Best Practice

SABP-H-001 Selection and Application of Reinforced Fiber Glass Lay up System for Repair of Storage Tank and Vessels Paints and Coatings Standards Committee Members
Khashram, Maher Saud, Chairman Hammad, Bakr Sulaiman, Vice Chairman Homayed, Mohammed Ali Mansour, Mana Hamad Nujaim, Salah Ahmed Seba, Zaki Ahmed Suller, Abraham A

24 June 2009

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 Introduction................ 2 Conflicts with Mandatory Standards........... 3 References......... 3 Definitions............... 4 Materials........................................................ 5 General Application Requirements............. 5 Quality Control and Inspection Plan............... 8 Application Procedure........................... 10

Appendix A......................................................... 16

Previous Issue: New Next Planned Update: TBD Page 1 of 16 Primary contact: Nujaim, Salah Ahmed on 966-3-8760258
CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

Introduction 1.1 Scope This Best Practice covers the minimum mandatory requirements for the selection and application of fiberglass reinforced coating laminates by hand layup. Fiberglass reinforced coatings are used mainly to provide strength and/or prevent corrosion inside tank bottoms and internal a vessels. The condition of the tank bottom or vessel should assessed to determine whether fiberglass coating can be used as an alternative to the total replacement of the tank bottom. 1.2 Intended User This Best Practice is intended for the applicators, engineers and inspectors in the proper application of the hand lay-up type of glass fiber laminate on tank and vessel internals. It consists of the following: 1.3 Approved Coating Materials Recommended Surface Preparation Recommended Application Techniques Quality Control and Inspection Plan

Disclaimer The material in this Best Practices document provides the most correct and accurate design guidelines available to Saudi Aramco and complies with coating industry practices. This material is provided for the general guidance and benefit of the applicator. The use of the Best Practices in designing projects for Saudi Aramco does not relieve the applicator from his responsibility to verify the accuracy of any information presented, or from his contractual liability to provide safe and sound applicators that conform to Mandatory Saudi Aramco Engineering Requirements. The use of the information or material contained herein is no guarantee that the resulting product will satisfy the applicable requirements of any project. Saudi Aramco assumes no responsibility or liability whatsoever for any reliance on the information presented herein or for designs prepared by applicators in accordance with the Best Practices. The use of the Best Practices by applicators is intended solely for, and shall be strictly limited to, Saudi Aramco projects. Saudi Aramco is a registered trademark of the Saudi Arabian Oil Company. Copyright, Saudi Aramco, 2009.

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

Conflicts with Mandatory Standards In the event of a conflict between this Best Practice and other mandatory Saudi Aramco Engineering (SAE) Standards, the SAES shall prevail.

References The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below, unless otherwise noted. 3.1 Saudi Aramco References Saudi Aramco Engineering Procedures SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement Performance Qualification of Coating Personnel

SAEP-316

Saudi Aramco Engineering Standards SAES-H-001 SAES-H-102 SAES-H-101V Coating Selection & Application Requirements for Industrial Plants & Equipment Safety Requirements for Coating Applications Approved Saudi Aramco Data Sheets - Paints and Coatings Saudi Aramco Inspection Requirement

Saudi Aramco General Instructions GI-0006.02 3.2 Safety Requirements for Abrasive Blast Cleaning

Industry Codes and Standards American Society for Testing and Materials SIS 05-59-00 Pictorial Surface Preparation Standard for Painting Steel Surfaces

NACE No.10/SSPC-PA-6 Fiberglass-Reinforced Plastic (FRP) Linings Applied to Bottoms of Carbon Steel Aboveground Storage Tanks ASTM D 5162 Standard Practice for Discontinuity (Holiday) Testing of Nonconductive Protective Coating on Metallic Substrates.
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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

ASTM D512 ASTM 2583

Standard Test Methods for Chloride Ion in Water Barcol Hardness Test

The Society of Protective Coatings SSPC-PA 2 SSPC-SP1 SSPC-SP10 SSPC-QP-1 Measurement of Dry Paint Thickness with Magnetic Gages Solvent Cleaning Near-White Blast Cleaning Standard Procedure for Evaluating Contractor (Field Standard Application to Complex Industrial Structure)

