INSTALLATION GUIDE - ClockSpring|NRI · 2020. 1. 28. · b. Face Protection i. Face shield or other similar equipment when performing surface preparation to avoid injury to face by

Acid-Shield™

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INSTALLATIONGUIDE

Doc. # ECRS-DIG-AS-R1 Document Release Date: 11.11.19 - 1 of 21 -

DETAILED INSTALLATION GUIDE

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System Reference:

As specified in CSNRI’s Technical Binder, the full Engineered Composite Repair (ECR) system being used is comprised of multiple products/steps and is referred to in general as the product name above. All instructions listed in the Technical Binder and Repair Specification documents shall be followed with regard to number of layers and length of repair required for the specific repair being installed.

QA/QC Material Traceability: The Product Lot or Batch Number is located on the packaging of all materials being used within the system. It is required by CSNRI training procedures that all lot numbers are recorded before beginning the repair project either on the Quality Control Records form provided by CSNRI, or on other similar approved documentation. This is required for full traceability of the materials used on site should the need arise.

Handling and Storage: For ideal shelf life of system:

• Epoxy: store in original, unopened containers, indoors at a max temp of 90°F (32°C).

• Fabric: store at temperatures below 100°F (38°C) away from moisture or any contaminants in original packaging.

Shelf Life: CSNRI provides a 12-month shelf-life if Acid-Shield and all components are stored according to proper specifications.

Contact: Should you have any questions regarding this installation guide or practical installation of any of CSNRI’s composite materials, please contact the Composites Division Training & Site Support department at [email protected], or by phone at any of our office locations.

Current Safety Data Sheets (SDS) available for download at www.neptuneresearch.com/sds.

Document #: ECRS-DIG-AS

Revision # Date Reason Revised By:

1 11.11.19 Document re-creation with new system details and company info MG

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http://www.neptuneresearch.com/sds



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CHAPTER 1: SCOPE ......................................................................................................................................... 3

CHAPTER 2: PERSONAL PROTECTIVE EQUIPMENT (PPE) ........................................................................................ 4

CHAPTER 3: SYSTEM & MATERIAL DESCRIPTIONS .................................................................................................. 5

CHAPTER 4: QUALITY CONTROL DOCUMENTATION ................................................................................................. 7

CHAPTER 5: SURFACE PREPARATION .................................................................................................................. 9

CHAPTER 6: INSTALLATION PROCEDURES ........................................................................................................... 11

CHAPTER 7: INSTALLATION INSPECTION & VERIFICATION ....................................................................................... 18

CHAPTER 8: ADDITIONAL INSTALLATION CONSIDERATIONS ..................................................................................... 20

CHAPTER 9: WARRANTY/DISCLAIMER STATEMENT ............................................................................................... 21



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CHAPTER 1: SCOPE This chapter will outline scope of this document as it applies to the installation and verification of the ECR system, Acid-Shield™. This Installation Guide is provided only as a proven guideline for the successful installation of the ECR system. The User of this document assumes all responsibility for the actual material installation and responsibilities associated.

1.1. Scope The ASME PCC-2 Article 4.1 “Nonmetallic Composite Repair Systems: High-Risk Applications” was used as the standard for qualification of the Acid-Shield™ system for the repair of pipelines and piping systems. This document will focus on the installation procedures for the specified repair system but will additionally address the various elements involved in an ECR system. An ECR system is defined by the ASME PCC-2 Article 4.1 (as well as similarly defined by the ISO 24817) “as a combination of the following elements for which qualification testing has been completed:

a. Substrate b. Surface Preparation c. Load Transfer Material d. Primer Layer Adhesive e. Interlaminar Adhesive (primarily of concern for pre-cured systems) f. Composite Material g. Application Method h. Curing Protocol”

1.2. Applicability

It is the responsibility of the User of this document to ensure that the material being installed per this document is correct and specified for the intended service based on the Repair Specification previously provided.

All procedures and guidelines provided in this document shall be followed by the User to ensure the installation is correct and comprehensive for the specific repair scenario. It is the responsibility of the User to obtain any additional written instructions for specific repair scenarios which may fall outside of the scope of this document. If specific chemical compatibility is required, please contact the appropriate CSNRI representative to review the chemical and compatibility with the ECR System.

