Pipeline Coatings and Linings

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
PIPELINE COATINGS AND LININGS
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Corrosion For additional information on this subject, contact

File Reference: COE-108.06 PEDD Coordinator on 874-6556
Engineering Encyclopedia Protective Coatings
Pipeline Coatings and Linings
Section Page
INTRODUCTION............................................................................................................ 3
Purpose ............................................................................................................... 3
Scope .................................................................................................................. 3
EXTERNAL COATINGS FOR UNDERGROUND AND SUBSEA PIPELINES ............... 4

Cathodic Protection Of Underground Pipe .......................................................... 5
Fusion Bonded Epoxy - Pipe Coating .................................................................. 5
FBE Quality Control .................................................................................. 7
Hot-Applied Coal Tar Enamel Pipe Coating......................................................... 8
Principal Uses of the Coal Tar Systems.................................................... 9
Saudi Aramco Specification for Coal Tar Enamel ................................... 11
Tape Wrap Systems ............................................................................... 13
High Density Polyethylene Pipe Coating ........................................................... 14
Pipeline Weight Coatings........................................................................ 15
INTERNAL PIPELINE COATINGS USED IN SAUDI ARAMCO................................... 16

Internally Lined Pipe - Purpose.......................................................................... 16
Plastic Internally Coated Pipe............................................................................ 18
FBE Internal Pipe Linings .................................................................................. 19
Cement Mortar Lined Pipe................................................................................. 19
Other Pipeline Coatings .......................................................................... 22
WORK AID 1. HOW TO SPECIFY EXTERNAL COATINGS USED TO PREVENT

CORROSION OF UNDERGROUND AND SUBSEA PIPELINE .......... 25
WORK AID 2. HOW TO SPECIFY INTERNAL PIPELINE

COATINGS USED IN SAUDI ARAMCO .............................................. 30
BIBLIOGRAPHY........................................................................................................... 32
Saudi Aramco DeskTop Standards i

List of Figures
Figure 1. Hot-Applied Coal Tar Enamel, Single Coat System ..................................... 10
Figure 2. Hot-Applied Coal Tar Enamel, Double-Coat System.................................... 11
Figure 3. Application of Tape Wrap ............................................................................. 13
Figure 4. Schematic of High Density Polyethylene (HDPE) Pipe Coating System ....... 14
Figure 5. Schematic Illustrating In situ Applications of CML to Existing Pipelines ....... 20
Figure 6. Schematic Depicting One Design of a CML Pipe Fit-up ................................ 22
Figure 7. Disbonding of Tape; Dielectric Barrier Formed Around Pipe......................... 23
List of Tables
Table 1. Internal Pipeline Coatings Characteristic (Water Service) ............................... 17
Saudi Aramco DeskTop Standards ii

INTRODUCTION
In order to ensure that the life of pipeline coatings are extended

to the greatest possible length, proper selection, application,
and inspections are necessary.
Purpose
This module provides information and knowledge to assist you
in inspection and determination of requirements for pipeline
coatings. It covers both external and internal coatings for
pipelines. External coatings include coatings for underground
and subsea pipelines. This module reviews the advantages and
disadvantages of each type of coating.
The purpose of pipeline coatings are as follows:
• Prevent Corrosion
• Improve Hydraulic Flow
• Combination of Above
Scope
This module only deals with coatings for pipeline. All other
types of coatings and linings are covered in other modules in
this course.
Saudi Aramco DeskTop Standards 3

EXTERNAL COATINGS FOR UNDERGROUND AND SUBSEA

PIPELINES
Protective coatings and internal linings are applied to pipelines
to prevent corrosion or to improve liquid or gas flow through the
pipeline. Three coatings are accepted by Saudi Aramco for
external corrosion prevention on underground and subsea
pipelines:
• Fusion Bonded Epoxy (FBE).

• Hot-applied coal tar enamel.
• Extruded high density polyethylene (HDPE) plastic.
FBE is the most widely used pipeline protective coating system,

and extruded high density polyethylene plastic is the least used
system.
Protective coatings are applied to the external surfaces of

pipelines to prevent corrosion. In Saudi Aramco, all pipeline
coatings are considered critical coatings and must be applied
and inspected by qualified coating personnel because of their
role in preventing underground corrosion.
Compared to above-ground pipelines, below-grade buried

pipeline coatings must resist immersed conditions (in soil or in
water), electrolytic/galvanic corrosion, and soils stress. Soils
stress is the force exerted on the pipeline coating when the
pipeline moves against the earth or the earth moves against the
buried pipe or both conditions. All investigations into the use of
pipeline coatings include an evaluation of the coating's ability to
resist soils stress.
Internal pipe coatings are used primarily to prevent corrosion

but also to improve flow through the pipeline by reducing the
hydraulic friction. A number of thin-film polymeric coatings
approved for use in the Saudi Aramco Engineering Standards
including FBE and epoxy copolymers. In addition, cement
mortar linings (CML) are recommended for onsite repairs to
existing pipeline systems.
However, before more information is given on coatings, it is first

necessary to understand the role of cathodic protection in
protecting buried or subsea pipelines.

