BR. C.A.T. INTERNATIONAL CO.

LIMITED

MASTER GAS SYSTEM EXPANSION PROJECT:

56 EWG-2 SECTION 1 SALES GAS PIPELINE
for
SAUDI ARAMCO
56 EWG-2 SECTION 1 SALES GAS PIPELINE

STOFAQ System (APCS-113C) Application

Procedure
Rev. 00

CAT-MGS/MS/10-00

00

QA Manager

Rev.

Prepared/Controlled by

Construction Manager
Date

Approved by

STOFAQ SYSTEM (APCS-113C) APPPLICATION

PROCEDURE REV. 00
CONTRACT # 6600032833 BI-10-01282
MASTER GAS EXPANSION EWG-2 SECTION 1
C.A.T. International Co. Ltd.

TABLE OF CONTENTS

1.0

SCOPE

2.0

SAFETY

3.0

REFERENCES

4.0

RESPONSIBILITIES

5.0

PROCESS CONTROL FOR COATING WORKS

6.0

HOLIDAY TEST AND REPAIRS

7.0

RESOURCES

8.0

HSE REQUIREMENTS

9.0

QA/QC REQUIREMENTS

10.0

ATTACHMENT

STOFAQ SYSTEM (APCS-113C) APPPLICATION

PROCEDURE REV. 00
CONTRACT # 6600032833 BI-10-01282
MASTER GAS EXPANSION EWG-2 SECTION 1
C.A.T. International Co. Ltd.

1. SCOPE
1.1 This working procedure will define the criteria of workmanship for the proper
execution of the STOPAQ Corrosion Protection System (APCS-113C) application
works in accordance with Saudi ARAMCO requirements, project specifications,
and manufacturers instructions for storage, application, and handling.
1.2 This coating procedure applies on both new and renovation construction of buried
pipeline, piping and associated appurtenances having service temperature range
of 10C minimum to 70C maximum.
STOPAQ System (APCS-113C) applications:

Buried Pipe Field Girth Welds (tie-in and non-tie-in)

Pipes under Road Crossings (open-cut only)
Buried Stainless Steel
Short-Run Pipe 60 meter
Buried Fittings

2. SAFETY

Safety during abrasive blasting and coating application shall meet the requirements
of SAES-H-102, GI-0006.021 and C.A.T. Safety, Health and Environmental Program.
3. REFERENCES
3.1 C.A.T Project Quality Plan
3.2 Project Coating Specification
3.3 SAEP-316 Performance Qualification of Coating Personnel
3.4 SAES-H-001 Selection Requirements for Industrial Coating
3.5 SAES-H-002 Internal & External Coating for Steel Pipelines & Piping for
Maintenance External Coatings
3.6 SAES-H-102 Safety Requirements for Painting
3.7 SAES-H-002V, APCS-113C Non-Curing (Visco-Elastic) Mastic Based Coating
System
4. RESPONSIBILITIES

4.1 The Project Manager will have overall responsibility for the work.
4.2 The Pipeline Engineer will be responsible for the repair activities.
4.3 The QC Coating Inspector (Saudi ARAMCO approved) will be responsible to
ensure proper adherence of all quality requirements.
4.4 The Safety Officer will be responsible for safe executing of the above activities in
strict compliance with approved HSE plan via:
4.4.1 Monitoring of toolbox meetings.
4.4.2 Inspect, approve or reject engaged resources.
4.4.3 Ensure that all HSE requirements are met and implemented while executing
the works.

STOFAQ SYSTEM (APCS-113C) APPPLICATION

PROCEDURE REV. 00
CONTRACT # 6600032833 BI-10-01282
MASTER GAS EXPANSION EWG-2 SECTION 1
C.A.T. International Co. Ltd.

4.4.4 Notify the person in charge on site if any deviation and/or corrective remedy
action to be applied before and while executing the works.
4.4.5 Ensure that recommendations of workplace precaution are followed up
strictly.
4.4.6 Stop any / or all works in case specified recommendations / observation
were not followed up by construction team.
5. PROCESS CONTROL FOR COATING WORKS
5.1 General Description of STOPAQ
STOPAQ Corrosion Preventive System consists of 1 layer 2 mm thick STOPAQ
Wrapping-Band CZH, 1 layer of 0.08mm thick of polyethylene foil, and 1 layer
0.4mm thick PVC Outer Wrap Tape or 1 layer of 2mm thick Polyester Sheathing
outer wrap.
STOPAQ Wrapping-Band CZH is wrapped with an overlap of 1 cm (regardless 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.
Because of the overlap percentage of 50% of the PVC Outer Wrap, a double
layer of mechanical protection was created. STOPAQ Corrosion Preventive as a
system has a total thickness of 2.88mm.
When utilizing the Polyester Sheathing as a mechanical and UV protection outer
wrap, STOPAQ Corrosion Preventive as a system has a total thickness of
4.00mm.