Definitions APCS - 20A: The Approved Protective Coating System -20 A for Fiberglass Reinforced coating Hand Lay up. Caulk: A heavy putty-like material composed of resin, curing agents, and fillers that are used to fill pitted areas, contour uneven surfaces, and encapsulate rivets. Curing: Chemical process of developing the intended properties of a coating or other material (e.g., resin) over a period or time. Fiber Mat: A woven glass fiber that is used as reinforcement of the epoxy resin lining to repair and/or add strength to tank bottoms. It is applied on a wet resin at about 450 g/sq m area. Fiberglass-Reinforced Plastic (FRP): Resin linings, usually polyester, or vinyl ester `Epoxies, into which layers of fiberglass are incorporated to optimize the linings structural capability and performance. Gel coat: The final coat applied over the fiberglass lining laminate to seal the laminate surface and enhance water and hydrocarbon resistance. This topcoat is also referred to as gel coat, seal coat or flood coat. Laminate: A reinforced plastic composed of coating of resin and fiberglass. Pitting: Localized corrosion of a metal surface confined to a small area that takes the form of cavities. For the purposes of this standard, there are two general types of pits; namely, shallow and deep. Shallow pits have diameters greater than their depths. Deep pits have depths greater than their diameters.

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

Surface Tissue: A thin layer of fiber glass that is used to restrain strands of glass fiber; thus, prevents wicking. It is applied over the last layer of glass fiber mat while the resin is still wet. Throat: Corner between the tank shell and bottom. Putty should be used to fill this area prior to regular coating application to reduce stresses. Wear pad: Metal plate welded to the tank bottom where the roof supports rest when the tank is empty. 5 Materials For materials, refer to Appendix.A 6 General Application Requirements 6.1 Surface Preparation 6.1.1 Degrease the surface to ensure the removal of all oil, grease, salts, dirt, and other surface contaminants prior to abrasive blast cleaning per SSPC-SP-1. Prior to the start of the blasting work, all surface irregularities including weld spatters, weld fluxes, rough capping, etc., shall be removed or grinded with the use of mechanical tools. The surface shall be blast cleaned to Sa 2 (near white metal) and a surface profile range from 50 to 75 microns should be achieved. The blast cleaned surface shall be vacuumed or blown with clean and dry air. Extra care shall be taken to avoid contamination of the blast cleaned surface. Severe corrosion, undercuts and/or welds porosity (Larger than 1 inch in diameter) shall be reported to the Saudi Aramco representative for proper disposition. The steel substrate shall be tested for chlorides contamination, using Saudi Aramco-approved methods and test equipment. Residual chlorides on the surface shall not exceed 40 mg/m. Substrates with chlorides level exceeding the limit shall be washed by fresh water washing and re-blasted. When the substrate is dried. The underside of floating roofs shall be abrasive blast cleaned followed with primer application to remove loose dirt and prevent it from falling and contaminating the wet coating. Figure 9

6.1.2

6.1.3

6.1.4

6.1.5

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

6.2

General Requirement 6.2.1 6.2.2 6.2.3 6.2.4 All stages/steps of work should be inspected by Saudi Aramco coating Inspector level II or equivalent. Blasting operations and coating applications shall be conducted by certified personnel prior to the start of work. The weld integrity between shell and angular or sketch plates must be checked for welding defects. The mixed resin shall be applied on the steel substrate within four hours after blast cleaning or before any oxidation (rust bloom) appears. A holding primer at a dry film thickness (DFT) of not more than 30 microns may be used prior to the resin application to prevent rust blooming. The glass fiber mat on the shell shall extend 30 cm minimum on the tank bottom. The lap joint on the tank shell shall be at least 75 cm. The use of either one or multiple layers of glass fiber depends on the amount of wear, size and number of corrosion pits, and the bottom plates thickness. The wetting resin components shall be mixed in accordance with manufacturers datasheet. The application of the resin shall start one meter up the shell and down the tank bottom.

6.2.5 6.2.6

6.2.7

6.2.18 The fiberglass mat shall be cut into convenient working lengths. The common size varies from 4-6 meters (12-20 feet). The overlap between the fiberglass mats should be between 4 to 6 inches. 6.3 Filling Pits, Over Lap Welds, Shell to Annular or Sketch Plates 6.3.1 Filling or caulking shall be applied on all sharp edges, pits and the overlap welds between bottom plates and around the connections between pipes and hull (See Figures 2 and 3). The corner between the shell and bottom shall also be filled. Excess or loose filler shall be removed before it cures. The throat shall be filled with a putty to reduce its sharpness; and thus, reduce the risk of wrinkles and bubbles. A throat measuring about 2 inches is adequate. (See Figure 4) A 500 micron wetting resin shall be applied on the shell and bottom, and followed with fiberglass mat installation. The resin shall be applied
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6.3.2

