Pipelines and Equipment Wrapping by STOPAQ Procedure | Method Statement

1. PURPOSE.
2. SCOPE.
3. REFERENCES.
4. RESPONSIBILITIES.
5. PROCEDURE.
6. SAFETY.
7. ATTACHMENT.

1.0 PURPOSE

This method statement shall provide minimum Guidelines for wrapping (STOPARQ) activities, commercial buildings, plants and refineries in accordance with Project Drawings and Project Specifications.

2.0 SCOPE

This procedure applies to wrapping( STOPAQ) for commercial buildings, plants and refineries.

3.0 REFERENCES

ASMEB31.3 Chemical Plant and Petroleum Refinery Piping
SAES-A-004 General Requirement for Pressure Testing
SAES-A-007 Hydrostatic Testing Fluids and Lay-up Procedure
SAES-B-017 Fire Water System Design
SAES-L-105 Piping Material Specifications
SAES-S-040 Saudi Aramco Water Systems
SATIP-L-350-05 Fire Water Distribution Piping Installation
STOPAQ MANUAL(VENDER)
STOPAQ Application Procedure

4.0 RESPONSIBILITIES

4.1 Construction Manager shall be responsible for the overall implementation of this procedure and shall appoint personnel to undertake periodic audits to ensure this procedure is being complied with.
4.2 Health Safety & Environment (HSE) Manager shall be responsible for ensuring that any Safety issues arising from the implementation of this procedure and regular inspections are followed up and recorded by all Field Supervisors and notified to Project management accordingly.
4.3 Materials Controller shall be responsible for ensuring that all materials are stored and transferred to the custody of the Construction Contractors in a clean and dry condition, suitably protected to ensure ingress of debris and moisture is prevented.

4.4 Field Superintendent shall be responsible for ensuring that all Field Supervisors and Contractor personnel are aware of the requirements of this procedure and for monitoring its implementation at site.
4.5 Field Supervisors shall be responsible for the detailed day-to-day operation of the procedure. They shall complete regular inspections in line with the agreed quality plans and random inspections of Construction Contractors operations to ensure the requirements are being successfully implemented.
4.6 QA/QC Manager has the responsibility to:
4.6.1 Review of all request including Daily Inspection Report.
4.6.2 Managing worker.
4.6.3 Managing control system.
4.6.4 Managing of quality control
4.6.5 Managing inspection and test with regard to wrapping.

5.0 PROCEDURE

This procedure is to provide the best possible description of the way in STOP AQ products have to be applied on hot rolled steel pipeline sections. Applications not in compliance with this application procedure will invalidate the 30-years STOP AQ Corrosion Preventative System guarantee.

5.1 General Description of STOPAQ Corrosion Preventive System.

5.1 .1 STOPAQ Corrosion Preventive System consists of 1 layer 2 mm thick of STOPAQ WRAPPINGBAND CZ H, layer 0.08 mm thick of Polyethylene foil and layer 0.4 mm thick of PVC Outerwear Tape.

5.1.2 STOPAQ WRAPPINGBAND CZ His wrapped with an overlap of 1 cm (irrespective of the width of the Wrapping band), and the PVC Outer Wrap Tape is wrapped with an overlap of 50% of the width of the PVC Tape.
5.1.3 Because of the overlap percentage of 50% of the PVC Outer Wrap Tape a double layer is created, STOPAQ Corrosion Preventative as a system has a total thickness of2.88mm.

5.2 Substrate surface preparation.

5.2.1 A surface preparation grade for the application of STOPAQ WRAPPINGBAND CZ of St2 is required, This requirement refers to surfaces of hot-rolled steel.

5.2.2 STOPAQ EUROPE defines preparation grade St2 as: Thorough scraping and wire­ brushing (machine brushing/grinding is preferable). The treatment shall remove loose mail scale, rust and foreign matter. Finally, the surface is cleaned with a dry cloth, a vacuum cleaner – clean dry compressed air, or a clean brush. The surface should then have a faint metallic sheen (no anchor pattern is required).

a) Sharp edges on the substrate.

It is to be noted that due to the visco-elastic behavior of STOPAQ WRAPPINGBAND CZ H, and due to its liquid like properties (plasticity), STOPAQ WRAPPINGBAND CZ H is self-repairing and is able to recondition possible defects.

Also because of its plasticity, expansion and shrinkage due to temperature changes will not lead to stress generation in the STOP AQ corrosion preventive system.
If there is a sharp edge less than 2mm., measured from the lowest point on the  substrate or average weld surface, STOPAQ WRAPPINGBAND CZ H will totally surround the sharp edge and prevent any corrosion from spreading to any point on the substrate.

If there is sharp edge more than 2mm measured from the lowest point on the substrate or the average weld surface, this sharp edge might penetrate the layer of polyethylene foil and the layer of PVC outer wrap tape. Although there will be no threat of corrosion spreading beyond the tip of the sharp edge, a holiday may be detected during holiday testing.

b) Substrate surface chloride contamination.