This document shall be applicable: a. For repair of 98% sulfuric acid piping when the maximum operational temperature is up to 150°F (66°C). b. When the maximum continuous operating temperature of the pipe is up to 216°F (102°C) for Type A defects, or up

to 198°F (93°C) for Type B defects. c. When the skin temperature of the pipe is between 75°F (24°C) and 120°F (49°C) during installation. d. For the repair of externally or internally corroded pipe provided the pipe is not actively leaking. e. For the repair of dented, gouged, wrinkled, or other mechanically damaged pipe. f. For above-ground, below-ground, and splash zone (when dry) repair locations.

This document shall not be applicable: a. When the maximum operational temperature of piping containing 98% sulfuric acid and a Type B defect is above

198°F (93°C). b. When maximum continuous operating temperature is above 216°F (102°C). c. When the skin temperature of the pipe is below 75°F (24°C) or above 120°F (49°C) during installation and not able

to be heated. d. If there is an active leak in the pipe (media is actively escaping the defect).

i. This document may become applicable if the active leak is completely sealed and verification is made to ensure there is no longer an active leak.

e. For subsea, under-water, or wet repair locations.



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CHAPTER 2: PERSONAL PROTECTIVE EQUIPMENT (PPE) This chapter will outline the general PPE as may be required when installing the ECR system. This is a general list applying to the handling of the ECR materials only and does not override any specific requirements of the site location or governing/regulating body of the project. It is the responsibility of the user/installer to know and understand the site-specific PPE requirements based on the location of work being performed.

2.1. Health Many components used within CSNRI’s ECR systems are non-hazardous in nature and rating. Each component’s SDS should be consulted to identify any possible concerns related to the handling of material. While the components may be safe to handle, everyone is unique and could possibly have an allergy (no different than a food allergy) to various resin systems, which may even be unknown to the individual until it is observed. If observed, it is the responsibility of the individual to seek aid from a medical professional as may or may not be needed.

2.2. Required PPE for Composite The following list of items shall be worn when handling the components of an ECR system.

a. Protective Eyewear i. Safety Glasses or Goggles ensure adequate eye protection when working with liquid polymer systems.

b. Face Protection

i. Face shield or other similar equipment when performing surface preparation to avoid injury to face by surface preparation equipment and debris.

ii. Face shield when a high RPM mixer is the choice of equipment to mix polymers that have a low viscosity and prone to splashing.

c. Protective Gloves i. Latex or Nitrile gloves should be worn when working with the ECR systems.

d. Protective Clothing

i. Tyvek suits or sleeves should be worn to ensure that all areas of potential contact are protected during installation.



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CHAPTER 3: SYSTEM & MATERIAL DESCRIPTIONS This chapter will provide the definition of the qualified ECR system, Acid-Shield, and the component products manufactured by CSNRI which are included in the qualification. System and component descriptions are provided in this document for quick reference only. Each individual product described shall conform to the product specifications listed on the specific product Technical Data Sheet (TDS) or Technical Binder. For most current versions, please consult the CSNRI website, or contact your Regional Sales Rep, Inside Sales Rep, or Distributor.

3.1. Qualified System Definition

a. Substrate i. Carbon Steel ii. Stainless Steel

b. Surface Preparation i. Grit Blasting (NACE 2, SSPC-SP10) ii. Power Tool (SSPC-SP11)

c. Filler / Load Transfer Material i. Acid-Shield Filler

d. Primer Layer Adhesive i. Acid-Shield epoxy (same as used to saturate)

e. Interlaminar Adhesive i. Acid-Shield epoxy (same as used to saturate)

f. Composite Material i. Basalt fiber

g. Application Method i. As outlined within this installation document

h. Curing Protocol i. 2 hours at 75°F (24°C) temperature, then 2 hours at 158°F (70°C), then finished with 8 hours at 248°F

(120°C) a. This cure profile MUST be followed to ensure the desired chemical resistance is achieved

3.2. Material Description

a. Acid-Shield™ Filler i. Acid-Shield™ Filler is a two-part, epoxy putty designed to bond and repair materials that will be exposed to

aggressive chemical environments. Acid-Shield Filler contains no solvents, is non-toxic and easily prepares



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for application in a variety of industrial maintenance applications. When fully cured, it produces a durable, resilient bond resistant to a wide range of chemicals including up to 98% sulfuric acid. Color of Part A is white, and color of Part B is dark orange, which mix to create a final color of light orange.

b. Acid-Shield™ Epoxy i. Acid-Shield™ epoxy is a two-part, epoxy compound designed for applications in harsh acid and chemical

environments. It is used as a primer coating on the pipe and as the saturant for the Acid-Shield™ system. When fully cured with required cure schedule, the material produces a durable, resilient bond that is resistant to many chemicals and adverse environments, including up to 98% sulfuric acid. Color of Part A is clear, and color of Part B is dark red, which mix to create a final color of translucent red.

c. Acid-Shield Fiber i. High performance, basalt fibers in a plain weave architecture. Dark gold / bronze in color.