6.3.3

Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

while the filler has only partly cured to ensure optimum adhesion due to the presence of reactive areas. If the filler has completely cured, it shall be roughened prior to the application of the wetting resin. 6.4 Wear Pad In floating roof tanks, a steel panel shall be welded where the support legs will rest when the tank is empty. The panel is also called wear pad, and is about 6 mm thick. It shall be blast cleaned and primed on both sides, but only one side shall be coated with the fiberglass mat system. The other primed side shall be glued onto the tank bottom. Installation of this new wear pad shall be done in the following manner: 6.4.1 6.4.2 To install the prepared wear pad, the roof legs shall be lifted by 10 to15 cm. Prior to installation, the existing wear plate below the roof leg shall be blast cleaned and coated with putty (filler). Just after application while the putty is wet, the newly painted side of the new wear plate shall be placed over the existing wear plate. This procedure shall be repeated on all the other roof wear plate pads. When the putty has set and hardened, the roof shall be lowered until the legs set on the wear pads. After this point, the pin shall be replaced and the jacks released. Any excess putty material shall be scraped off before it dries. Any gaps between the existing wear plate and the new wear pad plate should be filled with putty. The surfacing tissue applied over the tank bottom shall overlap the wear pad by about 2 inches on all sides. Prior to overlapping, the resin shall be applied to ensure wetting and proper adhesion. After surface tissue installation, resin (gel) is again applied at a wet film thickness of 300500 microns.

6.4.3

6.4.4 6.4.5 6.4.6

6.5

Application of One-Layer Fiberglass Mat The purpose of one-layer fiberglass system is mainly for corrosion protection on badly pitted substrates. 6.5.1 Prior to fiberglass lay-up installation, the resin shall be applied at a DFT of 500 micron on the steel substrate. An approved holding primer may be used to prevent flash rusting of the steel substrate prior to the resin

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

application. The application of the resin shall start one meter up the shell and down the tank bottom. 6.5.2 The fiberglass mat shall be installed over the wet resin at about 450g/m2 in accordance with the manufacturer specifications. For ease of application, the mat may be cut into convenient working lengths. Any air entrapped in the laminate or fiberglass mat shall be removed by ribbed steel roller. This step also enhances the wetting uniformity of the fiberglass mat and break-out any protruding or sticking out the fiber materials. (See Figure 9) The resin at a wet film thickness of 500 microns shall be applied over the fiberglass mat. When the resin becomes tacky, the surfacing tissue shall be installed. The tissue normally weighs about 25-30 g/m2. The use of ribbed steel roller shall again be employed to remove entrapped air. For final finish, resin shall be applied over the surfacing tissue at a WFT ranging from 300 to 500 microns.

6.5.3

6.5.4 6.5.5

6.5.6 6.6

Application of Two-Layer or Multiple Fiberglass Mat Two-layer or multiple systems is required to provide strengthening of the steel tank. 6.6.1 6.6.2 6.6.3 The procedure in paragraphs 6.5.1, 6.5.2, 6.5.3 and 6.5.4 shall be followed. The procedure in paragraph 6.6.1 shall be repeated except paragraph 6.5.1. For final finish, the procedure in paragraphs 6.5.5 and 6.5.6 shall be followed.

Quality Control and Inspection Plan 7.1 Inspection 7.1.1 Holiday testing shall be conducted after the coating has cured. A high voltage pulsating type holiday detector shall be used at a voltage setting of 100 volts per 25 microns (1.0 mil) DFT. All holidays detected shall be repaired with the same resin used in the system, and the repaired area shall be holiday tested.

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

7.1.2

Visual inspection Thorough visual inspection shall be performed to determine the condition of the finish surface, locate air pockets, dry mat, shrinkage and other defects.

7.1.3

Total Dry Film Thickness The total DFT of two-layers fiberglass, reinforced system is typically 2,500 microns minimum. For a single layer system, it is 1,500 microns.

7.1.4

Hardness Test The hardness of the fiberglass reinforced system shall be determined with Barcol Hardness Tester, Model No. 934-1, in accordance with ASTM D 2583. The hardness readings shall not be lower than the minimum requirement of the coating manufacturer.

7.2

Repair Procedure of Defects 7.2.1 Entrapped Air Areas with entrapped air shall be cut out followed with feathering of edges. The exposed steel substrate shall then be roughened by the use of properly dressed grinder. The installation of the fiberglass system shall then start by following the procedure of either 6.5 or 6.6 depending on the number of fiberglass layers used in the system. The fiberglass mat and tissue shall overlap the existing laminate by 50 mm. If the over coat interval is exceeded, the overlap area shall be roughened by manual sanding or grinding. For large areas, sweep blasting shall be employed. 7.2.2 Pinholes or Holidays These defects require grinding down to the steel substrate as the surface preparation. Since a portion of the coating system will be removed, the procedure in paragraph 7.2.1 shall be followed. 7.2.3 Dry Mat Dry mat is an area of the fiberglass mat which was not saturated with resin. Therefore, it is susceptible to premature delimitation and shall be removed. After removal, sweep blasting shall be employed to roughen the substrate in preparation for the installation of repair material. Remove dust and spent abrasive, then clean with solvent. The repair procedure shall be performed as in par. 6.5 or 6.6 as required.

