Saudi Aramco Best Practice 27 July 2020

SABP-W-005
Thermal Spray Coating for In-Situ Repair of Pressure
Equipment in Amine Service
Document Responsibility: Welding Standards Committee

Contents
1. Introduction ...…………………………………………….. 2
2. Conflicts and Deviations ................................................ 2
3. References .................................................................... 3
4. Terminology................................................................... 4
5. Thermal Spray Processes ............................................. 5
6. Thermal Spray Coating Feedstock ................................ 6
7. Surface Preparation ...................................................... 6
8. Abrasive Blasting and Profiling ...................................... 7
9. Thermal Spray Coating Application ............................... 8
10. Sealant Application ........................................................ 9
11. Thermal Spray Coating Repair .................................... 10
12. Inspection .................................................................... 10
13. Spray Coating Procedure ............................................ 11
14. Operator/Applicator Performance................................ 11
15. Safety …………………………………………………….. 11
Appendix A: Thermal Spray Application QC Checklist ....... 12
Document History .............................................................. 13

Revision Date: 27 July 2020 Contact Person: (RAGHUNSP)

Next Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 1 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

1. Introduction
1.1 Scope and purpose
Pressure vessels in refineries and gas processing plants are generally constructed
with bare carbon steel (CS). Amine stripper or regenerator columns are
commmonly constructed with Corrosion Resistant Alloy (CRA) coat material at the
top section of the column and the remaining section with CS. Carbon steel
materials maybe susceptible to localized or uniform corrosion in such
environments due to several potential damage mechanisms. To reduce corrosion
or to avoid cracking of weld repair locations without subsequent post-weld heat
treatment CRA strip lining, weld overlay or thermal spray coating can be used to
create a barrier between the carbon steel substrate/repair weld and the service
environment. Thermal spraying is a coating process where the corrosion resistant
alloy coating is deposited by melting feedstock with heat from combustion or
electric arc and propelling molten metal particles onto the substrate using
compressed air or another gas.
This best practice provides guidelines for the application of thermal spray coating
in pressure equipment including columns, vessels and heat exchangers
constructed of carbon steel and in amine service, at Saudi Aramco refineries and
gas plants. Its main objective is to ensure common understanding of the technical
requirements for thermal spray coating.
Current Saudi Aramco experience with thermal spray coating is limited to amine
service (DGA, MDEA and MEA). This best practice may be used for other thermal
spray coating applications. However, for any new service environments or
applications, CSD Materials Engineering Group must be contacted to determine
suitability of process, coating type, sealant for the specific application.
This best practice does not apply to thermally sprayed aluminium or non-metallic
coatings applied with thermal spray processes.
1.2 Disclaimer
This Best Practice is based on current industry experiences and is intended for
internal Saudi Aramco operations and maintenance applications. The use of this
information or material does not guarantee results that will satisfy any applicable
requirements of Saudi Aramco Standards. CSD assumes no responsibility or
liability whatsoever for the misuse of the information in this document. This Best
Practice is intended as a guideline and should not be considered as replacement
for Mandatory Saudi Aramco Engineering Requirements (MSAERs).
Saudi Aramco® is a registered trademark of the Saudi Arabian Oil Company.
2 Conflicts and Deviations
If there is a conflict between this Best Practice and any Mandatory Saudi Aramco
Engineering Requirements (MSAERs), the mandatory document shall take the
precedence. Other conflicts shall be addressed in writing to the EK&RD Coordinator

Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 2 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

3 References
All referenced specifications, standards, codes, drawings, and similar material are
considered part of this Best Practice to the extent specified applying latest revisions
unless stated otherwise.
3.1 Saudi Aramco References
Saudi Aramo Engineering Procedures
SAEP-203 Governance of Saudi Aramco Best Practices
Saudi Aramco Engineering Standards
SAES-D-008 Repair, Alterations and Rerating of Process Equipment
SAES-H-102 Safety Requirements for Coating Applications
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 Metals