3.3. Additional / Optional Components

The following items are used as additional components and may or may not fit based on the needs, parameters, and limitations of the specific project being installed.

a. Blue Compression Film i. 200-gauge Compression Film used as the final and temporary wrap over ECR systems condense layers,

reduce wrinkling, and keep the wrap protected during the curing process. Once composite wrap is cured, the compression film is removed. Color is blue.

b. Clear Compression Film i. 400-gauge Compression Film used as the final and temporary wrap over ECR systems condense layers,

reduce wrinkling, and keep the wrap protected during the curing process. Once composite wrap is cured, the compression film is removed. Color is clear.

c. Syntho-Glass® UV* i. Specifically designed to be an aesthetically pleasing, non-yellowing, superior wrapping system top coat that

provides UV stabilization to composite wraps. Syntho-Glass UV prevents UV degradation, future corrosion and abrasion due to mechanical impact, frost heave, crevice corrosion, galvanic corrosion and vibration/abrasion at soil-to-air interface, and water-to-air interface as well as pipe support areas. Color is white (but others available upon special request).

d. Syntho-Coat™ 500* i. Designed as a single component, paintable topcoat to protect the integrity and appearance of composite

repairs from deterioration due to UV exposure. Color is black/gray.

*Note: these options are for UV protection only, and do not have the same chemical resistance as the Acid-Shield repair system.



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CHAPTER 4: QUALITY CONTROL DOCUMENTATION This chapter will outline the requirements and process for Quality Control Documentation when performing an installation for an ECR system. Each system type will require different steps in the process due to the variance of resins used in each. It is important that each QC Hold Point be followed and noted in relevant paperwork. NRI provides a full document, (“Quality Control Records”) for each ECR system, or the technician may use an CSNRI-approved equivalent as may be required by specific clients for their internal processes.

4.1. Quality Control Records Quality documentation is an essential step in the installation process and helps to ensure that all procedures and hold points are being followed correctly. CSNRI provides detailed Quality Control Records forms for each of the ECR systems that it manufactures. These are included in shipments of the specific ECR system, however, to obtain a copy of CSNRI’s documents for use, please contact your CSNRI Distributor or email [email protected] with your request and specify the ECR system which you will be installing. Client-specific or other third-party/outside QC documentation may also be used provided that it has been reviewed and approved by CSNRI and should, at a minimum, contain the following information for traceability and record keeping purposes.

a. Project Verification All information from the Repair Specification should be recorded and verified before a project is started to ensure that the materials are being installed on the correct section of pipe they were designed for.

i. Record the Repair Specification # provided ii. Record Diameter of the Pipe iii. Record Total Number of Layers Required iv. Record Length of Repair Required

b. Product Lot Numbers

Product Lot Numbers must always be recorded prior to beginning the work in order to ensure that containers are not lost or discarded once the project begins as is typically the case. Without records of Lot Numbers, CSNRI will not be able to trace materials if needed.

i. Record Lot Number of Filler Material ii. Record Lot Number of Primer iii. Record Lot Number of Composite Wrap

c. Surface Preparation

This is a critical component of the ECR system as defined in Chapter 1. If the recommended surface preparation method cannot be completed, a record must be kept of the method used, as well as the surface cleanliness and profile achieved. This should also be provided during the design phase, if known, in order to complete a proper design case.

i. Record solvent used for surface cleaning ii. Record Surface Preparation method iii. Record Surface Profile upon completion

d. Resin Mixing and Application

With any two-part resins, it is critical to achieve complete mixing, or the product will not reach full hardness and material properties as designed. Application is also important in order to meet the design criteria based on tested and proven results.

i. Record mixing results ii. Record proper geometry of application of Filler Material iii. Record total length of Primer applied iv. Record wet film thickness of Primer

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e. Composite Wrap Application This is a critical step in the process as the entire repair has been designed based on proper application and insuring that correct number of layers and required length has been installed.

