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Maintain Potential Facilities Offshore

Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)
INSPECTION AND TEST PLAN FOR THE Doc. No. 00-C-C-00-SB-P-QA-00-047
APPLICATION OF FUSION BONDED
EPOXY COATING TO THE INTERNAL Rev. I1 Date: 05.12.2017
SURFACE OF INDIVIDUAL FITTINGS
Sheet 2 of 4
SPOOLS AND ASSOCIATED ITEMS

INDEX

INDEX ........................................................................................................................................................................ 2
AMENDMENTS AND REVISIONS ........................................................................................................................... 3
1. INSPECTION AND TEST PLAN-09, REV. 0 (9 PAGES ATTACHED) ............................................................ 4

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was
prepared.

UNCONTROLLED COPY
 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)
INSPECTION AND TEST PLAN FOR THE Doc. No. 00-C-C-00-SB-P-QA-00-047
APPLICATION OF FUSION BONDED
EPOXY COATING TO THE INTERNAL Rev. I1 Date: 05.12.2017
SURFACE OF INDIVIDUAL FITTINGS
Sheet 3 of 4
SPOOLS AND ASSOCIATED ITEMS

AMENDMENTS AND REVISIONS

Amendment
CONTRACTOR
and Date Page Description
Rep.
Revision

X1 02.12.2017 All Issued for IDC PB

I1 05.12.2017 All Issued for Information PB

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was
prepared.

UNCONTROLLED COPY
 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)
INSPECTION AND TEST PLAN FOR THE Doc. No. 00-C-C-00-SB-P-QA-00-047
APPLICATION OF FUSION BONDED
EPOXY COATING TO THE INTERNAL Rev. I1 Date: 05.12.2017
SURFACE OF INDIVIDUAL FITTINGS
Sheet 4 of 4
SPOOLS AND ASSOCIATED ITEMS

1. INSPECTION AND TEST PLAN-09, REV. 0 (9 PAGES ATTACHED)

SUBCONTRACTOR - ARABIAN PIPECOATING COMPANY Ltd.

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was
prepared.

UNCONTROLLED COPY
 Factory: P.O. Box 834,
ARABIAN Jubail 31951, Saudi Arabia
Telephone (966) 13-362-0543
Fax (966) 3-1362 3815
PIPECOATING
Head Office: P.O. Box 106,
COM PANY Al-Khobar 31952, Saudi Arabia
Tel: (966)-3-882-2933/3052
Fax: (966)-3-882-2487
ARABIAN PIPECOATING COMPANY E-Mail: rkhobar@apco-
coating.com

SAUDI ARAMCO DOCUMENT REFERENCE: 09-SAMSS-091

CUSTOMER: SAIPEM STAR

BID NO.: H-13020-SS
INSPECTION & TEST PLAN – 09 REVISION 0

Inspection and Test Plan for the Application of Fusion Bonded Epoxy Coating
To the Internal Surface of Individual Fittings Spools and Associated Items

ELECTRONIC DOCUMENTS ONCE PRINTED ARE NON-CONTROLLED AND MAY BECOME OUTDATED

nd
2 December 2017 Page 1 of 9
H-13020-SS

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 Arabian Pipecoating Company
Inspection and Test Plan for the Custom Application of FBE Coating to the Internal Surface of Individual Fittings and Spool Pieces - ITP-09

Frequency Inspection/Hold Points

ACT. Quality Related Activity Reference Clause Acceptance Criteria Report Prod. APCO SAIPEM Compa
No. Document Form Test ny