5.2 Materials and Storage

Purchased materials will be in accordance with Saudi ARAMCO requirements,
APCS-113C Coating System. Material receiving inspection will be in accordance
with relevant SATIP and SAIC.
Materials should be stored in shaded areas on site, all component shall not be
exposed to direct sunlight for more the 8-hours prior to application.
STOPAQ Corrosion Protection System (APCS-113C) consists of:
5.2.1 STOPAQ CZH Wrapping Band-SAP M/N 1000600006, 1000600007 and
1000600011 depending on width (corrosion protection)
5.2.2 STOPAQ CZH Paste-SAP M/N 1000600012 (corrosion protection)
5.2.3 STOPAQ PVC Outer Wrap-SAP M/N 1000600006, 1000600007,
1000600008, 1000600009, and 1000600011 depending on width
(mechanical protection)
5.2.4 STOPAQ Polyester Outer Wrap-SAP M/N 1000600010 (mechanical
protection)

STOFAQ SYSTEM (APCS-113C) APPPLICATION

PROCEDURE REV. 00
CONTRACT # 6600032833 BI-10-01282
MASTER GAS EXPANSION EWG-2 SECTION 1
C.A.T. International Co. Ltd.

5.3 Personnel
All STOPAQ applicators, abrasive blasters and crew supervisor shall be
qualified, approved and possess valid certification. Certification shall be obtain
from Saudi Aramco Level II Coating Inspector in accordance with SAEP-316.

5.4 Surface Preparation

The Crew Supervisor will ensure that the personnel to carry out the surface
preparation are qualified as required by SAEP-316.
5.4.1 Surface preparation will be carried out in order to remove contaminants
and any foreign matters that will affect the adhesion of the STOPAQ
System. Generally, commercial blast (SSPC-SP 6 or equivalent) will be
used. Wire brushing is acceptable on small areas (less than 1 meter long).
Wrapping can be applied over existing sound coating after the removal of
lose paints and debris.
5.4.2 The physical effect of the salt contamination will be eliminated when the
STOPAQ Corrosion Preventive System was applied as STOPAQ CZH and
STOPAQ Wrapping-Band CZH were not water permeable. Due to its
unique properties, chloride contamination is of no importance for the
performance of the STOPAQ.
5.5 Application of STOPAQ Corrosion Preventive System
The Crew Supervisor will ensure that the personnel to carry out the wrapping
applications are qualified as required by SAEP-316.
Proper accessibility in the working area should be created prior to the start of
application.
5.5.1 The surface temperature of the substrate prior to the application of
STOPAQ Wrapping-Band CZH should not exceed 70C. STOPAQ can be
applied in a humid atmosphere that does not reach dew point and thus
create a condensation on the substrate. In order to create optimum
adhesion of STOPAQ of STOPAQ Wrapping-Band CZH to prevent the
formation of corrosion cells on the substrate, the surface has to be dry
during the application process.
5.5.2 Before starting the wrapping of the Wrapping-Band CZH, Use CZH Paste
in areas of significant transitions.
5.5.3 Application of STOPAQ Wrapping-Band CZH
Prior to applying STOPAQ Wrapping-Band CZH on the substrate, the Crew
Supervisor should visually check the application area to ensure free
movement of labour during application and must regularly measure the
average thickness of the layer.
5

STOFAQ SYSTEM (APCS-113C) APPPLICATION

PROCEDURE REV. 00
CONTRACT # 6600032833 BI-10-01282
MASTER GAS EXPANSION EWG-2 SECTION 1
C.A.T. International Co. Ltd.