Cathodic Protection of Underground Pipe

Protective coatings are the primary means to resist underground
and underwater corrosion. However, because of the severity of
corrosion in some areas, cathodic protection (CP) is used to
supplement the coating system. Cathodic protection is an
electrochemical process in which the protected metal surface of
the buried pipeline is forced to behave as a cathode. Protective
coatings and cathodic protection act synergistically to protect
the pipeline. CP will provide protection at holidays or soil-
damaged areas in the coating system. Previous work has
shown that most pipeline holidays and failures are found at field
girth welds because of poor surface preparation, inadequate
thickness, and improper application. However, if improperly
applied, cathodic protection can have a negative effect on
pipeline durability.
CP is applied to pipelines per SAES-X-600, "Cathodic

Protection In-Plant Facilities", and SAES-X-400, "Cathodic
Protection of Buried Pipelines". If the polarization potential
reaches -1.2 V versus copper/copper sulfate reference
electrode, hydrogen gas may be evolved at the cathode (the
coated pipeline surface). This gas evolution can damage the
pipeline coating; therefore, a pipeline protective coating system
must be selected that is resistant to this type of damage.
Fusion Bonded Epoxy - Pipe Coating

The preferred Saudi Aramco external pipeline coating for burial
or immersion service is Fusion Bonded Epoxy (FBE). FBE is
the most widely used pipe coating system in Saudi Aramco
facilities. However, if a FBE-coated subsea pipeline requires a
weight coating for negative buoyancy, it must be applied by the
compression coat method. All buried or subsea pipelines have
cathodic protection applied to protect the pipeline from corrosion
at holidays or damaged areas in the coatings.
FBE is also preferred for internally lining pipe in water service if

the lining will be applied in the shop. If the pipeline is to be lined
in situ, especially if the pipeline has been in service, then
cement mortar linings should be used.

For long-term durability, all internal and external pipeline

coatings for use in Saudi Aramco facilities are classified as
critical coating applications.
FBE can be used for buried and subsea pipelines up to a

maximum temperature of 105°C. FBE can be used subsea if a
weight coating (to provide negative buoyancy) is not used, or if
the weight coating is applied by the compression coat method.
FBE is resistance to ambient and high operating temperatures,
soil stress, water, hydrocarbons, abrasion, and flexibility. The
coating is usually shop-applied, but repairs can be performed in
the field with similar epoxy materials. Compared to hot-applied
coal tar enamel and HDPE, it is a thin coating system. FBE
coated pipe must therefore be stored, handled, and installed
more carefully in the field.
The applicable Saudi Aramco specifications for external coating

of pipe with FBE are:
• SAES-H-002, Internal and External Coatings for Steel

Pipelines and Piping.
• APCS-104, FBE - Shop or Field Applied FBE Pipe Coating.
• 09-SAMSS-089, Shop Applied External FBE Coatings.
• SAES-H-201, General Specification for Over-the-Ditch
FBE External Coating of Field Girth Welds.
• SAES-H-200, Storage, Handling, and Installation of Pipe
Externally Coated with Fusion Bonded Epoxy or
Polyethylene.
A description of the FBE application process follows; such

applications are made under very controlled conditions because
of their importance.

FBE applied to pipe and equipment and to reinforcing steel for

concrete construction is applied in generally the same manner.
First, the steel is decontaminated and abrasive blast cleaned to
SSPC-SP-10 (SA 2 1/2). It is then preheated by electrical
induction heaters to a temperature prescribed by the epoxy
coating powder manufacturer. A differential electrostatic charge
is generated between the powder application equipment and the
steel pipe or surface. Powder can then be applied uniformly
and without holidays to the entire steel surface. Inspection for
holidays or damage and later repairs are made consistent with
09-AMSS-089. The dry film thickness should be 17-22 mils.
Color Plates 54 and 55 are, respectively, FBE field-applied to
pipe and a photomicrograph of an FBE internally and externally
applied to a pipe wall and girth weld section. It is important that
the girth welds are coated properly because it has been shown
that protective coatings frequently fail there compared to the
pipe body.
SAES-H-201 covers FBE applied to girth welds in the field. It

directs that FBE be applied in the field in the same manner as in
the shop. The powder is not applied by electrostatic spray
equipment, but it is blown onto the surface. FBE is the
preferred method for protecting field girth welds, but HDPE heat
shrink sleeves may also be used (see Color Plate 56). This
application should follow APCS-110, APCS-111, and APCS-112
heat shrink sleeve application instructions.
FBE Quality
Control
FBE requires strict QA/QC precautions when it is applied,
carried to the field, joined, and buried. These precautions are
enumerated in SAES-H-201. For example, a vendor's quality
control program must include, but not be limited to:
• Pipe surface preparation and blast profile

