STOPAQ Application Guidelines & Training Manual

Dr. Fikry Barouky [email protected] Revised date: October 2010

Contents
General preparation of a pipeline for STOPAQ application STOPAQ Coating to repair pipeline Pipeline Coating with STOPAQ for Rehabilitation Seamless Pipeline Longitudinal Seam Pipeline Risers Coating Field Joint (Girth weld) Coating Flange Coating

Dr Fikry Barouky [email protected] 2

Coating repairs with STOPAQ

General The pipe section that needs to be coated must be excavated sufficiently to have enough clearance around it. Ensure excavation of 0.3m under the pipe section. The working area must be kept dry during application. Check regularly to ensure the pipe section stays above dew point i.e. with no condensation.

Coating repairs with STOPAQ

Surface Preparation & Quality Control The old damaged coating must be removed from the pipe surface that needs to be re-coated. Finish as square as possible. The surface to be coated must be clean and dry and free of loose parts. At the spot where connection to the bitumen/PE is, this must be bevelled under an angle of 30. The base surface must be dry and clean. Should abnormalities be found around the repair spot, then consult with Anti Corrosion Technology. If the coating consists of asbestos bitumen, then the applicable regulations for removal must be followed.
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Coating repairs with STOPAQ

Application of STOPAQ CZH Wrappingband The first wrapping must be applied tightly to the bitumen/PE after it has been brushed or grit blasted. Start by wrapping one straight band on each end of the pipe section to cover 50mm of the existing coating. Then continue spiral wrapping the STOPAQ CZH Wrappingband over itself maintaining a minimum 10mm overlap.

Coating repairs with STOPAQ

Application of STOPAQ PVC Outerwrap The STOPAQ PVC Outerwrap provides the primary mechanical strength to STOPAQ CZH Wrappingband. Start tightly wrapping one straight band over the STOPAQ CZH Wrappingband on one end of the pipe section. The continue to spiral wrap STOPAQ PVC outerwrap tightly on the STOPAQ CZH Wrappingband maintaining a minimum 30% overlap. On both sides, leave 3mm of STOPAQ CZH Wrappingband visible.

Coating repairs with STOPAQ

Application of STOPAQ UV cured Polyester outerwrap
STOPAQ UV cured Polyester outerwrap is applied over the STOPAQ CZH Wrappingband or PVC outerwrap in situations where protection against heavy mechanical strength is necessary. The STOPAQ UV cured Polyester outerwrap must be kept dry, clean and out of direct exposure to light. Immediately before application, pre-cut STOPAQ UV cured Polyester outerwrap to size. Remove any grease with isopropanol (CAS-nr 67-63-0) and condensation with a dry rag. UV-lamps must be used for hardening. Daylight contains UV-A light. Taking weather conditions into consideration, it is advisable to have UV-lamps available at the working area. After hardening the product can be painted with an appropriate PU coating. There is a water curing version of this outerwrap, so please consult ACT if this is a more suitable option.

Pipeline coating
Application of STOPAQ CZH Wrappingband on seamless pipes

Apply first STOPAQ CZH wrappingband wrapping squarely. Apply next wrappings with a minimum overlap of 10mm. On field joint sections, overlap by 50%. Apply wrapping with a light tension. End squarely. Use Holiday Detector to check for any voids (spark test up to 15KV) before applying the outer wrap. When applying the STOPAQ PVC outerwrap, 3mm of the STOPAQ CZH Wrappingband must be visible on both ends of the pipe section.

Pipeline coating
Application of STOPAQ CZH Wrappingband and PVC outerwrap on seamless pipes Use STOPAQ PVC outer wrap to provide mechanical protection. Apply first STOPAQ PVC outerwrap wrapping squarely. Overlap STOPAQ PVC outerwrap spiral application by minimum 30%. Finish STOPAQ PVC outerwrap wrapping always on the lower side of the pipe in general. 3mm of STOPAQ CZH Wrappingband must be visible on both ends of the pipe section under the STOPAQ PVC outerwrap.

Pipeline coating
Application of STOPAQ CZH Wrappingband on pipes with longitudinal weld Welds with sharp edges and protrusions must be dressed by grinding for suitable roundness fillets Apply STOPAQ CZH Wrappingband strips longitudinally to cover the weld line (as illustrated) Spirally wrap the whole pipe with STOPAQ CZH Wrappingband and STOPAQ PVC outwerwrap as previously illustrated. Application can be done reinstate existing coating. the coated surface must be clean and dry to ensure adequate cohesion of the STOPAQ CZH Wrappingband. Overlap the existing coating with a minimum of 5cm.

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Risers Coating
General The transition sections of the pipeline from below ground to above ground causes major concern for corrosion. The STOPAQ System guarantees longlasting protection against corrosion where cathodic protection is also less effective. This system can be strengthened on the outside with STOPAQ UV cured Polyester outerwrap to protect against any mechanical damage. STOPAQ UV cured Polyester outerwrap can be painted with PU if required to match safety coding colour. Application of STOPAQ system is illustrated below.