Upon commencing with applying the subsequent rolls of STOPAQ

Wrapping-Band CZH, the subsequent wrap shall overlap circumferentially
by 20% of the width of the viscous-elastic layer over the previous layer,
and 100 mm longitudinal overlap over the previous layer.
STOPAQ Wrapping-Band CZH should be applied without tension, rather in
a relax way making sure all the time that the Wrapping-Band is completely
adhering to the total circumference of the substrate. After completing each
roll, the applicator must ensure that a minimum of 100 mm longitudinal
overlap is followed. Previously coated surface shall be de-gloss by using
abrasive paper prior to application of STOPAQ and a minimum of 50 mm
overlap should be maintained.
5.5.4 Application of PVC Outer Wrap
At either end of the substrate where the STOPAQ Corrosion Preventive
System is applied, two complete superimposed circumferential layers of
PVC Outer Wrap Tape had to be applied, starting 5mm inside the
Wrapping CZH. Subsequent to applying the two superimposed layers,
50% longitudinal overlap is required.
The Crew Supervisor has to visually check the application of the PVC
Outer Wrap to ensure fidelity of 50% overlap.
Upon commencing application of subsequent rolls of the PVC Outer Wrap
Tape, the new roll should be initiated at a distance of at least 250 mm
before the end of the finished outer wrap roll.
The PVC Outer Wrap Tape must be applied with tension, making sure that
the PVC Tape is tightly adhering to the STOPAQ Wrapping-Band CZH and
follow its exact contour. There shall be no blisters between the WrappingBand and the PVC Outer Wrap, and that the overlap is constantly applied
at 50% of the width of the PVC Outer Wrap.

5.5.5 Application of Polyester Sheathing Outer Wrap (road crossings open cut)
Pre-measured and calculate the 50mm overlap on Polyester to Polyester
and Polyester direct on the sound adjacent coating outside the STOPAQ
corrosion protective layer.
Loosen and gradually remove the protective film on the under-side of the
precut polyester sheet, attach the sheet to the underlying substrate and
wrap with tension around the object. In overlaps, loosen the outer
protective film, apply the 50mm overlap and fold back the protective film.
Make sure that there are no air enclosed under the applied polyester and
that it follows the contour of the underlying STOPAQ CZH wrap or
STOPAQ CZH Paste. Keep the applied Polyester sheet in place and
under tension by means of several wraps of transparent household foil.
Cure the Polyester sheet by means of exposing to sunlight, degree of
curing could be checked by knocking on several places of the applied
sheet.
6

STOFAQ SYSTEM (APCS-113C) APPPLICATION

PROCEDURE REV. 00
CONTRACT # 6600032833 BI-10-01282
MASTER GAS EXPANSION EWG-2 SECTION 1
C.A.T. International Co. Ltd.

5.5.6 Patch Repair

Cut-out the damage area using a sharp blade cutter and chamfer the
surrounding coating.
Apply a new wrapping band CZH without
overlapping on the sound coating. Then install an outer wrap to
completely cover the wrapping band CZH of 100mm away from the
edge of the patched wrapping band CZH.
6.0 HOLIDAY TEST AND REPAIRS
When STOPAQ Corrosion Preventive System was applied, Holiday Testing is not
normally recommended, but if required, used of a high voltage Holiday Detector at a
voltage ranging from 10KV to 15KV should be applied.
When a holiday is detected, it has to be repaired as per paragraph 5.5.6 and retested
under the supervision of the Crew Supervisor and witnessed by QC Inspector.
7.0 RESOURCES
7.1 Pipeline Engineer
7.2 Coating Inspector
7.3 Crew Supervisor
7.4 STOPAQ Applicators
7.5 Abrasive Blasters
7.6 Labors
7.7 Permit receiver
7.8 Abrasive Blasting rig
8.0 HSE REQUIREMENTS
Safety during abrasive blasting and coating application shall meet the requirements
of SAES-H-102, GI-0006.021 and C.A.T. Safety, Health and Environmental Program.
8.1 All personnel shall wear minimum PPE (like helmet, safety Shoes, hand gloves,
coverall and safety goggles).
8.2 Additional PPE if necessary (like dust mask and ear plug).
8.3 Authorized personnel to be assigned at site to do the work.
8.4 Tool Box talk to be carried out prior to commence the work.
8.5 First Aid Kit will be available.
8.6 Equipment, as applicable, should be tested & certified.
8.7 Sufficient drinking water will be available for workforce at all times.
8.8 Ensure with fire extinguishers on site.
8.9 Housekeeping must be done on daily basis.

9.0 QA/QC REQUIREMENTS

All necessary Testing & Inspection will be carried out according to approved quality
plan and procedure. SATIP-H-002-11 with its relevant Inspection Checklists and
Test report will be utilized.
7

STOFAQ SYSTEM (APCS-113C) APPPLICATION

PROCEDURE REV. 00
CONTRACT # 6600032833 BI-10-01282
MASTER GAS EXPANSION EWG-2 SECTION 1
C.A.T. International Co. Ltd.

10.0

Attachment
10.1 STOPAQ CZH Paste Product Data Sheets
10.2 STOPAQ Wrapping-Band CZH Product Data Sheets
10.3 STOPAQ PVC Outer Wrap Tape Product Data Sheets
10.4 STOPAQ Polyester Product Data Sheets