• Abrasive blasting material and equipment
• Metal inspection
• Pipe temperature control
• Coating thickness
• Adhesion

• Holiday detection and repair

• Color, uniformity, and appearance
The inspector, in addition to assuring that these QA/QC

procedures have been carried out, must spot check:
• Thickness
• Adhesion
• Coating quality and repairs
• Shipment preparations
This detailed inspection and quality control program, and further

inspection criteria are detailed in SAES-H-200. After the
pipeline is welded and joined in the field and the girth welds
have been completely coated, the entire surface is again
inspected for holidays with a high-voltage spark test, and any
holidays or damaged areas are repaired prior to ditching the
pipe. This holiday test is carried out at a potential of
approximately 2400 V, a much lower voltage than what is
specified for the hot-applied coal tar enamel or high density
polyethylene coating systems.
Hot-Applied Coal Tar Enamel Pipe Coating

If a weight coating is required, hot-applied coal tar enamel is
specified for use on buried and subsea pipelines (refer to
APCS-106.) As discussed in COE 108.02, coal tar enamel is a
natural, convertible coating system based on the use of coal tar
pitch. Pitch is a distillation product from the production of coal-
based coke. It is received as a solid block and then melted in
kettles until the temperature of the coal tar liquid is
approximately 375°F. It is shop-applied by a traveling weir to a
length of rotating pipe. The coal tar cools and solidifies. At
room temperature it is black, glossy, hard, and very resistant to
water and corrosion damage. It has been used for centuries as
a protective coating.

There are a number of components to a coal tar enamel

protective coating system that include the following:
• Primer - Coal tar or synthetic primer thinly applied to a

commercial abrasive blast cleaned surface.
• Body Coat - Hot-applied enamel 3/32 ± 1/32 in. thick;
succeeding coats are applied 2/32 ± 1/32 in. thick.
• Reinforcement - Glass mat is wrapped into the coal tar
enamel to strengthen the coating to increase resistance to
soils stress.
• Felt Wrapping - A coal tar saturated tape is bonded to the
outer layer of the coal tar enamel to increase resistance to
damage from backfilling the pipe trench.
• Kraft Paper - A heavy duty wrapping paper is applied over
the completed protective coating system in order to support
the applied system until the coal tar coating has cooled,
hardened, and strengthened.
• Rock Shield - This is a heavy duty shielding material to
prevent damage to the coating system from falling rocks
during trench backfilling.
These coatings have a long, very successful history in ambient

or slightly higher than ambient temperature service pipelines. It
may be used up to 70°C when buried and up to 80°C subsea.
However, it should not be used when benching of the pipe is
required after coating application.
Principal Uses of
the Coal Tar
Systems
A number of hot-applied coal tar enamel systems are used by
the pipeline industry. Two of the most typical ones are shown in
Figure 1 and Figure 2.
Single-coat/single-wrap and single-coat/double-wrap systems

are generally used in relatively dry, sandy, or loamy soils where
little soils stress is expected. SAES-H-002 specifies that this
coating is suitable for temperatures of 70°C onshore and 80°C
offshore.

A double-coat/double-wrap system is pictured in Figure 2. This

is generally applied with glass mat embedded in the first layer of
hot-applied coal tar enamel and felt wrapping embedded in the
second layer. This is a heavy-duty, anticorrosive system that is
used for water immersion locations or for soil burial where there
may be severe soils stress.
Single-Coat, Single-Wrap
Glass Fiber
Coal Tar Coal Tar Wrap
Clean Primer Enamel
Pipe
Coal Tar Felt
Glass Fiber
Wrap
Coal Tar
Enamel
Coal Tar
Clean Primer
Pipe Single-Coat, Double-Wrap
Source: Extracted from "Bitumastic Pipeline Handbook," Koppers Company, 1953.

COE 108.09V (12)
Figure 1. Hot-Applied Coal Tar Enamel, Single Coat System

C o a l T a r F e lt
C o al T ar
E n am el
G la s s F ib e r
W ra p
C o al T ar
E n am el
Coal T ar
P rim e r
C le a n
P ip e
D o u b le -C o a t, D o u b le -W ra p
S o u rc e : E x tra c te d fro m " B itu m a s tic P ip e lin e H a n d b o o k ," K o p p e rs C o m p a n y , 1 9 5 3 .
C O E 1 0 8 .0 9 V (1 3 )
Figure 2. Hot-Applied Coal Tar Enamel, Double-Coat System
Saudi Aramco
Specification for
Coal Tar Enamel
SAES-H-002 contains some information on coal tar enamel pipe
coating but detailed information on hot-applied coal tar enamel
applied to pipe is contained in 01-SAMSS-012, Submarine Pipe
Weight Coating. The reasons for the inclusion of the coal tar
enamel system description within this specification are:
• Hot-applied coal tar coating systems are frequently used

offshore.
• Hot-applied coal tar coating systems are used when
concrete must be applied to a submarine pipeline to
provide negative buoyancy.