i. Record that 1” of Primer remains on each end of the Composite Wrap ii. For MCU wraps, record that it was fully saturated with water while wrapping iii. For Epoxy wraps, record that it was fully saturated with epoxy resin with no dry spots iv. Record total number of layers applied v. Record total length of pipe wrapped

f. Final Project Inspection & Validation

The final step in the installation process is the inspection and verification that the ECR system was installed correctly and has reached the appropriate hardness as required for each system.

i. Record Shore D Hardness of Primer ii. Record Shore D Hardness of Composite Wrap iii. Verify length of Composite Wrap is correct as per the Design iv. Verify the total number of layers (thickness) is correct as per the Design

g. Submit Final Paperwork

Once the project is complete, all paperwork shall be finalized and submitted as required and appropriate for record keeping requirements.

i. Installation Technician to sign the QC paperwork (include assigned CSNRI Training ID#) ii. Client inspector/engineer/supervisor to sign final QC paperwork iii. Submit copies to Client, CSNRI, and retain for Installation Technician’s Company



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CHAPTER 5: SURFACE PREPARATION This chapter will define the required surface preparation necessary for successful and compliant ECR system installations. Proper surface preparation is required for all CSNRI’s ECR systems. Variations and/or alterations in specified methods may be accepted based on a case by case basis, provided full details are supplied to the CSNRI Engineering Department during the design phase to ensure proper calculations are made to account for this.

5.1. Considerations and Requirements When performing surface preparation for an ECR System, it is required that the surface preparation meet the minimum surface preparation performed during the qualification of that ECR system. That is, if grit blasting was used for qualification testing, then only grit blasting may be used in the field to maintain compliance. If a power tool was used, only then may the power tool be used for repairs in the field if compliance to the standard is to be maintained. It is acceptable to use a method which provides a better surface profile, but not vice versa.

a. Preparation Area i. When performing surface preparation, the area prepared must be over the entire area of the surface being

repaired unless otherwise noted and accounted for within the design specification. ii. If less than 100% of the area may be prepared according to the requirements, then the design of the repair

must reflect the size of the unprepared surface as the defect size. iii. If surface preparation may not be completed over a specified length of the substrate, then special design

considerations are required (see Section b below). b. Special Considerations for “Large Unbonded Area” Repairs

i. Special surface preparation needs for sections of substrate that cannot be adequately prepared may be allowed if properly considered within the design specification.

ii. In this case, the “Circumferential Slot” design equations must be used, and the entire length of unprepared substrate must be considered as the defect to meet with compliance to the standard.

iii. In this case, “Terminating Rings” must be established on sufficiently thick substrate at both ends of the repair area, as well as recommended “Bands” within the length. The general recommendation for these is as follows:

a. Terminating rings must be, at minimum, 12 inches (30.5cm) in length, or two times (2x) the L-over

value as calculated within the design specification document, whichever is greater.

b. Recommended distance between surface preparation bands should be no more than ten times

(10x) the Terminating Ring length or four times (4x) the pipe diameter, whichever is greater.

5.2. Qualified Surface Preparation Standards

CSNRI has tested and qualified various methods and standards of surface preparation. The below standards outline each of these options in detail. For the full standard description and detail, these may be purchased from the organizations named.

a. NACE (National Association of Corrosion Engineers) i. NACE 2 – Near-White Blast Cleaning (equivalent to SSPC-SP10)

b. SSPC (Society for Protective Coatings)

i. SSPC-SP1 – Solvent Cleaning



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ii. SSPC-SP10 – Near-White Blast Cleaning (equivalent to NACE 2) iii. SSPC-SP11 – Power Tool Cleaning to Bare Metal

5.3. Surface Preparation Procedures

The following procedures will describe the order of steps to successfully complete the full surface preparation regimen before beginning the ECR system installation process.

a. Solvent Cleaning of Pipe The first step is to clean the entire pipe surface with an approved solvent. No oil-based solvents should be used. Denatured alcohol, Isopropanol alcohol, or Acetone are all approved for use as a solvent with CSNRI’s ECR systems.

b. Surface Preparation Surface preparation may be performed after the first solvent clean is completed. Surface preparation may be done by grit blasting or by power tool provided that the specific tools are of the two which have been tested and qualified by CSNRI*. The following are surface preparation options and typical results which may be achieved with each.

i. Grit Blasting: Results can vary greatly with this method based on the type and size of grit being used, ranging from 1.5 mil (40 microns) up to 5 mil (127 microns). Common media types include garnet, silica (be aware of potential safety concerns), wet slurry, and dry ice.