0.1 Pre-Inspection Meeting P.O. - MOM - H H H

(if required)
COATING MATERIALS
1.0 Coating Material Receipt PP-09 7.0 Saudi Aramco approved materials RF-012A All Batches CH R R
PP-19 Packaging secure, marking legible
175-091300 0020/ FBE powder stored at a temperature recommended
0010 by the manufacturer
1.1 Quality Control Laboratory Testing PP-09 7.2.2 Test Standard Acc. Criteria QLR-004 All Batches CH R R
of FBE Powder. PP-19 Moisture CSA Z245.20 < 0.5%
content Manf. C of C
Gel time CSA Z245.20 Manf. C of C
Sieve CSA Z245.20 Manf. C of C
analysis
Density CSA Z245.20 Manf. C of C
Adhesion 09-SAMSS-091 Refusal to peel or
X Cut a cohesive failure
Fluidization APCO STM-004 Min 35%
Coatability APCO STM- Smooth, uniform
005/ STM-006 in colour and
gloss
Flexibility @ APCO STM-009 As per
Ambient manufacturer C of
Temp. C
Tg Powder CSA Z245.20 As per
(Tg1) manufacturer C of
C
Tg Cured CSA Z245.20 As per
(Tg2) manufacturer C of
C
ΔH CSA Z245.20 As per
manufacturer C of
C
ΔTg Cured CSA Z245.20 As per
Coating manufacturer C of
(Tg4 - Tg3) C
Note: in the event that the manufacturer is testing to
an older CSA standard /or alternative test standard,
APCO will follow the manufacturer’s test standard.

Revision: 0 H-13020-SS
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Inspection and Test Plan for the Custom Application of FBE Coating to the Internal Surface of Individual Fittings and Spool Pieces - ITP-09

Frequency Inspection/Hold Points

ACT. Quality Related Activity Reference Clause Acceptance Criteria Report Prod. APCO SAIPEM Compa
No. Document Form Test ny

1.2 Repair Material PP-09 7.3 Saudi Aramco approved repair material Mfr. All Batches CH R R
C. of C
1.3 Quality Control Testing Abrasive PP-09 7.1.2 Less than 100 PPM sulphates and chlorides. Manufactur All Batches R R R
Blast Material 175-091300 0010/ < 2% by weight calcium carbonates, ers
0020 Manufactures certificate of conformance certificate
and /or
Ind. Lab.
Cert.
1.4 Coating Material Certification PP-09 7.0 Manufacturers Certificate of Conformance for each C of C All R R R
PP-19 batch of material. batches
175-091300 0010/
0010
1.5 Coating Material Non- PP-09 7.0 Quarantined RF-037 - H H R
conformance PP-19
PRE-INSPECTION
2.0 Spool Receipt PP-09 8.1.3 Handling equipment designed and maintained to FIRF-001 All Fittings CH R M
PP-02 prevent steel/ coating damage. Store on wooden
175-091300 0020/ pallets/supports. Record each spool identification
0020 number.
Inspect each spool for:
 Oil and grease
 Debris inside spool
 Mechanical damage
 Sand, tape or other foreign material adhering
to spool
2.1 Adhering Debris/Sand PP-09 8.1.4 Remove all adhering debris, sand - If Required H M M
2.2 Solvent Cleaning (if required) PP-09 8.1.5 No Oil/Grease RIRF-001 If Required CH M M
SSPC SP 1
2.3 Fitting Non-conformance PP-09 8.1.6 Stored separately, hazard tape attached NCR-001 - H H M
PP-02
AMBIENT CONDITION
3.0 Climatic Conditions PP-09 8.2.2 Surface Temp. > 5˚C and > 3°C above dew point QRF-001 Start of CH R M
175-091300 0020/ shift/ 2
0040 hours
3.1 Compressed Air Supply PP-09 8.2.5 No moisture/ Oil QLR-003 Twice per CH R M
175-091300 0040/ shift
0040
ASTM D4285-
83
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 Arabian Pipecoating Company
Inspection and Test Plan for the Custom Application of FBE Coating to the Internal Surface of Individual Fittings and Spool Pieces - ITP-09

Frequency Inspection/Hold Points

ACT. Quality Related Activity Reference Clause Acceptance Criteria Report Prod. APCO SAIPEM Compa
No. Document Form Test ny