As specified in 01-SAMMS-012 the coating system must

conform to American Water Works Association's
AWWA-C-203, double-coat/double-wrap, as follows:
• Primer
• Hot-applied coal tar enamel
• Glass mat wrap
• Hot-applied coal tar enamel
• Felt overwrap
No Kraft paper wrap is applied, and the minimum coating

thickness is designed to be 5/32 in.
In addition to the coal tar enamel coating, this specification also

covers the requirements for the weight coating concrete
including the strength, reinforcement, and thickness (4 in. or
more). The specification also sets the requirements for placing
bracelet zinc sacrificial anodes around the pipe to cathodically
protect the pipeline.
Inspection procedures include, but are not limited to,

requirements of AWWA-C-203 for the hot-applied coal tar
enamel coating and the purchase specification and its
referenced documents for the concrete jacket coating. Holiday
detection is carried out with a high voltage spark detector at
15,000 V maximum. The compressive strength of the concrete
shall not be less than 4000 psi in order to insure a dense, strong
concrete. The storage, handling, and installation of coal tar
enamel weight-coated pipe are covered by SAES-H-202. The
storage, handling, and installation of coal tar enamel weight-
coated pipe are covered by SAES-H-202.

Tape Wrap Systems

When pipe sections are welded together, the girth weld must be
protected with APCS-107 tape wrap, which is applied in a
unique manner as shown in Figure 3. After power tool cleaning
(SSPC-SP-2), the tape wrap is first applied directly over the
weld; then to seal off the tar outerwrap joint, and finally over the
entire area with a 50% overlap, resulting in a minimum of two
full layers of tape. To protect the tape, a heavy plastic mesh, to
be recommended by the Corrosion Control Division - Dhahran,
should be applied over the taped joint. The cavity, as shown in
Figure 3, is then filled with a high density polyurethane foam
encased in a steel sleeve. This protective girth weld system is
also used when weight coatings are applied with other specified
subsea coatings systems.
Coal Tar Coating

Concrete Weight Coating Girth Weld
Welded Joint
Tape Wrap
Metal Mold Urethane Foam
Figure 3. Application of Tape Wrap

High Density Polyethylene Pipe Coating

High density polyethylene (HDPE) pipe coating may be used for
buried and subsea pipelines. If a weight coating is needed it
must be applied by the compression coat method. It can be
used up to 80°C service temperature. The high density
polyethylene jacket is applied in the shop to the pipe as it
passes through a plastic extrusion machine. The pipe is
abrasive blast cleaned, and an epoxy primer is applied to the
steel surface. Then an ethylene copolymer adhesive is
extruded onto the pipe, followed by the HDPE jacket. This
system is identified as APCS-105 in SAES-H-002, and details
are given in 09-SAMSS-090, Shop Applied Extruded
Polyethylene - External Coating. A schematic of this system is
shown in
Figure 4 and a photograph is provided in Color Plate 57. The

extruded coating is applied according to manufacturer's
standards; therefore, there are no QA/QC procedures to follow.
Extruder Extruder
for Adhesive for HDPE
Ring Slot Die

SSPC Induction
SP-10 Heating
Pipe
Movement
Primer Coating Adhesive HDPE Coating

Spray Applied
Figure 4. Schematic of High Density Polyethylene (HDPE) Pipe Coating System

HDPE-coated pipes are stored, handled, and installed in the

field in accordance with AES-H-200. The girth weld where pipe
is joined is protected with HDPE heat shrink sleeves (APCS-111
or APCS-112, depending on maximum operating temperatures).
The details concerning application of these sleeves is given in
SAES-H-204 or SAES-H-204V. Repairs to damaged areas are
made with heat shrink patches or sleeves. A high voltage
(~20,000 V) spark test must be carried out to ensure that the
coated pipe and welded joints are completely free of holidays.
HDPE-coated pipe is the least used by Saudi Aramco of the

three protective coating systems. HDPE-coated pipe may be
used to protect underground pipelines, but it can be used only
when recommended by the Corrosion Control Division -
Dhahran. The largest application to date is the IPSA pipeline
system. However, this system is specified and used by other
major oil companies worldwide. Its use in the Kingdom is sure
to grow.
Pipeline Weight
Coatings
As discussed previously, weight coatings are frequently applied
to subsea pipelines to provide negative buoyancy which causes
the pipeline to sink to the sea bottom. The weight coating can
be applied by two procedures. First, it can be applied by
gunning or casting it into place on a rotating pipeline. Or, it can
be applied by the compression coat method by placing the
concrete mix on a polyethylene outer wrap that is applied under
tension to a rotating pipeline. In the first method the concrete
can impact on the pipeline and this can damage a thin film
protective coating such as FBE. This does not occur when the
weight coating under compression is wrapped onto the pipeline.
This is the reason SAES-H-002 specifies compression coat
weight coating for FBE and HDPE.

