and a “H” shaped profile with 750 mm high}

and 13 mm thick. If work involves coating of a pipe, specimen shall be cut from 200 mm, 6 inches pipe.

13 Documentation

The coating Contractor or Applicator shall keep a nd submit to the Principal accurate records of all relevant data of the surface preparation, spray process, coating materials including sealer and top coat if applicable and coating test results.

The documentation shall include:

13.1 Abrasive material type and size, grit size range, mixture ratio (if any), chemical composition, and MSDS, cleanliness of abrasive, compressed air cleanliness, surface cleanliness and surface anchor profile.

13.2 Metallic coating Materials: brand name and manufacturer, type/designation, lot number, wire diameter, certified chemical composition of the wire lot, and MSDS. 13.3 Sealer and topcoat: Manufacturer’s product and application datasheets, and

MSDS, DFT of top coat, thinner type and name and manufacturer, batch number, manufacturing date and shelf life.

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13.4 Surface Preparation: compressed air cleanliness, surface finish and anchor profile. 13.5 TSA application – information on the type of spray equipment, equipment

capabilities, spray parameters, and application procedures, and in -process quality control checkpoints.

13.6 Adhesion test results – bend test and pull-off adhesion strength. Thickness measurements.

13.7 All quality assurance and inspection measurements and results as indicated on the accomplished TSA Inspection Checklist.

13.8 All the in-house tests and relevant information during the prequalification test shall be documented and kept with CSD. Inspection shall be documented as per check list in Appendix II.

14 Safety

14.1 Contractor applicator shall comply with Saudi Aramco Safety Requirements established in SAES-H-102 “Safety Requirements for Coating Applications” and Construction Safety Manual Section 9; GI-0002.100; and GI-0006.021 for the steps pertaining to surface preparation.

14.2 The basic precautions for TSA application are the same as for welding and cutting. Consult ISO 12679-2011 sect 13; Chapter 11 (Safety), AWS Thermal Spraying: Practice, Theory, and Application; ANSI/ASC Z49.1, Safety in Welding and Cutting and NFPA 58, Liquefied Petroleum Gas Code.

14.3 TSA application requires a Hot work permit and firewatching every time this activity is undertaken.

14.4 For PPE equipment to be worn read and follow Manufacturer's Material Safety Data Sheet for specific feedstock materials. Also refer to Saudi Aramco Safety Handbook, page 25; SAES-H-102; Construction Safety Manual Section 9.

14.5 Paper, wood, oily rags, cleaning solvents, sealers, and paints should be stored at least 20 feet away from the thermal spraying area.

14.6 Airborne metal dusts, finely divided solids, or accumulations should be treated as explosives. Adequate ventilation in the thermal spray work area and collection of the overspray should be made to minimize the danger of dust explosions and fires. In shop environments, wet bag, and filter-cartridge collectors may be used to collect the fine overspray particles, thus minimizing the explosion and fire hazard and release of controlled and hazardous materials. Bag- and filter-cartridge

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collector units should be at least 15 m (50 ft.) removed from the spraying area to preclude ignition from the flame or heat of thermal spray guns.

14.7 The following are basic safety principles for handling aluminum powders:

 Read and follow the manufacturer's instructions on the Materials Safety Data

Sheet.

 Avoid any condition that will suspend or float particles in the air creating a

dust cloud.

 Avoid actions that generate static electricity, create sparks or otherwise

result in reaching the ignition energy or temperature. This includes NO SMOKING.

 Take actions to minimize and dissipate the generation of static electricity,

such as bonding and grounding, to avoid spark discharge.

 Take steps to limit the size of a fire or explosion and to hold any resulting

damage to the very minimum, i.e., store aluminum and zinc powder containers separately and away from flammable materials and ox idizing agents such as sulphur and nitrates. Zinc dust forms an explosive mixture with dry and moist air.

 Do not use water to extinguish aluminum or zinc fires. Use dry sand or a

Class D extinguisher.