ASM Handbook Volume 5A Thermal Spray Technology

American Society for Testing and Materials

ASTM D4285 Standard Test Method for Indicating Oil or Water in
Compressed Air
ASTM E337 Standard Test Method for Measuring Humidity with a
Psychrometer (the measurement of Wet and Dry-Bulb
Temperatures)
ASTM D4417 Standard Test Methods for Field Measurement of
Surface Profile of Blast Cleaned Steel
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 prepared for painting (pressure-sensitive tape
method)
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
CHAPTER 11(Safety) Thermal Spraying: Practice, Theory and Application

Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 3 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

National Association of Corrosion Engineers

NACE No.1/SSPC-SP 5 White Metal Blast Cleaning
NACE RP 0287 Field Measurement of Surface Profile of Abrasive Blast
Cleaned Surfaces Using Replica Tape
The Society for Protective Coatings
SSPC SP 1 Solvent Cleaning
SSPC QP-6 Standard Procedure for Evaluating the Qualifications of
Contractors Who Apply Thermal Spray (Metallizing) for
Corrosion Protection of Steel and Concrete Structures
American National Standard Institute
SSPC-Vis 1 Guide and Reference Photographs for Steel Surfaces
Prepared By Dry Abrasive Blast Cleaning
4. Terminology
4.1 Acronyms
DGA Diglycolamine
DFT Dry Film Thickness
HVAS High Velocity Arc Spray
HVCC High Velocity Continuous Combustion
ITP: Inspection and Test Plan
MDEA Methyl Di-Ethanol-Amine
MEA Monoethanolamine
PWHT Post Weld Heat Treatment
QCP Quality Control Plan
TSC Thermal Spray Coating
4.2 Definitions
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.
Pressure Equipment: Include vertical and horizontal vessels, reactors, columns, drums
and heat exchangers within the scope of ASME SEC VIII Division 1 or 2.
Rust Bloom: Discoloration indicating the beginning of rusting. For the purpose of this
best practice , rust bloom is rusting that occurs after specified surface preparation.
Sealer: A material used to fill porosity and voids in the metalized surface. The sealer is
a thin coat that is absorbed into the pores of the TSC.

Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 4 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

5. Thermal Spray Processes

Thermal spraying is a technology that involves melting/heating a feedstock material
(metallic or non-metallic), where the molten droplets are accelerated in a gas stream
which strike/impact the surface of substrate to be coated. The feedstock may be in the
form of wire, powder, or rod. The molten droplets impact on the surface where it solidifies
and forms a solid layer. The total coating thickness is usually achieved by applying
multiple passes of the thermal spray coating. Figure 1 is a schematic of thermal spray
coating process

Figure 1: Typical Thermal Spray Coating Schematic (Ref ASM Handbook Vol 5A)

The various types of thermal spray coating processes, their uses, the various coating
materials used, and the components on which these processes are applied are
summarized in Figure 2. When CRA coating is applied for corrosion protection or cracking
prevention using thermal spray processes, it is called thermal spray coating (TSC). At
Saudi Aramco, TSC has been applied to reduce corrosion in sweet or sour environments
or to prevent sulfide stress cracking of weld build-up used to repair corroded areas, both
of these in amine services. In the latter case, TSC has been used as an alternative to
PWHT of the weld build up.
Commonly used processes at Saudi Aramco for TSC in amine services are HVAS and
HVCC processes. Other thermal spray processes for TSC may be used subject to
approval by CSD. The type of process to be used for each project is typically stated in the
project specific Quality Control Plan (QCP).

Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 5 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

Figure 2: Thermal spray processes - taxonomy

Unless locally supported within 50mm by adjoining or adjacent structures, TSC should
only be applied if the susbtrate wall thickness exceeds 6.35mm (0.25 inches) to avoid
inducing stresses on the substrate during the spraying process. This should not be
confused with the minimum wall thickness to meet service requirements based on
mechanical design or fitness for service evaluation.
6. Thermal Spray Coating Feedstock
There are several corrosion resistant coating types that can be engineered to provide a
corrosion resistant barrier for substrate materials in different corrosive environments. High
Nickel-chromium alloys such as Alloy C-276 or other nickel based alloys produce good
corrosion resistant coating. Most thermal spray service providers modify the composition
of the material by adding trace elements to reduce stress, oxide formation and porosity.
This will improve the resistance to flaking and prevent corrosive attack through porous
connections. Each service provider may modify the material composition to specifically
suit their thermal spray process.
Given the proprietary nature of the thermal spray coating feedstock and the availability of
a wide variety of types of TSC CRAs, every application needs evaluation and approval of
the TSC type on a case by case basis. This is done on basis of demonstrated past
experience with successful service life in similar applications or laboratory based testing.
Laboratory testing typically includes determination of physical properties including levels
of porosity, carrying out accelerated corrosion testing and sometimes even simulated
testing in environments replicating actual service conditions including pressure,
temperature, media (sweet/sour) and flow rates.
7. Surface Preparation
7.1 Welds, cut edges, and other areas with surface imperfections should be prepared
according to ISO 8501-3 prior to blasting. Prior to blasting, visual inspection should be
Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 6 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