ii. MBX Bristle Blaster: Typical results (as published by the manufacturer) obtained yield 2.5 – 3.3 mil (63.5 – 83.8 microns) on carbon steel provided the belt is in good, working condition. Belts should be changed as needed to ensure minimum results are being generated.

iii. Safety Tool Cold Grinder: Typical results (as published by the manufacturer) obtained yield 1.5 – 3.0 mil (40 – 75 microns) on carbon steel with the Rough Boy files which are typically used for preparing pipe.

iv. R.U.S.T. ATEX Cold Grinder: Typical results (as published by the manufacturer) obtained yield 3.0 – 4.1 mil (75 – 105 microns) on carbon steel with grinding disc.

*Note that tool approval from CSNRI does not indicate tool is approved by a specific client within their facility. Tooling must be approved by client for use on site and is not the responsibility of CSNRI to know which tools clients have approved.

c. Final Cleaning of Pipe

The final step is to perform a thorough cleaning of the prepared surface to remove any residual dust, grease, or other surface contaminates which remain after the surface preparation. An air hose or dry brush may be used to remove dust/debris from the surface and the same solvents as given above may be used for this step as well. In addition, CSNRI has tested the use of distilled water with additives for cleaning of the pipe surface and removal of chlorides which show an improvement to adhesion results over solvent cleaning. Holdtight® 102 and Chlor*Rid® have both been evaluated and approved as a cleaning agent with CSNRI’s ECR Systems.

5.4. Surface Preparation Measurement

The final surface profile shall be measured to ensure that surface preparation was completed and meets the minimum requirements as set forth by NRI based on testing and qualification. Minimum surface profile shall be not less than 1 mil (0.025mm, 25 micron) to be considered in compliance with qualification. Surface profile may be measured by various means using standard industry tools available for this purpose.



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CHAPTER 6: INSTALLATION PROCEDURES This chapter will define the actual process and steps for carrying out the installation of the Acid-Shield™ full repair system once the surface preparation has been completed and verified. Each product option available as part of the fully qualified system will be given for each step. This does not mean that each step will require each product, but only the choice of one product in each step.

NOTE: It is important to note that the ECR resin systems provided by CSNRI may NEVER be thinned nor thickened with additives in the field without written approval. These resins are specially designed and pre-portioned for exact mechanical properties calculated and changing or adding ingredients will have negative effects which will invalidate the material.

6.1. Installation and Site Preparation

Prior to beginning the actual installation of the composite repair system, there are preparations which are required and will aid in the installation of the materials to ensure consistent and successful results.

a. Staging

i. Ensure there are enough installation technicians dedicated to the repair based on kit size recommendations noted in the material descriptions.

ii. Ensure that there is a dedicated work area for staging materials and mixing, etc. iii. Plan work flow to ensure there are no delays between steps of the installation process which would cause

issues or materials to cure before the next step is accomplished. iv. Only stage and prepare a length of pipe which can be wrapped in any given working time range.

- Ex: Do not begin priming a section of pipe, then take lunch and allow that primer to harden. - This may not be a showstopper but will require additional steps outside the scope of this installation

guide. - Complete the full wrapping process on a given length of pipe prior to taking breaks or finishing for

the day.

b. Identify the Defect and Repair Location i. Identify the defect and repair location as designed and provided in Repair Specification document. ii. Confirm that the pipe, defect, and site conditions are as described within the Engineering Assessment form

and subsequent Repair Specification and record on quality documentation and relevant forms to verify repair location and validity.

c. Surface preparation

i. Surface preparation must be completed in accordance with procedures outlined in Chapter 5 of this document. ii. Surface preparation must be done at least 2” beyond the calculated repair length provided by the Repair

Specification. iii. This should be completed with at least 1” additional length on each end of the repair area with the defect

centered in this area. iv. Repair lengths may be marked by applying tape around the pipe at the repair ends (to include the 2” additional

length). v. Perform Surface Profile measurements and record on quality documentation and relevant forms to verify

surface preparation meets requirements as given. d. Repair Area Marking

i. The repair length (plus the extra 1” beyond each end) should be marked again as this is typically removed during the surface preparation stage.

ii. Only mark the area which can be completed in the given working time range to ensure the full installation process can be completed.