14.8 Work may require partial or complete containment of the work site for surface preparation and thermal spraying and the collection and safe disposal of the used blasting media and thermal spray overspray. Follow the industrial safety and

environmental compliance requirements cited in 3.1 and Section 13 of AWS C2.18. Consult local community (city, county, and state) and Saudi Arabia air quality and hazardous materials control agencies for amplifying information as required. 14.9 Field work may require partial or complete containment of the work site for

surface preparation and thermal spraying and the collection and safe disposal of the used blasting media and thermal spray overspray. Follow the industrial safety and environmental compliance requirements cited in 3.1 and Section 13 of AWS C2.18. Consult local community (city, county, and state) and Saudi Arabia air quality and hazardous materials control agencies for amplifying information as required.

14.10 A Job Safety Analysis shall be performed to identify hazards and controls and discussed with all personnel involved before start of the activity as per LPD Safety Management Guide JSA 06-003-2013. Materials MSDS shall always be made readily available to personnel involved.

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Safety Precaution:

The fine aluminum particles produced in thermal spraying may be an extreme explosion hazard. Special precautions shall be taken when arc spraying due to higher spray rates and higher amounts of metal dust produced, especially if multiple arc-spray guns are being used in the same work area. Thermal spray aluminum and zinc powders, nominally 40-110 nm (0.0016-0.0044 in.) diameter, are not combustion or explosive hazard when handled and used in

accordance with powder manufacturer's instructions. Do not use water to extinguish aluminum fires. Use dry sand or a Class D extinguisher.

Revision Summary

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Appendix I

Testing Methods for Qualification

1. Bend Test

1.1 Test Objective

This test is performed to qualify equipment, Personnel and Coating Integrity. The bend test (180 degrees bend on a mandrel) is used as qualitative test for proper surface preparation; equipment set up and spray parameters. The bend

test puts the TSA in tension. The mandrel diameter for the threshold of cracking depends on substrate thickness and coating thickness.

1.2 Test Specimens

The test panels should be a material that closely matches the work piece or cold rolled steel. Test panel measurements shall be: 3” x 6” x .050” (76.2 mm x 152.4 mm x 1.27 mm). These test panels should be clean blasted using the same media and in the same manner as that used in performing the particular job. The TSA shall be sprayed in a range of 250 to 400 microns. A minimum of five specimens for bend test shall be prepared according to the requirements of

ISO 4624 using minimum 5 mm thick panels.

1.3 Procedure

Thermal spray applicators should apply the coating to prep ared test panel and conduct the bend test. The thermal spray coating should be applied to the sample using the same spray parameters as the ones being used to perform the job. Techniques and specified coating parameter used in spraying the job should be duplicated when spraying the coupons, i.e., Cross hatching.

The test consists of bending coated steel panels 1 80º around a specified diameter steel mandrel or a ½” (0.5 inch) diameter c ylindrical mandrel. This mandrel may be pneumatic or manually operated.

Once the coupons are bent then proceed with a visual inspection to evaluate coating for cracking. If the bend test fails, corrective actions must be taken to assure proper application of the thermal spray coating.

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1.4 Visual Inspection and Pass/Fail Criteria

Test panels should be examined visually without magnification. The bend test is acceptable if the coating shows no cracks or exhibits only minor cracking with no lifting of the coating from the substrate. If the coating cracks and lifts from the substrate more than 1/16” from the center (see chart below) in any of the test specimen the results of the bend test are unacceptable. Corrective measures must be taken and test should be performed again until 100% pass.

Note: _{A visual inspection should be taken of all areas that are coated with particular}

attention being made to particular areas. These areas include but are not limited to:

 Edges / Corners of substrate  Inside Square Corners

 Areas with multiple heights and angles

2. Pull-Off Strength of Coating Using Portable Adhesion Testers and others

2.1 Test Objective

This test is performed to qualify equipment, Personnel and Coating Integrity.

2.2 Test Specimen

Test panels shall be in accordance with that pretreatment method which is

intended to be carried out on the original surface. The chosen pretreatment shall be reported in the test report. There are no specific panel measurements although

the panel shall have a selected test area with a flat surface large enough to

accommodate the specified number of replicate tests. The surface may have any orientation with reference to gravitational pull. Each test site must be separated

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by at least the distance needed to accommodate the detaching apparatus. The size of a test site is essentially that of the secured loading fixture. For qualification purposes, at least five replications must be prepared and tested in order to

statistically characterize the test area. For regular quality control (Table 2) at least three test coupons shall be tested and evaluated. Panels must be 5 mm thickness minimum and shall be clean blasted using the same media and in the same manner as that used in performing the particular job.