carried out to ensure the surface is free of imperfections such as surface cracks, pin
holes, weld spatters, rough welds, under cuts, sharp edges etc. Imperfections should be
removed by grinding or by appropriate means. Rough welds and sharp edges should be
ground to a minimum radius not less than 2 mm to ensure proper coating application.
Serious defects that may impair the coating, such as extensive laminations, burrs,
gouges, pits, metal slivers or cold laps, or uneven weld cap or weld irregularity should be
reported and addressed before thermal spray coating is applied.
7.2 Where weld seams in pressure vessels or weld build up areas are to be coated, the welds
should be subject to 100% NDT prior to applying TSC, as repair after application of TSC
could be quite difficult. Defects should be repaired prior to TSC. All welds should have a
smooth profile. Any pits or grooves in the weld bead should be opened to the surface by
grinding and all edges should be ground smooth (blend). It is adviseable that the final
inspection of the welds in the area to be coated is inspected by the TSC applicator and
accepted/approved before abrasive blasting.
7.3 Metal surface should be free of hard scales, products residue and chemical
contamination. This should be ensured prior to blasting to ensure adequate bond
strength between the TSC and the substrate. It is recommended that the components are
degreased by applying acetone or other non toxic degreasing solvent by the “wipe down”
method according to SSPC-SP1, or as specified by TSC service provider (whichever is
better). The use of benzene, gasoline, carbon tetrachloride and chlorinated hydrocarbons
for cleaning should be avoided. The area should be inspected visually or by using other
aids such as black light to assure all oil has been removed. All oil / grease/ hydrocarbon
traces should be removed from the equipment completely before abrasive blasting. If
not, contaminated abrasives could re-contaminate clean surfaces.
8. Abrasive Blasting and Profiling
8.1 Compressed air used for blasting and coating should be free of oil, moisture and
contamination. The water and oil content of the compressed air for surface preparation
and coating operations should be measured in accordance with ASTM D4285 or other
recognized standards. This is typically done by holding a piece of white absorbent paper
or cloth in the air stream, under normal operating pressure, as close as possible to the
blast/coating equipment (< 60 cm from the nozzle) for a minimum of 2 minutes upon
connection to the air source. The paper/cloth is then visually inspected for contamination
by oil or moisture. Discoloration of the absorbent paper indicates unacceptable air quality.
Poor air quality must be rectified before blast or spray work can commence. As a
minimum, the inspector should check and approve the air quality at the start and mid-
point of each 8 hour period.
8.2 Blast pressure should be periodically measured at the blast nozzle in accordance with
recognised methods and standards. Pressure measurements are typically performed
once per shift for all nozzles or whenever work conditions are altered such that the
pressure may change. Steel substrates may need approximately 0.6 to 0.7 MPa (87 to
100 psi) air-blasting pressure at the nozzle.
8.3 Blasting and coating should be avoided when the relative humidity is greater than 85%.
Prior to blasting and coating, humidity should therefore be determined in accordance with
ASTM E337 or other recognised standards.
Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 7 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