3.2 Abrasive Contamination Test PP-09 8.2.6 No oil or contamination QLR-003 Once per CH R M
SSPC shift
Publication 91-
12
ABRASIVE BLASTING INSPECTION
4.0 Steel Surface Defects PP-09 8.3.7 No weld spatter, protrusions, laminations etc. QF09-002 All Spools CH W M
175-091300 0020/ Repair area < 75mm in any direction
0050
4.1 Abrasive Blast Visual Inspection PP-09 8.4.1 White Metal Finish as per QF09-002 All Spools CH W M
175-091300 0020/ ISO 8501-1 SA 3
0050 SSPC-SP5/NACE No.1
Internal weld root reinforcement shall be < 2.5mm
4.2 Surface Profile PP-09 8.4.3 50 – 100 Micrometres QRF-001 Start of CH W M
(Profilometer and / or anvil type ISO 8503-4 RPC 20-40 p/cm Shift/
micrometer shall be used) ASTM D4417 2 Hours
175-091300 0020/
0050
2
4.3 Residual Surface Chlorides PP-09 8.4.2.1 ≤ 20mg/m QF09-002 First Spool/ CH R M
175-091300 0020/ One measurement per spool 40 Spools
0060
4.4 Residual Surface Chlorides PP-09 8.4.2.2 3 Acceptable spools prior to and after the failed spool QF09-002 As CH H M
Failure Required
4.5 Surface Dust level PP-09 8.4.1 ≤ Rating 2 QRF-003 First 3 CH R M
ISO 8502-3 spools per
Shift/ 20
Spools
4.6 Masking Tape Application PP-09 8.3.10 No contamination to blast cleaned surface - All Spools H M M
8.3.11 as
Required
4.7 Non-Conforming Steel Surface PP-09 8.3.8 Quarantine, hazard tape attached NCR-001 If required CH H M
4.8 Elapse Time from Abrasive Blast PP-09 8.3.12 Relative Humidity % Elapsed time QRF-001 Start of CH W M
to Primer Application/ Pre-heat 175-091300 0020/ (Hours) Shift/2
0090 80 2 hours
≥ 60 ≤ 80 3
< 60 4
Any fitting not placed in the heating oven and/or
primed within the limits above shall be re-blasted.

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Inspection and Test Plan for the Custom Application of FBE Coating to the Internal Surface of Individual Fittings and Spool Pieces - ITP-09

Frequency Inspection/Hold Points

ACT. Quality Related Activity Reference Clause Acceptance Criteria Report Prod. APCO SAIPEM Compa
No. Document Form Test ny

PRIMER APPLICATION
5.0 Primer Mixing PP-09 9.1.1 As per manufacturers data sheet - All Batches H M M

5.1 Phenolic Primer Viscosity PP-09 9.3.2.1 As per manufacturers data sheet VTRF-001 Every Mix H M M

5.2 Spool Surface Temperature Prior PP-09 9.3.2.4 Water Base Primer - Minimum 40°C Maximum 93˚C QF09-002 All Spools CH W M
to Primer Application 175-091300 0020/
0090
5.3 Phenolic Primer DFT PP-09 9.3.2.2 Primer applied in a uniform manner. QF09-002 All Spools CH W M
175-091300 0020/ DFT shall be approximately 12 to 25.4 microns, or an
0100 appearance of just wetting the surface. The DFT shall
not be measured as it is not possible to obtain an
accurate measurement. The DFT shall be determined
visually where the surface profile peaks are faintly
exposed indicates the DFT is acceptable.
5.4 Water Base Primer Application PP-09 9.1.2 Semi-automated and Manual application as required QF09-002 All Spools CH W M
9.1.3 Ensure the entire surface is completely covered,
175-091300 0020/ applied in a uniform manner.
0100
5.5 Delay from Primer Application to PP-09 9.3.2.3 Plastic sheets or end caps shall be fitted - As H M M
Pre-Heating 9.3.2.6 Phenolic Primer - maximum time 12 hours Required
Water Base primer- maximum time 3 hours
COATING APPLICATION
6.0 Pre-Heat PP-09 9.2.2 Calibrated infra-red gun/touch type pyrometer QF09-001 All Spools CH W M
175-091300 0020/ As per manufacturers recommendations.
0090
6.1 Coating Application PP-09 9.2.3 Semi-automated and Manual application as required N/A All Spools H M M
9.2.4 Smooth and even application.
175-091300 0020/ Ensure the minimum pipe temperature is maintained.
0080
6.2 Post Cure PP-09 9.2.7 Pipes requiring cure shall be placed in the cure oven QF09-002 All Spools CH M M
(if required) ≤ 2 hours after powder application. Heat to the
manufacturers recommended temperature and time
limit
FINAL INSPECTION
7.0 Visual Inspection PP-09 9.3.3.1  Uniform in colour and gloss QF09-001 All Spools CH W M
175-091300 0030/  No mechanical damage
0020  Free from blisters, sags etc.