INTERNAL PIPELINE COATINGS USED IN SAUDI ARAMCO
A number of protective coatings and linings for internal

application to pipelines are specified in SAES-H-002:
• APCS-100 - Shop Applied Baked Phenolic or Phenolic

Epoxy
• APCS-101 - Shop Applied Baked Polyurethane
• APCS-102 - Shop Applied Internal Fusion Bonded Epoxies
(FBE)
• APCS-103 - Shop or Field Applied Cement Mortar
APCS-100 and -101 are used principally to line oil production

drill pipe or tubing. These can only be applied in the shop
because of the heat curing step. APCS-103 (cement mortar
lined pipe) is used to line corroded water pipelines onsite. The
APCS-102 system is a shop-applied FBE for new pipe to be
used in corrosive water service. It is important to note that the
internal pipeline coatings specified in SAES-H-002 are not
considered mandatory unless required in other specifications
and documents.
Internally Lined Pipe - Purpose

Pipelines are internally coated for three reasons: to resist
corrosion, to improve hydraulic flow, or a combination of both
reasons. The major reason Saudi Aramco internally lines pipe
is for corrosion resistance and to control the pickup of solids in
the water; improvement of hydraulic flow is of minor importance.
Characteristics of several internal pipe linings are given in Table
1, where corroded carbon steel is compared to pipes lined with
fusion bonded epoxy, cement mortar (CML), and coal tar
enamel for water service. As shown, the linings have much
better frictional flow characteristics than carbon steel. These
factors play a major role in the design of a piping system since
they reduce pipe diameter and pump capacity. They also
extend useful life and reduce the need for major pipe
replacement.

Table 1. Internal Pipeline Coatings Characteristic (Water Service)
MAX. VELOCITY MAX. TEMP. FRICTION FACTOR

SYSTEM
ft/s °F Hazel-Williams
Corroded Carbon Steel 4 120 C80-120
CML 15 150-200 C140
FBE 8-10 180 C140
Coal Tar 8-10 80 C145
In the past, Saudi Aramco specified thin-film, epoxy, or epoxy

copolymer linings for pipelines. These thin-film plastic linings
are no longer used because of poor performance. The main
reason these linings are not used for welded pipe is that there is
no practical method for internally coating the welded girth joint.
These thin-film plastic coatings continue to be used in
production for oil field tubular goods where there are no welded
joints and the pipe is joined mechanically.

Plastic Internally Coated Pipe

As noted, there are three thin-film plastic linings recognized by
Saudi Aramco: baked phenolic, phenolic-epoxy, and
polyurethane. These are all heat-cured coatings applied in
multiple coats with dry film thicknesses of approximately 9-13
mils. Color Plate 57 shows an internally epoxy-phenolic lined
pipe in noncorrosive gas transmission service. In this service,
the lining is used to reduce friction and promote flow.
Thin-film plastic coatings are applied to pipelines and oil field

tubulars in the following manner. First the pipe is
decontaminated by baking it at high temperatures ( > 700°F) to
burn off oil and scale. The pipe is internally blasted to a white
metal surface; in addition, chemical cleaning may be specified
and then the coating is applied by special spray equipment
which deposits the coating evenly around the entire pipe
circumference. The coating is baked to some intermediate cure
state and subsequent coats applied until the desired dry film
thickness is achieved. A final higher temperature bake assures
complete polymerization and cure. Inspection is required during
all application steps.
The APCS specifications referenced previously for these thin-

film plastic coatings contain primarily use data such as
temperature limits, suitable pH range, and environmental
exposure limits including pressure and gas concentrations. The
details concerning application are contained in the SAMSS
documents referenced by the APCS specification:
• Baked phenolic/phenolic-epoxy - 09-SAMSS-080 (System

A).
• Baked polyurethane - 09-SAMSS-080 (System B).
Specifically these documents require final inspection of the

coated pipe by holiday detection, visual inspection, dry film
thickness and adhesion testing. Each of these are "special"
techniques and instruction is required for their correct use.