Coating thickness shall me mutually agreed with CSD and must be representative of the coating applied in the field. It shall be consistent throughout all the

qualification and quality control tests.

2.3 Procedure

For testing procedure refer to ASTM D4541, methods B, C, D, E, F.

No single measurement of pull off strength at failure must be less than values established in Table 1. Examination of the test specimen shall be conducted after rupture to determine the cause of failure. Pay special attention to the following features:

 Areas with little or no coating, any lifting of metalizing

 Lighter colored areas ( lighter than the rest of the metalized coating)  Darker colored areas (darker than the rest of the metalized Coating)

Retesting is required if the failure occurs at the adhesive/coating interface.

3. Porosity Test

3.1 Test Objective

The main purpose of porosity measurement is to determine the quality of a thermally sprayed coating and its freedom from porosity, particularly on those areas of the significant surface that demands a functional requirement. The test is performed in the electronic microscope.

3.2 Test Specimen, Magnification and Field of View

The representative panel shall be in accordance with that pretreatment method which is intended to be carried out on the original surface. Coating thickness shall between 250 and 400 microns and shall be consistent throughout all the qualification tests.

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At least three test specimens of dimensions 10 mm by 10 mm shall be taken from the representative panel for observation in the electronic microscope. The minimum number of fields of view per test specimen shall be four and the magnification shall be 400X.

3.3 Procedure

Porosity measurements in Thermal Spray Aluminum is heavily reliant on the sample preparation and interpretation of the results. Technical Report ISO / TR 26946 provide guidelines in regards methods for characterizing the porosity of thermally sprayed coatings by metallographical examination. The Lab in charge of this analysis shall have the experience and sounded engineering judgment to interpret and report results.

Porosity average values must comply with values in Table 3. Some qualitative visual examples are given below for reference:

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Appendix II

Inspection Checklist

TSA INSPECTION CHECKLIST

PROJECT : ________________________ DATE ______________________ LOCATION :________________________________________________________ STRUCTURES:_____________________________________________________

ACCEPT REJECT

1 BLASTING ABRASIVE TYPE: STEEL GRIT

GARNET COAL SLAG

SIZE : ______________ Mesh CONDUCTIVITY: ___________ µS/cm

2 COMPRESSED AIR QUALITY : 3 CLIMATIC CONDITIONS :

4 SURFACE PROFILE AND CLEANLINESS :

CLEANLINESS STD: Sa 3 Sa 2 ½

PROFILE : ______________ µm

SALT CONTAMINATION TEST: _______________mg/m² DUST LEVEL CHECK : _______________Rating MASKINGS OF WELD PREPS, ETC.

5 TEST COUPON PREPARED :

6 ALUMINIUM WIRE BATCH No./ SIZE : ARC SPRAY

7 APPLICATOR BADGE No.

8 APPLIED TSA APPEARANCE / FINISH

9 AVERAGE DFT OF TSA _______________ µm

10 SEALER COAT THINNING / MIXING / APPLICATION 11 SEALER COAT MICROSCOPIC EXAMINATION 12 BEND TEST OF TSA COUPON

13 ADHESION TEST AVERAGE VALUE _______MPa

QC INSPECTOR TSA SUPERVISOR

NAME : ____________________________________________ _________________________________________ SIGNATURE : ____________________________________________ _________________________________________ Note : This check list must be filled- up for all TSA applications and shall be attached to Daily Inspection Reports.

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Appendix III

APCS-30TSA Approved Data

1. Type of Coating

Thermal Spray Aluminum (TSA)

2. General Data

2.1. Typical Use

For onshore/offshore structures exposed to atmospheric corrosion areas and/or under insulation

2.2. Service Condition Limitations

Temperature limits: 45 to 595°C (-50 to 1100°F) 2.3. Purchase Specification

Included in SAES-H-005.

3. Surface Preparation Requirements

The steel substrate shall be prepared to the minimum of near-white metal finish Sa 2 ½/NACE 2/SSPC – SP 10. Blast profile shall be between 75 and 125 microns.

4. Material Composition

Materials shall conform to the requirements of ISO 209-1, AWS C2.25/C2.25M,