8.4 For good TSC bonding with substrate, the steel substrate surface to be coated should be
blasted with abrasive to a white metal finish Sa 3/ NACE No.1/SSPC-SP 5.
8.5 Abrasive material may be selected based on the coating requirement and the substrate
condition as illustrated in NACE No. 12; AWS C2.23; SSPC-CS 23.00 and evaluated per
SSPC-AB1. Abrasive should be free from harmful contaminants such as oil and grease.
In addition, the abrasives should be tested for oil contamination in accordance with
recognised methods or standards. Aluminum oxide is evaluated in accordance with
SSPC-AB 1 and steel grit in accordance with SSPC-AB 3. Use of silica sand for abrasive
blasting in Saudi Aramco is prohibited by GI-0006.021.
8.6 Ideally, the substrate temperature should be maintained more than 3°C (5°F) above the
dew point temperature by introducing dehumidified air or using heaters. Gas burning
direct heaters should not be used for this purpose. Sufficient dust suction blowers should
be fitted adequately to remove dust and fine blasting debris during the blasting operation.
Blast surface preservation products should not be used for TSC. Spent abrasive should
be removed from cleaned internal surfaces by dry brushing and vacuum cleaning.
8.7 Only areas scheduled for coating in the same shift should be profiled. The surface should
be maintained free of contamination from process media and body oils from hands and
arms after profiling, until coating is complete. The blasted surface should be visually
inspected to SSPC-SP-5 standard.
8.8 The surface should be 100% visually inspected to visual comparison standards. The
surface profile should be measured in accordance with ASTM D441722 (Method B or C)
in accordance with SSPC-PA 1723, NACE RP 0287 or other recognised standards, using
replica tape (e.g. TESTEX profile tape and micrometer), ISO profile comparator or stylus
type profile meter. Measurement frequency should be specified in the QCP and the
results should be recorded/documented.
8.9 The time lapse between profiling and coating should not exceed 4 hours.
9. Thermal Spray Coating Application
9.1 Thermal spray coating application should commence immediately upon inspection of the
profiled surface. The maximum allowable time between surface profiling and application
of first coating should be as per para. 8.9. No coating should extend beyond the cleaned
and profiled area. Coating should be evenly applied until the specified thickness has been
achieved.
9.2 Equipment for TSC should be set up and operated according to the instructions and
technical manuals of the equipment manufacturer or TSC applicator/service provider. All
thermal spray equipment should be inspected prior to operation to and sufficient spare
parts should be available at the job site.
9.3 The limits for perpendicular stand-off should be specified by the TSC service provider
and verified during application. Wide stand off may result in oxidation of the coating
layer(s) and short stand off may result in high stresses on the coating.
9.4 Each TSC pass deposits a coat thickness of approximately 2-3mils (50-60 µ). Coating
should be applied in multiple crossing passes. Each pass should overlap the previous
pass in order to achieve an even coating thickness as much as possible. Methods such
as the “cross-hatch” are used for the TSC, whereby each series of spray passes is
followed (where possible) by another series of overlapping passes at 90° to the first. This
Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 8 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

method minimizes variations in the sprayed coating thickness. For small areas to be
coated, the oscillatory overlapping method may be used provided that it is carried out with
multiple thin passes and final thickness of TSC is uniform and acceptable.
9.5 The spray torch/nozzle should be maintained as close to perpendicular as possible with
a spray angle never exceeding ±45º from the perpendicular to susbtrate surface. At no
point should the thermal spray spot be stationary with respect to the substrate surface.
9.6 Desired nominal thickness of TSC is 20mils (500 µ). Coating thickness and allowable
variance should be evaluated and approved on a case by case basis.
9.7 Coating thickness is measured using magnetic lift off technique in a grid pattern. The size
of the grid and the measurement frequency should be specified and approved through
the QCP. Equipment for measurement/ verification of thickness should be calibrated by
each technician at the beginning of the shift, and prior to any inspection activitites.
Readings should be documented on a schematic of the vessel and as specified in agreed
QCP.
9.8 Coating thickness above as well as below limits are generally problematic and unsuitable.
Over thickness could lead to undue stresses in TSC and cracking, whilst under thickness
could compromise the corrosion resistance. Therefore areas with coating thickness below
specification should be re-sprayed to achieve minimum thickness while areas with
thickness above specified limits should be 100% visually inspected for cracks. If cracks
are found, cracked areas should be repaired. If no cracks are found, coating with
thickness above limits can be left as is but should be recorded and the areas inspected
during future turnarounds/T&Is, whenever access permits.
9.9 The surface of each pass should be visually examined for uniformity and freedom from
blisters, cracks and loose particles. The final surface of the TSC (before the sealant is
applied) should be 100% visually inspected for uniformity and freedom from coarseness of
TSC and loosely adherent particles.
9.10 TSC should be applied as a circumferential band exceeding at least 150 mm (6 inches) on
either side of the area to be protected. Circular Patch TSC repairs should be avoided
especially in sweet environments or conditions where galvanic corrosion is a concern.
Careful consideration should be given to the termination of the TSC due to galvanic
corrosion at the termination especially in sweet service, though this is not as severe a
problem as for weld overlay or strip lining termination.
9.11 Internal attachments such as Tray Support Rings (TSRs) and downcomer brackets (i.e.,
structural attachments) do not need 100% TSC application. Coating the entire TSR
including the edges and around the end is not considered necessary and TSC may be
terminated at a distance of 25 – 50 mm (1 - 2 inches) from the shell.
10. Sealant Application
10.1 Sealants (also known as sealers) maybe used to fill porosities open to the surface of the
TSC by capillary impregnation and film formation. Some thermal spray service providers
apply sealant following the application of proprietary coatingsystem, while others do not.
Also, sealant type and composition varies from one service provider to the other. If used,
the sealant should be compatible with the TSC and resistant to the corrosive service
environment. Where sealant is specified, it should only be applied after the final

Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 9 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

acceptance of TSC by the Inspector. However, the sealant should be applied as soon as
possible to avoid contamination of the coating.
10.2 Sealants, like TSC, are applied using mutiple coats. Sealants should be applied according
to manufacturers’ instruction using brush, rollers or spray guns. This is also based on the
penetration requirement. Brushes are generally used in areas with complex geometry to
ensure sufficient penetration of sealer, whilst rollers or spray guns are used when the
surfaces to be treated are large. The sealing principle is by capillary impregnation and
film.
10.3 Sealant should be inspected visually by the inspector to verify coverage of all coated
areas.
11. Thermal Spray Coating Repair
11.1 Areas of thin coating should be re-sprayed within two hours of the initial application and
while the surface is clean and dry. This should be done before sealant application, as far
as possible. If TSC thickness is deemed insufificent after sealant application, follow repair
steps as below for the repair.
11.2 If TSC is damaged and the substrate is exposed during any operation after TSC
application (such as removal of scaffolding or installation of trays), coating repair should
follow the steps outlined below (see preceeding sections for control and verification of
each step, where available):
11.2.1 Solvent cleaning – All oil and grease contamination should be removed by solvent
cleaning.
11.2.2 Scrape off loosely adherent TSC – A scraper blade should be pushed underneath
the loose TSC to push and scrape away all loosely adherent TSC until reaching a
well-bonded TSC area.
11.2.3 Abrasive blasting – The surface to be repaired should be abrasive blasted to a
white metal finish with an anchor profile of 75 - 125 µm. The blasting nozzle should
be kept perpendicular to the work surface.
11.2.4 Feathering – A 50 - 75 mm (2 – 3 inches) border should be feathered by blasting
into the undamaged TSC area.
11.2.5 TSC should be re-applied in the prepared area.
11.2.6 Sealant – Sealer should be applied in accordance with Section 10.
11.2.7 Coating repair should be re-inspected to ensure compliance with the requirements
specified in QCP and this best practice.
12. Inspection
12.1 All specified checks inspection and hold points should be specified and agreed through
the QCP.
12.2 The Inspection Supervisor should conduct and organize inspection at all stages of
cleaning, blasting, profiling, TSC application, sealant application and final inspection.
During abrasive and profile blasting, compressed air should be monitored as per this best
practice guidelines. Spent blast materials should be subject to a water settlement test to
check for (oil in air) contamination. All test results should be recorded/documented in
relevant inspection reports (See annexure for a typical inspection report format). Whilst
Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 10 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