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 Arabian Pipecoating Company
Inspection and Test Plan for the Custom Application of FBE Coating to the Internal Surface of Individual Fittings and Spool Pieces - ITP-09

Frequency Inspection/Hold Points

ACT. Quality Related Activity Reference Clause Acceptance Criteria Report Prod. APCO SAIPEM Compa
No. Document Form Test ny

7.1 Adhesion Test PP-09 9.3.3.2 X Cut (Approximately 13mm long). Cohesive failure. QF09-001 One test CH W M
175-091300 0030/ 1mm from the tip of the x cut any disbondment shall per
0010 be ignored. Production
Lot.
7.2 Adhesion Test Failure PP-09 9.3.3.3 3 Acceptable spools both before and after the failed RIRF-001 If Required CH H M
item.
Failed spools shall be quarantined, hazard tape
attached, stripped to bare metal and re-processed
7.3 Dry Film Thickness PP-09 9.3.3.10 APCS-102A: 15 – 25mils (375 – 625µm) QF09-001 All Spools CH W M
Maximum D.F.T. on the coating overlap area 1250µm
(50 mils), inclusive of girth welds.
7.4 Holiday Detection PP-09 9.3.3.6 100% of the coated surface shall be holiday detected QF09-001 All Spools CH W M
11.2 and shall not exceed 75cm/sec and shall not remain
175-091300 0030/ stationary when the power is on.
0010 A maximum of 3 holidays are permitted on fabricated
spools and induction bends.
Repair if these holidays are accessible, otherwise
stripped to bare metal and reprocess.
Individual Spools/ Fittings shall be free of holidays.
7.5 Cut Back PP-09 9.2.8 Spools/Fittings > 6” 50 to 75mm QF09-001 All Spools CH R M
9.3.3.11 Spools/Fittings ≤ 6” 25 to 50 mm as
Required
7.6 Reject Spools PP-09 9.3.3.12
Quarantine, hazard tape attache4d. RIRF-001 If required CH M M
Stripped to bare metal and re-processed
REPAIRS IDENTIFICATION STORAGE AND PREPARATION FOR SHIPPING
8.0 Repairs PP-09 11.0 All repairs ≤ 233 sq. cm may be repaired by use of QF09-001 If Required CH R M
manufactures and/ or customer approved repair
material.
Repairs shall be holiday free when holiday detected at
2.2kV.

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 Arabian Pipecoating Company
Inspection and Test Plan for the Custom Application of FBE Coating to the Internal Surface of Individual Fittings and Spool Pieces - ITP-09

Frequency Inspection/Hold Points

ACT. Quality Related Activity Reference Clause Acceptance Criteria Report Prod. APCO SAIPEM Compa
No. Document Form Test ny

8.1 Fitting Identification Markings PP-09 12.0 ≤16”Ø: Stencil externally approx. 60 cm from end N/A All Spools H W M
175-091300 0030/ > 16ӯ: Stencil internally approx. 15 cm from end
0010 Size permitting; fittings of these diameters shall be
stencilled at any convenient location.
As a minimum:
 P.O Number
 Spool/ Fitting Size
 Fitting Class
 Item Number
 Fitting Number
 Induction Bend Degree
 Coating Type
 Coating Date
In the event that the fitting is of a size where it is not
possible to stencil mark, labels shall be attached to
the fitting detailing required marking
8.2 Spool/Fitting Storage PP-09 13.0 Store on elevated pallets/wooden supports. Spools N/A All Spools H W M
175-091300 0030/ and Induction Bends may be stored on sand berms
0030 covered with polyethylene sheeting.
Coated flange faces shall be protected by plywood or
cardboard.
LABORATORY TESTS
9.1 DSC Analysis (Cure test) PP-09 10.2.2 -2°C DSC-001 Once per CH W M
CSA-Z245.20 Lot
175-091300 0030/
0010
9.2 DSC Analysis Failure PP-09 10.2.4 Re-cure and retest DSC-001 If required CH R M