FBE Internal Pipe Linings

Pipe may be externally and internally coated with FBE. The
Saudi Aramco specifications covering both these applications
are located in Module COE 108.05.
Identical measures for application and quality assurance/quality

control should be used for both internal lining and external
lining. If both an external coating and internal lining are applied
simultaneously to pipe sections, then both the coating and the
lining must be inspected and evaluated.
If the diameter is 12 in. or greater, then the field girth weld may
be coated from inside the pipe with suitable pipeline crawlers.
For detailed information concerning application and inspection,
contact the responsible organization, Corrosion Control Division,
Dhahran. If the pipe is less than 12 in. in diameter, FBE internal
linings cannot be used. The pipeline must be internally lined
onsite with a cement mortar lining. This type of pipeline coating
can be applied onsite to pipelines as small as 4 in. in diameter.
Cement Mortar Lined Pipe

CML pipe is also used for Saudi Aramco water services. It is
also used worldwide for new construction and for repair of
existing pipelines that have suffered severe corrosion. Some of
the Saudi Aramco specifications concerning CML pipeline
applications were covered in Module COE 108.05. Additional
information is given in the American Water Works Association
standards that follow:
• AWWA-C-205, Cement-Mortar Protective Lining and

Coating for Steel Water Pipe, 4 in. and larger, Shop
Applied.
• AWWA-C-602, Cement-Mortar Lining for Water Pipelines,

4 in. (100 mm) and larger, In Place.

It should be noted that Saudi Aramco 01-SAMSS-005 is a

modification or commentary on AWWA-C-205 covering shop
application of CML. Therefore, both 01-SAMSS-005 and
AWWA-C-205 must be must be referred to for detailed QA/QC
information. For in situ applications of CML, AWWA-C-602
must be used to obtain detailed QA/QC information. Saudi
Aramco has more in situ applications than shop applications of
CML. Figure 5 schematically illustrates in situ applications of
CML to existing pipelines.
For Pipelines 4 in. Through 36 in. in Diameter

Mortar Mixer
Lining Mortar Pump

Winch Lining Machine Lined Pipe
Mortar
Supply Hose Trowel
Cleaned Pipe
Corroded Pipe
Access Opening
Up to 1000 ft.
Figure 5. Schematic Illustrating In situ Applications of CML to Existing Pipelines

For Larger Pipelines to 264 in. in Diameter
Mortar Mixer
Material
Lining
Trowels Machine
Mortar
Lined Pipe Cleaned Pipe
Up to 2000/ft. Mortar Supply
Figure 5. (Cont’d)
CML linings are approximately 3/16-1/4 in. thick. They are

recommended for most water services: salt, aquifer, fresh,
sweet, and potable water. Shop-coated pipe sections may be
successfully welded in the field. Figure 6 schematically depicts
one design of a CML pipe fit up to achieve a sound weld. Other
welded joint designs for CML pipe are shown in Library Drawing
L-AD-036090. Small openings at the weld of the CML rapidly
"choke" with scale and lime deposits, essentially stopping
corrosion. The handling procedures detailed in AWWA-C-205
must be followed; otherwise, flexing and bending of the CML
pipe during transit will cause early lining failure followed by pipe
wall corrosion.

37 1/2Þ 37 1/2Þ
1/8 in.
Pipe Wall
Cement Lining 1/16 in.
Figure 6. Schematic Depicting One Design of a CML Pipe Fit-up
Other Pipeline
Coatings
Other pipeline coatings such as pipeline tapes are not
acceptable for use on new Saudi Aramco pipeline facilities.
Reasons for this include lack of durability and limited resistance
to soil damage. In the case of pipeline tapes, aggressive under-
soil corrosion has occurred when there has been disbonding
and a dielectric barrier has formed around the pipe (see Figure
7). As shown, this can occur on a pipeline that has been
protected by pipeline tape when ground water electrolytes have
penetrated along the pipewall. Cathodic protection is not
effective because of the high IR drop in protective potential
behind the tape; corrosion occurring behind the tape cannot be
prevented. This type of coating failure has occurred worldwide
and includes Saudi Aramco, Exxon and other facilities where
extensive corrosive damage to pipelines has occurred. Pipeline
tapes within Saudi Aramco are limited to in-trench renovation
coating of pipelines, as discussed in COE 108.07.

