2010 11-05-14 stopaq training presentation
TRANSCRIPT
2
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 [email protected]
3
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.
4
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.
5
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.
6
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.
8
Pipeline coating
• 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.
Application of STOPAQ CZH Wrappingband on seamless pipes
9
Pipeline coating
• 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.
Application of STOPAQ CZH Wrappingband and PVC outerwrap on seamless pipes
10
Pipeline coating
• 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.
Application of STOPAQ CZH Wrappingband on pipes with longitudinal weld
11
Risers Coating
General
• The transition sections of the pipeline from below ground to above ground
causes major concern for corrosion. The STOPAQ System guarantees long-
lasting 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.
12
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.
13
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.
14
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 15°C and surface must be
dry with no condensation.
15
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.
16
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.
17
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.
18
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 .
19
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.
20
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.
21
Please visit the STOPAQ website:
www.stopaq.comor email any queries to: [email protected]
THANKS FOR YOUR COLLABORATION AND SUPPORT
For more information...