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 Arabian Pipecoating Company
Inspection and Test Plan for the Custom Application of FBE Coating to the Internal Surface of Individual Fittings and Spool Pieces - ITP-09

Frequency Inspection/Hold Points

ACT. Quality Related Activity Reference Clause Acceptance Criteria Report Prod. APCO SAIPEM Compa
No. Document Form Test ny

9.3 Bend Test PP-09 10.1 Two test bars approximately 25mm x 192mm x FF-001 One test CH W M
Powder from the application fluid 175-091300 0030/ 9.5mm shall be coated; DFT 475 - 575 micrometers. per shift/
bed 0010 Holiday detected at 2200 volts; Start of
Test temp. Each New
5, 10 and 25°C + 3°C Batch of
Bent flat wise at 60 degrees over a 25.4mm thick Material
shoe of the following dimensions:
Shoe radius - 95.2mm
Chord- 152mm
Arc- 178mm
Bending shall be accomplished in less than thirty (30)
seconds. The coated specimen’s shall show no signs
of cracks to base metal when examined at 10X
magnification. If visual examination cannot determine
whether a crack extends to base metal, holiday
detection shall be carried out at 2200 volts. If no
holidays are recorded the crack-like defect is
acceptable.
9.4 Bend Test Failure PP-09 10.1.5 Repeat test, if the re-test fails suspend coating with FF-001 If Required CH R M
10.1.6 the suspect powder batch All fittings coated with the
suspect batch shall be stripped to bare metal and re-
processed.
CALIBRATION
10.0 Micrometer Calibration PP-09 8.4.1.3 Calibrated thickness shim ±5µm QLR-003 Start of CH R M
175-091300 0020/ Shift/
0070 4 Hours
10.1 Pyrometer 175-091300 0020/ ± 2ºC QLR-003 Start of CH R M
0070 Shift/
4 Hours
10.2 Dry Film Thickness Gauge PP-09 9.3.3.7 ±5% QLR-003 Start of CH R M
Calibration SSPC PA 2 9.3.3.9 Shift/3
175-091300 0020/ hours
0070
10.3 Holiday Detectors Calibration PP-09 9.3.3.4 Calibrated volt meter QLR-003 Start of CH R M
9.3.3.5 Test voltage shall be 2200 ± 50 volts H/D
175-091300 0020/ /4 hours
0070

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Inspection and Test Plan for the Custom Application of FBE Coating to the Internal Surface of Individual Fittings and Spool Pieces - ITP-09

Frequency Inspection/Hold Points

ACT. Quality Related Activity Reference Clause Acceptance Criteria Report Prod. APCO SAIPEM Compa
No. Document Form Test ny

DOCUMENTATION
11.0 Documentation and Inspection - - As per customer requirements IRC/ IRN All Spool H R M
Release QC Tally Releases
Sheets
Notes:
Monitor: Monitor work in progress.
Witness: SAIPEM/ Company shall be notified of the timing of Inspection or test in advance. However, the inspection or test shall be performed as scheduled if SAIPEM/ Company
representative is not present.
Hold: Inspection or test shall not be carried out without SAIPEM/ Company representative in attendance.
Legend: C: Record & Raise Document; R: Review Document; H: Hold ; W: Witness; I: Random Inspection; M: Monitor;
APCO Procedures:
PP-09 Procedure for the Application of FBE to the Internal Surface of Individual Fittings Spools and Associated Items
PP-02 Procedure for the Receipt Handling, Quality Control and Despatch of Customer Supplied Tubular Goods.
PP-19 Procedure for the Identification, Traceability, Quality Control and Testing of Incoming Raw Material

Note: Arabian Pipecoating Company have been approved by Lloyd’s Register Quality Assurance Limited to BS EN ISO 9001:20015 Quality management systems-Requirements Certificate
No. MEA3105008/A

Revision: 0 H-13020-SS
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