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6.2. Installing the Filler Material

a. Acid-Shield Filler i. Usage

- Used as a filler material and for load transfer. Filling of all external corrosion pits, dents, to fill gaps, smooth blunt edges, and/or smooth transitional areas.

- Two-part epoxy provided in pre-measured canisters with proper mixing ratios per kit. - Each kit will have Part A (resin base) and Part B (hardener/curing agent) with specific ratios

according to requirements of the material. Material must be mixed in correct ratios. - Working time is approximately 20-30 minutes once fully mixed (at 75°F [24°C])

ii. Mixing - It is required that the mix ratio be correct and exact according to the specifications which are provided

on the label of the epoxy kit. - It is highly recommended that appropriate kit sizes are used so that all of the kit may be mixed at

one time. - Remove all of Part A and place into a clean, plastic mixing pail/bucket. Remove all of Part B and

place into same mixing pail/bucket. - Mix thoroughly either by hand and mixing stick, or by using a drill with mixer. - Mix until there is only one, solid color with no marbling or streaking visible.

a. Caution: Unmixed sections will never fully harden and will be soft points in the mixture that could potentially cause failure of the putty.

iii. Installation - Once fully mixed, install into defect or onto surface profile within 20 minutes. - Force into pits, dents, or profile areas to create a surface that matches as closely as possible to the

original pipe geometry. - If using as transitional filler such as over bolts, etc., be sure the transitional area is sufficient to

smooth and ease the application of composite material. A 5:1 length to height ratio is recommended for best results (if possible based on repair length) but may be dictated otherwise by site specific details.

- Push firmly into all surfaces using a spatula, putty knife, and/or straight edge to ensure no air pockets remain within the cured Acid Shield Filler and the putty contours to the original pipe geometry.

- Acid-Shield Filler may be sanded (once fully hardened) if needed to help smooth the profile or remove excess putty applied.

- Once installed, record mixing and installation on quality documentation and relevant forms.

6.3. Installing the Primer

a. Acid-Shield Epoxy i. Usage

- Used as the primer adhesive and fiber saturation component for the composite system. - Two-part epoxy provided in pre-measured canisters with proper mixing ratios per kit. - Each kit will have Part A (resin base) and Part B (hardener/curing agent) with specific ratios

according to requirements of the material. Material must be mixed in correct ratios. - Working time is approximately 40-50 minutes (depending on temperature) once fully mixed.

ii. Mixing - It is required that the mix ratio be correct and exact according to the specifications which are provided

on the label of the epoxy kit. - It is recommended that appropriate kit sizes are used so that all of the kit may be mixed at one time. - Remove all of Part A and place into a clean, plastic mixing pail/bucket and mix thoroughly. Remove

all of Part B and place into same mixing pail/bucket. a. Mix thoroughly either by hand and mixing stick, or by using a drill with mixer.



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- Mix until there is only one, solid color with no marbling or streaking visible. a. Caution: Unmixed sections will never fully harden and will be soft points in the mixture that

could potentially cause failure of the putty. iii. Installation

- Once fully mixed, install Acid-Shield epoxy as the primer over the entire area as previously marked for installation.

a. Note: For this system, the same epoxy is used both for priming and for saturating the fiber. The priming and saturating steps may be done simultaneously if personnel are available.

- Force the mixed epoxy onto the pipe surface using a brush, roller, or your hand to fully saturate the surface and fill small pits which may be present.

- Use back-and-forth and circular motions to ensure complete saturation of the pipe surface with no air pockets.

- The Acid-Shield epoxy should be applied at a wet thickness of 5-15 mils (0.13-0.38 mm) over the entire marked surface.

- Measure thickness using a wet film thickness gauge in multiple locations around the pipe and over the length of the marked surface to ensure a uniform coverage within the thickness range.

- Record measurements and verify installation on quality documentation and relevant forms. - The tape used to mark the repair ends may now be removed.

