General Requirements and SOP for STOPAQ/EGS Installation

Procedure (STOPAQ Application)

1. Coating Removal
1.1. Coating Supervisor shall inspect the Pit / Trench for adequacy of working space for coating
repair and the subsequent operation.
1.2. The trench sizes need to be approved for adequacies by CCED and Contractor site
personnel.
1.3. The stanely knife shall be used only for initial cut mark on the coating such that well defined
pattern of 200 MM to 300 MM of coating can pulled and disbanded from the pipe with the
help of puller. The cut pattern could be circular or spiral depending upon the site conditions
but ensuring that the knife at no moment of time gets in contact with pipe surface
1.4. Chisel and lightweight hammer shall be used tangential to pipe surface just for removal of
small patches which are firmly bounded to pope surface left out during pulling operation.
1.5. Small area where the bonding between pipe and coating which cannot be removed by
above method, shall be removed with help of scraper or manually by blunt chisel and
hammer such that pipe is not damaged at all.
1.6. Visual inspection of the pipe shall be carried after removal of the coating to ensure no
damage to the pipe surface due to the coating removal operation.

2. General Requirements
2.1. Prior to start ensure that the activity is scheduled properly and all authorities are informed
and all required personnel are available,
x A material checks to be carried out by contractor Inspector / Coating Supervisor to
ensure that the materials are free from damage (as per manufacturer’s product data
sheets).
x Wrapping material to be protected from the possible damage by providing adequate
measure for protection.
x Care shall be taken during the handling of "STOPAQ Wrapping Band CZH" wrapping
material and keep it in a clean environment as recommended by Manufacturer.
x Ensure that the Wrapping material is kept in a dry, ventilated area and away from direct
sunlight, rain, snow, or other adverse environmental element.
x Ensure that the Wrapping Band is kept in original sealed container until ready for use.
 General Requirements and SOP for STOPAQ/EGS Installation

x Excavation for underground pipeline Wrapping Band installation shall be carried out in
such a way that it shall provide sufficient access for the surface preparation, coating
application and Inspection.
x Excavation shall be carried out Once the excavation is completed, Contractor shall take
the photos of existing condition of the coating. This shall be provided to CCED upon
request.
x Applicators shall be trained and certified by STOPAQ
x Applicators shall be approved by CCED representative before the commencement of the
job.

3. Material
x The following materials and consumables shall be utilized for "STOPAQ"coating system,
o Wrapping Band CZH (InnerWrap).
o Outer wrap PVC.
x The inner wrap (Wrapid Bond) is a Universal, inert, amorphous, non-cross linked
monolithic polymer wrap coating with cold flow, self-healing, viscous-elastic properties.
STOPAQ® Wrapping band CZH is a non-toxic wrap material adhering extremely well to
steel and line pipe coatings like PE, PP,FBE. It is fully resistant to water and has a very
low gas and water vapour permeability.
x STOPAQ® Wrapping band CZH is always viscous at the temperatures of use, -45°C up to
+70°C (cold flow) and therefore flows, into all irregularities on the steel surface and is
able to self-heal small damages like dents and cuts. The Wrapping Band CZH (Innerwrap)
extremely well to steel and line pipe coatings like PE, PP, FBE. It is fully resistant to water
and has a very low gas and water vapor permeability (refer data sheet)
x The outer wrap PVC, is UV-resistant, flexible polyvinyl chloride tape, coated with a
modified, pressure sensitive rubber resin adhesive. STOPAQ® Outer Wrap PVC is used
for mechanical protection of corrosion protective systems, such as the STOPAQ®
Wrapping band CZH and CZ.
x The Outer Wrap has high puncture and aging resistance. Is well suited for above-ground,
underground and submerged applications. The heavy-duty adhesive layer provides high
adhesion strength to the outer surface of the STOPAQ® wrapping band as well as to its
own backing. The Outer Wrap has a good resistance to impacts and abrasion as well as
resistance against the influences from alkalis and acids.
 General Requirements and SOP for STOPAQ/EGS Installation

x Storage: Shall be stored indoors clean & dry away from direct sunlight in temp below
400C.
x Shelf Life: Unlimited.

4. Surface Preparation
x Surface preparation shall not be undertaken when:
o Steel temperature below 5°C.
o Surface temperature is less than 3°C above dew point of the surrounding air.
o The relative humidity of the air is greater than 85%.
o Outside day light hours on external surfaces.
o High wind speeds (greater than 15 knots)
o In the presence of airborne dust or sand
o Rain, fog, mist or when there is free moisture on the prepared surface
o Steel substrate temperature greater than the maximum allowable application
temperature as specified in vendors data sheets.
o Air temperature less than 5oC
o In conditions of insufficient lighting where available light is <500 lux

All the above weather monitoring shall be conducted every 2hrs interval.

NO GRIT BLASTING SHALL TAKE PLACE ON PIPELINE WALL THICKNESS LESS THAN 3mm. CLEANING
SHALL BE PERFORMED USING HAND TOOLS TO AS SURFACE FINICH TO ISO 8501-1: SA 2.5.

x Before any surface preparation commences, the surface shall be inspected to ensure it is
free of oil, grease and any substrate defects.
x If observed any kind of Mechanical defect or dent on the pipe surface, shall be reported
to UIPT4 for further action. Until further action is confirmed, the location shall be under
hold.
x Grease, oil, etc, shall be removed by means of solvent cleaning if observed in accordance
with SSPC SP-1. The cleaned surface shall be rinsed with clean fresh water and allowed
to dry. Rags shall not be used for drying. Excessive rust scale may need to be removed
using power cleaning tools.
x The surface shall be free from all loose strains, paint and foreign materials.
 General Requirements and SOP for STOPAQ/EGS Installation

x Steel surface should be cleaned using abrasive Grit blasting to standard of SA 2.5 prior to
coating application. The Grit shall be OMGRIT and required profile shall be more than 60
microns.
x While performing blasting the existing coatings which are in good condition shall be
protected from the Grit by covering with polyethylene covers wrapped around.
x Factory coated edges should be abraded for a minimum width of 50mm from the
cutback edge.
x No surface preparation shall be performed on surfaces that are moist or may become
moist before application of the coating.