The physical effect of osmosis is eliminated when STOP AQ Corrosion Preventative System is applied as STOPAQ WRAPPINGBAND CZ H is mot water permeable.

Because of this unique property, chloride contamination is of no importance for the performance of SROPAQ Corrosion Preventative System.
As chloride contamination is of no importance, washing the substrate (with any kind of solution O prior to applying STOPAQ Corrosion Preventative System it is not required.

c) Relative humidity

During application of STOPAQ corrosion preventative system the relative humidity is of no importance. STOPAQ corrosion preventative system can be applied in a humid atmosphere that does not reach dew point and thus create condensation on the substrate. In order to create optimum adhesion of STOP AQ WRAPPPINGBAND CZ H to prevent the formation of corrosion cells on the substrate surface, the surface has to be dry during the application procedure.

d) Substrate surface temperature

The surface temperature of the substrate prior to the application of STOPAQ WRAPPPING BAND CZ H, should not exceed 85 ·c (18YF).

5.3 Application of STOPAQ Corrosion Preventative System

5.3.1 Prior to start of the application of STOPAQ Corrosion Preventative System, a certified STOP AQ application supervisor should check the substrate surface preparation.

a) Start-up of the wrapping sequence on a pipe section

Always start the application sequence on a cleaned portion of the substrate surface.  Never let pieces of the none preparated pipe section(i.e. parts of the old tape wrap if previously applied on the pipe section) of the substrate surface be trapped underneath the STOPAQ wrappingband CZ H. Applying STOP AQ wrappingband CZ H over old wrap tape will not yield the intended adhesion to the substrate surface.
b) Application of STOPAQ WRAPPINGBAND CZ H Prior to applying STOPAQ WRAPPINGBAND CZ H on the substrate a certified STOP AQ application supervisor has to visually check the application and must regularly measure the average thickness of the layer.
Upon commencing with applying subsequent rolls of STOPAQ WRAPPINGBAND CZ H, the subsequent wrap has to start with a 1 em circumferential overlap over the previous wrap, and a 1 em longitudinal overlap.

STOPAQ WRAPPINGBAND CZ H should be applied without tension, rather in a relaxed way making sure all the time that the wrappingband is completely adhering to the total circumference of the substrate surface. After completing each circumferential layer the applicator must ensure that a minimum of 1 em overlap is followed.

c) Application ofthe PVC OUTER WRAP TAPE

At either end of the substrate where the STOPAQ corrosion preventative system is applied, two complete superimposed circumferential layers of PVC outer wrap tape has to be applied. Subsequent to applying the tow superimposed layers, a 50% overlap is required.

The certified STOP AQ application supervisor has to visually check the application of the PVC outer wrap tape to ensure fidelity of the 50% overlap. His observations are to be recorded on the application checklist.
Upon commencing with applying subsequent rolls of the PVC outer wrap tape the new wrap has to start on the previous one with a circumferential overlap of 50% and a longitudinal overlap If at least 25 cm.

The PVC outer wrap tape must be applied with tension making sure that, firstly, the PVC tape very tightly adheres to the STOPAQ WRAPPINGBAND CZ H and follows its exact contour, and secondly, that there is no air blisters between the wrapping band and the PVC outer wrap, and that the overlap is constantly at 50% of the width of the PVC outer wrap.

d) Holiday testing

When STOPAQ corrosion preventative system is applied it is highly recommended that a holiday test of between 25.000 and 35.000 volt is executed under supervision of a certified STOPAQ application supervisor and a representative of the client.

When holiday is detected, it has to be repaired and re-tested under supervision of the certified STOPAQ application supervisor and a representative of the client. Repair of holidays can be done by means of patching a small piece of STOPAQ WRAPPING BAND CZ H wrapping band over the position of the holiday and applying two full circumferential layers of PVC outer wrap over that patch. At the end of the application process of the STOPAQ corrosion preventative system final certification by the certified STOP AQ application supervisor.

e) The encode of the newly coated pipeline section

When application of STOPAQ corrosion preventative system is completed and certified by the certified STOP AQ application supervisor, it is recommended to encode
that pipe section. Each individual encode number should be noted on the corresponding STOPAQ application checklist.

f) Burial of the newly coated pipeline section

Excavated pipeline sections that are coated with STOPAQ corrosion preventative system are to be backfilled to the original requirements with clean sand, free of rocks or other material which may damage the coating system. Grade of backfilling material to be approved by the certified STOP AQ application supervisor.

6.0 Safety

6.1 Ensure that all personnel involved in the work are wearing standard Personnel protective equipment (PPE).
6.2 Maintain warning devices such as warning tapes, signboards and barriers around the work area to prevent injury to all personnel affected by the operations.
6.3 Tools (Hand Tools and Machined Operated tools) and Safety Harnesses shall be monitored and coded as per safety monthly monitoring guidelines for acceptance and compliance of these equipment to daily site activities.