inspection is critical, it should be ensured that the inspection does not interfere and affect
the TSC quality, for example by delaying the TSC application after surface preparation.
12.3 Production coupons may be used for additional verification of TSC quality. This involves
the use of a series of sprayed test coupons that are prepared and thermal sprayed
concurrent to the application of the TSC inside a column or pressure vessel. These
samples may be subject to destructive tests such as pull-off adhesion tests and
microscopic examination of cross sections to determine the “as-sprayed” condition of the
coating. If needed, the method, frequency and tests (as well as acceptance criteria)
should be agreed upfront through the QCP.
13. Spray Coating Procedure
It is recommended that a TSC procedure or method statement is prepared to supplement
the QCP. The procedure should include details of the materials, equipment type, process
type, “essential” variables, consumable datasheets, testing requirements and acceptance
criteria as a minimum. Qualification and testing of procedure on coupons followed by
testing conducted by third party laboratories may be used to ensure adequacy of the TSC
application procedure. Currently, there is no international code or standard that gives
requirements for TSC application procedure qualification.
14. Operator/Applicator Performance
Similar to any other special process, thermal spray operators/applicators should
demonstrate experience, job knowledge (spraying process, materials and safety
requirements) and be subject to performance qualification testing at periodic intervals as
part of the quality management. Currently, there is no international code or standard that
gives requirements for TSC applicator performance qualification. Pre-qualification tests
before the start of a project may be carried out to demostrate abilities of applicators.
Alternatively, at the start of each shift coupons may be used for each applicator and
subject to destructive testing in field as part of the quality management.
15. Safety
15.1 Safety requirements applicable to TSC including surface preparation can be found in
SAES-H-102, Contractors safety manual, Construction Safety Manual Section 9, GI-
0002.100 and GI-0006.021.
15.2 TSC being a hot work activity, GI-0002.100 and Chapter 11 (Safety), AWS Thermal
Spraying: Practice, Theory, and Application safety requirements related to hot work
should be followed.
15.3 Blasting media and thermal spray overpsray should be collected and disposed safely
following industrial safety and environmental compliance requirements such as those
stated in Section 13 of AWS C2.18.
15.4 Adequate ventilation during TSC application is important to ensure TSC quality and safety
of personnel. Air must be moved in sufficient quantity to meet TSC service providers’
requirements for spray process and visibility.
15.5 A Job Safety Analysis to identify hazards and controls should be discussed with all
personnel involved before start of the activity (see LPD Safety Management Guide JSA
06-003-2013 for details).
Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 11 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

Appendix A: Thermal Spray Application QC Checklist

Thermal Spray Application QC Check List (Typical)
Date of Pre-inspection Time
Date Started Technician
Time Started Time Complete

Pre-inspection of vessel
Surface Inspection
Black light Inspection
Contamination cleaned
Second blakc light inspection completed

Safety walk down completed

Internal element protection inspection completed

Abrasive Blasting
Date Time Humidity Dew Point Heater

Clean Dry air test (cotton absorbent)

Oil Sheen Test
Blast pressure measurement

Surface blast comparitor test completed

Scaffolding blown down

Profiling
Steel/Aluminium Oxide sample collected per batch

Testex tape profile test

PLACE TAPE HERE

Area Measured out to be no more than 150 [Link]

Scaffolding blown down
Thermal Spray Application:
Date Time Humidity Dew Point Heater Atomizing air

Machine Parameters Amps Volts

checked

Visual inspection of spray parameters at the gun to be 6” – 8” stand off, 70-90 degree
Angle of spray, 50% overlap
Bond coating thickness verified
Substrate Temperature
Measurement < 400 F
Final coating thickness measurements compiles
Final visual inspections completed

Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 12 of 13

Saudi Aramco: Company General Use

 Document Number SABP-W-005 Thermal Spray Coating for In-Situ Repair of
Pressure Equipment in Amine Service

Document History
27 July 2020 Major revision.
25 March 2020 New

Summary of Changes

Paragraph Change Type

No. (New, Modification,Technical Change
No. etc.)
1 Content Addition Added “1. Scope”
2 3.2 Addition Added reference to ASM Handbook Volume 5A
Rephrase the first paragraph and replaced
3 5 Modification
Figure 1.
Deleted the 2nd paragraph highlighting the
various types of thermal spray processes.
4 5 Deletion
These various processes is already
summarized in Figure 2
5 7.3 Modification Editorial
6 12.3 Deletion Last sentence deleted.
Appendix
7 Modifications Editorial
A

Revision Date: 27 July 2020

Nexrt Revision: 27 July 2030 ©Saudi Aramco 2020. All rights reserved. Page 13 of 13

Saudi Aramco: Company General Use