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Risers coating
Surface preparation Existing damaged coating must be removed from the pipe surface which is to be repaired with the STOPAQ system. Masking tape should be used to ensure a clean and square finish, and to protect the rest of the pipe section. The surface to be coated must be clean, dry and free of loose scales. This can be achieved by wire brushing to Sa 2 and if extremely corroded the surface must be abrasive blasted to Sa 2.5. It is imperative to apply STOPAQ CZH Wrappingband on a dry surface without oil, grease, and condensate.

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Risers coating
Application of STOPAQ CZH Wrappingband If there is a circle weld or longitudinal weld on the riser to be protected, this weld must be firstly coated with one strip of STOPAQ CZH Wrappingband prior to the spiral application of the STOPAQ CZH Wrappingband. Application procedure as per the illustration below.

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Risers Coating
Application of STOPAQ PVC outerwrap The STOPAQ PVC outerwrap gives the primary mechanical strength to STOPAQ CZH Wrappingband. It is applied with a little bit of pressure on the underlying STOPAQ CZH Wrappingband. The overlap must be maintained at a minimum of 30%. On both sides 3mm of STOPAQ CZH Wrappingband must be left visible. It is best to apply STOPAQ PVC outerwrap at a minimum temperature of 15C and surface must be dry with no condensation.

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Coating of field joints (girth weld)

General The field joint can be coated either over the ditch or in the ditch. The pipe section must be excavated sufficiently so that it can be handled on all sides. Excavate 0.3m under the lowest pipe part. The working area must be kept dry during application. Check regularly whether the pipe stays above dew point by means of a dew point gauge. Drain (if necessary). Keep free from rain, but provide sufficient ventilation with regard to dew point.

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Coating of field joints (girth weld)

Application of STOPAQ CZH Wrappingband

Girth weld to be coated as illustrated.

If there are sharp edges on the welds, they should be ground off and apply STOPAQ CZH Wrappingband as illustrated. The adjacent coating must be bevelled to an angle of 30. The coating must be lightly sanded and cleaned where STOPAQ CZH Wrappingband is applied. Start at 30mm past the circle weld and then wrap a cuff squarely on the pipe with an overlap of 100mm over its own wrap.
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Coating of field joints (girth weld)

Application of STOPAQ CZH Wrappingband Apply 2nd wrapping squarely, 30mm over the circle weld, end with 100mm overlap on the underlying STOPAQ CZH Wrappingband. Pipes < 30 5cm overlap over the existing coating. Pipes > 30 10cm overlap over the existing coating. The second wrapping is shifted in respect of the first one, in such a way that the dry joints are not over one other. Apply wrappings lightly tensioned. Now Quality control using spark tester at 15 kV. Select the proper outerwrap. STOPAQ PVC outerwrap, UV cured Polyester, water cured outerglass shield or HSS all can be used depending on the soil and service condition.
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Coating of underground and above ground flanges

General Underground flanges can be protected against corrosion, effectively and simply, with the STOPAQ system. The pipe section that needs to be coated must be excavated sufficiently to have enough clearance around it. Ensure excavation of 0.3m under the lowest pipe section. The working area must be kept dry during application. Check regularly to ensure that the pipe section and flanges stay above dew point i.e. with no condensation, and in a temperature above 15 deg C .

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Coating of flanges
Application of STOPAQ system for flange protection using FN4200 gun grade paste, CZH Wrappingband and PVC outerwrap Clean flanges to remove any loose scales, rust, contamination or old peeling paints. Use hand brushes, power tools. Remove oil and grease using proper solvent. Make sure that steel substrate is dry and its temperature is above 15 deg C during application of STOPAQ products. Apply STOPAQ FN4200 to fill the gap between flange faces. Use masking tape on the circular faces to get a neat filling. Remove excess paste with scraper. Remove masking tape before applying CZH wrappingband. Apply STOPAQ FN4200 to cover all bolts and nuts to achieve homogenous contour all around the flange.
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Coating of flanges
Application of STOPAQ CZH Wrappingband and STOPAQ PVC outerwrap Apply STOPAQ CZH Wrappingband on the top of the flange in such a way that the bolts- and nuts-ends (which are covered with a layer of STOPAQ FN4200) are extra protected by the STOPAQ CZH Wrappingband.

Wrap the whole STOAPQ coated flange with STOPAQ PVC outerwrap as explained and illustrated in previous applications in the training presentation. STOPAQ PVC outerwrap is used to add mechanical strength to STOPAQ CZH products.
STOPAQ UV cured Polyester may also be used in case of heavy mechanical protection is required. Consult ACT for adequate selection and application.

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For more information... Please visit the STOPAQ website:

www.stopaq.com
or email any queries to: [email protected]

THANKS FOR YOUR COLLABORATION AND SUPPORT

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