4.1. Follow the below method of surface preparation for exiting coatings found after
excavation.
4.2. Old Existing 3LPE Coating (Regardless of its Condition, on premise that it has aged way
past its design life
x Remove completely and prepare surface to Sa 2.5
x Coat with Stopaq
4.3. Surface Dust Test Procedure
x 50mm wide x 100mm long piece of clear adhesive tape shall be pressed on the top of
pipe and rub gently for few seconds.
x Pull it back and compare the pattern of observed dust with photographs shown in ISO
8502-3 as acceptance criteria.
x If pattern doesn’t meets the requirement, use blow of pressurized clean air on the
cleaned surface and retest till the pattern is achieved.

4.4. Surface Cleanliness Check:

x The surface cleanliness check has to be carried out for each section of the pipeline
where STOPAQ coating has to be applied.
x Apply ±150mm Stopaq Wrapping band onto the surfaces of the pipeline and adjacent
applied coating [1] and press the material into the pores of the substrates. Remove the
 General Requirements and SOP for STOPAQ/EGS Installation
Stopaq after approx. 5 minutes in an angle of approx. 135° and with a speed of
100mm/min [2]. Cohesive
x failure should occur and the remaining Stopaq material should cover ≥95% of the
surfaces [3]. If this is less, further cleaning is required. Repeat cleaning and cleanliness
check until ≥95% of the surface remains covered.

4.5. Application Method:

For Coating work conditions refer 8.4.
Application of STOPAQ Wrapping band CZH (Inner Wrap)
x Apply the sticky side of the Wrapping band on the substrate. Do not apply with TENSION,
but LAY the Wrapping band on the substrate. Avoid air-enclosures. Massage the Wrapping
band tight on the substrate surfaces. Do not remove the release foil before application of
the CZH. Remove only at the moment of adhesion of the CZH when applied to the surface.
x Overlap – Stopaq to Stopaq ≥ 10mm
x Overlap – Stopaq on Factory Coated Pipelines = 50mm
x Overlap of ends of STOPAQ wraps Spiral wrap on pipes:
x STOPAQ on STOPAQ: ≥ 50mm. Start with one, full straight wrapping, follow with one wrap
from “straight to spiral” and then continue spiral wrapping end with one straight,
circumferential wrapping.
x Field joints :
Two wide STOPAQ Wrapping band CZH sheets are used. Each (straight) wrap should overlap
the factory coating with min. 50mm and the weld seam with min. 30mm.
x For areas where cathodic protection is provided, it shall be ensured that the overlap on the
existing pipeline coating is restricted to 10cm (100mm) to help maintain effective cathodic
protection to the existing coating and interface.

4.6. Inspection (Thickness check & Holiday Testing)

x Upon completion of wrapping band application (Inner wrap). It shall be ensured visually that
there are no air inclusions, tenting, and bridging.
 General Requirements and SOP for STOPAQ/EGS Installation

x Upon completion of Wrapping band application ( Inner wrap), thickness check shall be
carried out randomly on the surface @ around 12, 3, 6 & 9 o’clock position to ensure
required thickness of minimum 1.8mm is achieved and same shall be witnessed by
CCED/ALG Inspector. The Holiday Test shall be carried out by the competent supervisor.
x A holiday test using a high voltage tester shall be carried out on the Stopaq Wrapping band
CZH prior to the application of Stopaq Outer wrap PVC.

x 100% Holiday test shall be carried immediately after wrapping. Thickness measurement is to
be carried out for each repair area.
x As per NACE SP 0188-2006 voltage for Holiday Inspection will be 5V per 1 mm coating
thickness, using a 15KV Holiday tester.

4.7. Repair.
x If encountered any holiday on Wrapping band (Inner Wrap), the area shall be applied with
patch of Wrapid band (Patch), covering with minimum 50mm overlap all side of the repair
area. Further
x Holiday test shall be carried out to ensure that repair is successful.
x If any repair observed visually on the Outer Wrap, it shall be repair by wrapping
circumferentially around the surface with minimum 50% overlap.

8.8 Application of STOPAQ Outer Wrap PVC (Outer Wrap)

x The STOPAQ® Outer Wrap PVC must be applied with little TENSION.
x Start the wrapping 3mm with one full circumferential wrap. Leave 3mm of STOPAQ CZH
visible.
 General Requirements and SOP for STOPAQ/EGS Installation
Then follow with spiral wrapping with minimum 50% overlap. Avoid air-enclosures.
x End full-circle overlap, Outer Wrap on Outer Wrap: minimum 300mm.
x Finish the wrapping 3mm inside the STOPAQ Wrapping band with two straight, TENSIONLESS
circumferential wrappings. Cut the tape end in a 45º angle at the downwards side with the
longest tip pointing in the direction of the wrapped part.
x When more than one roll of outerwrap PVC is needed to continue wrapping, an overlap on
the end of the previously applied outerwrap PVC should be created of at least 100mm
Visual inspection:
x The applied Outer Wrap must look smooth and tight and should be shaped around all details
and into corners.