Pipeline Tape - Well Bonded

Corrosion Pits Under
Insulating Barrier Ground Water Enters
Between Tape and Pipe
Pipe
Exposed Pipe
Pipeline Tape Disbonded From
Pipe Forms a Dielectric Jacket
Figure 7. Disbonding of Tape; Dielectric Barrier Formed Around Pipe

GLOSSARY
sweating A term to describe the moisture given off by equipment

operating below the atmospheric dew point of water in the air
dew point The temperature at which water vapors condenses and starts
to collect as a liquid on the surface of equipment and
pipelines.
paints
coatings
anchor pattern The pattern or surface features left upon the steel substrate
after cleaning and surface preparation.
critical coatings

WORK AID 1. HOW TO SPECIFY EXTERNAL COATINGS USED TO

PREVENT CORROSION OF UNDERGROUND AND
SUBSEA PIPELINE
Follow these steps for specifying external coatings for

underground and subsea pipelines.
1. Determine cathodic protection requirements referring to

SAES-X-600, "Cathodic Protection In-Plant Facilities", and
SAES-X-400, "Cathodic Protection of Buried Pipelines".
2. Determine which of the three major types of underground

and subsea coatings must be used by referring to SAES-H-
002, Internal and External Coatings for Steel Pipelines and
Piping.
FBE COATING: Follow steps 3 through step 6a.
3. Select the applicable Saudi Aramco specifications for

external coating of pipe with FBE which are:
a. SAES-H-002, Internal and External Coatings for Steel

Pipelines and Piping.
b. APCS-104, FBE - Shop or Field Applied FBE Pipe

Coating.
c. 09-SAMSS-089, Shop Applied External FBE

Coatings.
d. SAES-H-201, General Specification for Over-the-

Ditch FBE External Coating of Field Girth Welds.
e. SAES-H-200, Storage, Handling, and Installation of

Pipe Externally Coated with Fusion Bonded Epoxy or
Polyethylene.

4. Application:
a. Steel is decontaminated and abrasive blast cleaned to

SSPC-SP-10 (SA 2 ½).
b. Steel is preheated by electrical induction heaters to a

temperature prescribed by the epoxy coating powder
manufacturer.
c. Create a differential electrostatic charge between the

powder application equipment and the steel pipe or
surface.
d. Apply powder uniformly and without holidays to the

entire steel surface of the thickness prescribed by
manufacturer.
e. Inspection for holidays or damage and later repairs

are made consistent with 09-AMSS-089
f. The dry film thickness should be 17-22 mils
5. Ensure vendor's quality control program includes, but not

be limited to:
a. Pipe surface preparation and blast profile
b. Abrasive blasting material and equipment
c. Metal inspection
d. Pipe temperature control
e. Coating thickness
f. Adhesion
g. Holiday detection and repair
h. Color, uniformity, and appearance

6. The inspector, in addition to assuring that the vendors

QA/QC procedures have been carried out, must spot
check:
a. Thickness
b. Adhesion
c. Coating quality and repairs
d. Shipment preparations
Note: Also refer to the inspection work aids in Module COE

108.06 for further inspection tips and equipment. This
detailed inspection and quality control program, and
further inspection criteria are detailed in SAES-H-200
7. Final Inspection including holiday testing is performed after

all work is complete including repairs of damaged or
unacceptable areas.
a. Holiday test is carried out at a potential of

approximately 2400 V
HOT-APPLIED COAL TAR ENAMEL PIPE COATING:

Follow steps 7 through 11
8. Verify that if a weight coating is required, hot-applied coal

tar enamel is specified for use on buried and subsea
pipelines (refer to APCS-106). Detailed information on hot-
applied coal tar enamel applied to pipe is contained in 01-
SAMSS-012, Submarine Pipe Weight Coating
9. Verify that the coating system must conform to American

Water Works Association's AWWA-C-203, double-
coat/double-wrap, as follows:
a. Primer
b. Hot-applied coal tar enamel
c. Glass mat wrap

d. Hot-applied coal tar enamel
e. Felt overwrap
f. No Kraft paper wrap is applied, and the minimum

coating thickness is designed to be 5/32 in.
10. Inspection procedures include, but are not limited to:
a. Requirements of AWWA-C-203 for the hot-applied

coal tar enamel coating
b. 01-SAMMS-012 and other purchase documents
c. Verify holiday detection is carried out with a high

voltage spark detector at 15,000 V maximum
d. Verify that the compressive strength of the concrete

shall not be less than 4000 psi.
11. Verify that proper storage, handling, and installation of coal

tar enamel weight-coated pipe are in accordance with
SAES-H-202.
12. Verify tape wrapping with APCS-107 in the following

manner:
a. First wrap, directly to the girth weld joint
b. Second wrap, to seal off the tar outerwrap joint
c. Third wrap, finally over the entire area with a 50%

overlap, resulting in a minimum of two full layers of
tape.
d. A heavy plastic mesh wrap to protect the tape
e. The cavity is then filled with a high density

polyurethane foam encased in a steel sleeve

HIGH DENSITY POLYETHYLENE PIPE COATING:

Follow steps 12 through 15
13. Verify that this coating meets the specifications of APCS-

105 in SAES-H-002, and purchase detains given in 09-
SAMSS-090, Shop Applied Extruded Polyethylene -
External Coating.
14. The extruded coating is applied according to

manufacturer's standards; therefore, there are no QA/QC
procedures to follow.
15. Verify that HDPE-coated pipes are stored, handled, and

installed in the field in accordance with AES-H-200.
16. HDPE heat shrink sleeves (APCS-111 or APCS-112):
a. Verify correct selection. Selection depends on

operating temperature.
b. Verify application requirements of these sleeves in

accordance with SAES-H-204 or SAES-H-204V.
c. Verify that repairs to damaged areas are made with

heat shrink patches or sleeves.
d. Verify that a high voltage (~20,000 V) spark test is

performed on sleeve installation and repairs.