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

7.2.4

Glass Protruding through Laminate Fiberglass protruding from the system is not acceptable, and shall be cut down to the laminate surface. This area shall then be abraded to about 100 mm in diameter, and touched up with the wetting resin.

7.2.5

Burnt Areas (Fiberglass System) due to Welding These areas shall be repaired in the same procedure as in paragraph 7.2.1.

7.2.6

Areas where the laminate is wetted but does not appear to be resin rich shall be required with an extra layer of surface tissue and resin.

Application Procedure

Figure 1 Abrasive Blasting and Holding Priming

Figure 2 Corrosion Pits Filling

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

Note: Remove weld spatter and sharp edges Visual inspection of the annular weld line shall be done to detect cracks Filling and single fiberglass mat application at annular and bottom plates and shell

Figure 4 Shell-to-Annular Plates Reinforcement: Filling and single fiberglass mat application at annular and sketch and shell.

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

Figure 5A Shell (Wall) Lamination Technique

Figure 5B Shell (Wall) Lamination Application Technique

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

Figure 6 First Smoothing Edges & Application of Epoxy System

Figure 7 Placing the Fiberglass Mat

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

Figure 8 Application of the Second Fiberglass Mat on the First Mat

Figure 9 Application of the Tank Bottom with the Fiberglass Lamination on Top of the Tank Bottom

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

The process follows the following sequence: 1. Epoxy resin layer 2. First glass mat (450g/m 2 ) 3. Epoxy resin 4. Second layer of glass mat 5. Epoxy resin 6. Surface tissue 7. Gel coat

Figure 10 Lamination System Applications

24 June 2009

Revision Summary New Saudi Aramco Best Practice.

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Document Responsibility: Paints and Coatings Standards Committee SABP-H-001 Issue Date: 24 June 2009 Selection and Application of Reinforced Fiber Glass Next Planned Update: TBD Lay up System for Repair of Storage Tank and Vessels

Appendix A
System Provider Hempel Primer Hempadur 15590 40 microns Filler Aggregate to make Hempel caulk caulking resin 05500 curing agent 98500 + anti-slint 67500 Glass Fibre Mat Hempels GlassFibre Mat 690-SA (450 g/m2) + GlassFibre Mat surface tissue 691SA Wetting Resin Hempels wetting resin 05500-SA curing agent 98500 1200 microns 450 g/m fiberglass chopped strand mat (CSM) Araldite GY 257 (Curing gent Aradur 830 & Aradur 850. 100:52:8 (by weight) surfacing tissue of 30 g/m Epoxy mix/ gel coat to give a resin rich finish 1550 -2550 microns Surface Tissue GlassFibre Mat Surface Tissue 691SA (30 g/m2) Seal Coat Resin 05500 300 microns Nominal Dry Film Thickness 1550 -2550 microns

Ciba Specialty Chemicals

Hempadur 15590

Caulking Araldite Ciba Specialty Chemicals mixed with Aerosil 202 or Cabosil; Alternative Caulking Hempadur 3588 Corrofil

Corrocoat

Polyglass PPA

Dynatronglassfib er matting weight 600 g/m2 U.K Made Chopped Strand Mat- M705 (450 g/m2)

Corroglass 600

Polyglass VEF @ 900 microns DFT U.K made Surfacing C-GLASS Tissue M524-C35

VEF @ 900 microns

1550 -2550 microns

Shell Manufactured Epikote epoxy resin represented by Global Suhaimi Company

Hempadur 15590 shall be applied to a DFT of 50 mic.

German Made Fumed Silica CABOSIL M-5 mixed with Shell epoxy resin shall be applied as caulking material. Chemtech Wetting Putty

Shell Manufactur ed Epoxy Resin EPIKOTE 816 & EPICURE 160 Chemtech 340 Glass reinforced wetting resin system

Seal coat to be applied using Shell Epoxy Resin to a DFT of 250 mic.

1550 -2550 microns

Jotun

Penguard primer

layer system 450 g/m2 glass fiber mat

surfacing tissue of 30 g/m

Chemtech 340 Glass reinforced wetting resin

1550 -2550 microns

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