WORK AID 2. HOW TO SPECIFY INTERNAL PIPELINE COATINGS

USED IN SAUDI ARAMCO
Specify internal pipeline coatings by following these steps:
1. Select the correct coating for the project. A number of

protective coatings and linings for internal application to
pipelines are specified in SAES-H-002 as follows:
a. APCS-100 - Shop Applied Baked Phenolic or

Phenolic Epoxy
b. APCS-101 - Shop Applied Baked Polyurethane
c. APCS-102 - Shop Applied Internal Fusion Bonded

Epoxies (FBE)
d. APCS-103 - Shop or Field Applied Cement Mortar
Note: Internal pipeline coatings specified in SAES-H-002

are not considered mandatory unless required in other
specifications and documents.
PLASTIC INTERNALLY COATED PIPE:

Follow these steps (2 and 3)
2. Select specification documents for these types of linings:
a. Baked phenolic/phenolic-epoxy - 09-SAMSS-080

(System A).
b. Baked polyurethane - 09-SAMSS-080 (System B).
3. These documents contain requirements for the following:
a. Final inspection of the coated pipe by holiday

detection
b. Visual inspection
c. Dry film thickness testing and specifications
d. adhesion testing

FBE INTERNAL PIPE LININGS:

Follow these steps (4 through 6)
4. Select the correct specification documents. 09-SAMSS-

091 covers the minimum requirements of shop-applied,
heat-cured powder epoxy coating systems internally
applied to pipe.
5. If the diameter is 12 in. or greater, then the field girth weld

may be coated from inside the pipe with suitable pipeline
crawlers.
6. If the pipe is less than 12 in. in diameter, FBE internal

linings cannot be used. The pipeline must be internally
lined onsite with a cement mortar lining
CEMENT MORTAR LINED PIPE: Follow these steps (7)
7. Select the correct specification documents:
a. AWWA-C-205, Cement-Mortar Protective Lining and

Coating for Steel Water Pipe, 4 in. and larger, Shop
Applied.
b. AWWA-C-602, Cement-Mortar Lining for Water

Pipelines, 4 in. (100 mm) and larger, In Place.
c. 01-SAMSS-005, Pipe, Cement Lined, Shop Applied
Note: 01-SAMSS-005 is a modification or

commentary on AWWA-C-205, therefore,
both 01-SAMSS-005 and AWWA-C-205 must
be must be referred to for detailed QA/QC
information
d. For in situ applications of CML, AWWA-C-602 must

be used to obtain detailed QA/QC information.
e. The handling procedures detailed in AWWA-C-205

must be followed; otherwise, flexing and bending of
the CML pipe during transit will cause early lining
failure followed by pipe wall corrosion.

BIBLIOGRAPHY
01-SAMSS-005, Shop-applied Cement Mortar Lining of Steel

Pipe, 29 October 1997
01-SAMSS-012, Submarine Pipe Weight Coating,
31 December 1996
09-SAMSS-080 (System A), Baked Phenolic/Phenolic-Epoxy,
31 December 1996
09-SAMSS-080 (System B), Baked Polyurethane,
31 December 1996
09-SAMSS-089, Shop Applied External FBE Coatings,
1 December 1996
09-SAMSS-090, Shop Applied Extruded Polyethylene - External
Coating, 1 December 1996
09-SAMSS-091, Shop Applied Internal FBE Coating,
1 December 1996
SAES-H-002, Internal and External Coatings for Steel Pipelines
and Piping, 31 August 1997
SAES-H-200, Storage, Handling, and Installation of Pipe
Externally Coated with Fusion Bonded Epoxy or Polyethylene,
31 August 1997
SAES-H-201, General Specification for Over-the-Ditch FBE
External Coating of Field Girth Welds, 30 November 1997
SAES-H-202, Storage, Handling, and Installation of Weight-
Coated Pipe, 30 October 1997
SAES-H-204, General Specifications for Applying Heat-Shrink
Sleeves to Coated Pipe, 29 October 1997
SAES-H-204V, Approved Vendor Installation Procedures for
Heat-Shrink Sleeves, 1 December 1996
SAES-X-400, Cathodic Protection of Buried Pipelines,
1 December 1996
SAES-X-600, Cathodic Protection In-Plant Facilities,
1 December 1996

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