6.4. Installing the Composite Wrap

a. Acid-Shield™

i. Usage - Used as the composite wrap, this provides the structural strength and pressure retaining capacity of

the ECR system. - Supplied in rolls of unsaturated/dry fiberglass and kits of epoxy. - The total number of layers applied, and total length repaired shall be that as specified by the Repair

Specification document provided for the specific repair being conducted. ii. Saturating the Fiber

- Hand Saturation Method a. Use the epoxy which has been mixed previously as it is used for both the primer and the

saturant for the dry fiber. b. A flat work area will be best to saturate the fiber. c. Cover the flat surface with a polyethylene (Visqueen or equivalent, etc.) sheet and tape

down the edges with duct tape to ensure the polyethylene sheet will not move during the field impregnation process.

d. Pour some of the mixed epoxy down the length of your workspace. Use an epoxy spreader or paint roller to apply a generous amount of the mixed epoxy onto the surface of the polyethylene sheet first. This helps to ensure that the back side of the tape is saturated.

e. Unroll the fiber tape onto the flat polyethylene surface covered with the mixed epoxy resin. Only unroll the fiber at a distance that is less than the length of the flat surface you are working on. For example, if your working area is 6 feet long and 2 feet wide only unroll 4 feet of the fiber from the roll.

i. NOTE: Do not cut the fiber into strips that will result in a total length that is shorter than the circumference of the pipe plus 25%.

f. The resin that was applied onto the polyethylene sheet will be used to impregnate the fiber from the bottom. A second application of resin will be applied onto the top of the fiber cloth using an epoxy spreader or paint roller.

g. Work the mixed epoxy into the fiber by applying firm pressure with the spreader or roller. The pressure applied by the spreader or roller to the fiber will allow the epoxy to impregnate the fiber from both sides.



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i. NOTE: Check the fiber as you are applying pressure for dry areas to ensure that 100% of the fiber has been impregnated with the mixed epoxy.

h. Work the spreader or roller firmly to squeeze out all excess resin so that the material is not over-saturated.

i. Once the section of fiber has been fully saturated with the epoxy, use the plastic cores provided and tightly roll the fiber onto the core.

i. NOTE: Applying a small amount of pressure when rolling the saturated fiber onto the cores will ensure that there is not excessive resin in the fiber. During this process, you may inspect the tape as it is being rolled onto the core for any dry areas on the back side.

j. Unroll the next length of dry fiber and repeat these steps until the required length of fiber has been saturated with the epoxy.

- Using the Resinator® for Saturating the Fiber The Resinator is a unique and patented device to be used in the field for saturation of the composite repair system fibers in a clean, controlled, and expedited way. Proper use of this tool will ensure that the resin to fiber ratio is correct for the fiber being utilized and will speed the saturation step by up to 10 times faster than typical hand saturation methods.

NOTE: The Resinator being used with the Acid-Shield system should be the most current version of the Resinator tool in order to be successful and fully functional with this system. Please consult CSNRI to obtain the most current version of the Resinator tool or to confirm that your version is correct for the scope of work.

a. Ensure that the Resinator is staged appropriately in the work flow. b. Ensure that the Resinator is on a flat, level surface easily accessible by the technician. c. The Resinator utilizes a one-size-fits-all design that allows for using a Resbox (resin tray)

to accommodate two sizes for narrower widths (6” and below) and larger widths (12” and below). If the smaller Resbox is to be used, simply remove the center bar by pulling the pins and removing so that the large Resbox fits.

d. Ensure the metal rods are secure in the Resbox. e. Place the Rexbox into Resinator with the angled edge toward the take-up roller and turn the

Resbox anchor tabs on the Resinator to hold it in place. f. Place an empty core onto the take-up side which the fiber will be rolled onto after passing

through the Resbox. g. Tighten the rear squeeze roller bar in place so that it is firmly set. h. Loosen the front squeeze roller bar so that the gap may be opened, and the fiber can be

fed through the two squeeze bars. i. Place the bulk roll of fiber onto the backside roller bar with the fiber coming up and over the

top toward the Resbox and not from the bottom side. j. Pull the fiber from the roll and slide under both rods and up through the gap in the squeeze

rollers leaving 2”-3” of fiber above the squeeze rollers. i. NOTE: Do not pull the fiber all the way up and onto the take-up roller yet.

k. Using 0.02” shims, set the gap in the squeeze rollers according to the specific fiber that is being saturated by placing a shim on either side of the fiber and firmly squeezing the rollers together while tightening the front squeeze roller in place.

i. NOTE: Check for proper gap setting by pushing the shims in and out of the gap. The rollers should both touch the shim as it is being pushed in and is considered ideal if the shim causes the rollers to rotate while doing this.

l. Once the Resinator is properly set up, mix the appropriate resin system in accordance with the mix ratio and mixing instructions to begin the next step in the process.



ACID-SHIELD

m. Pour the mixed resin into the Resbox. Pull the fiber up to the take-up roller and tape the fiber to the previously installed core across the full width of the fiber so that the take-up roller pulls the fiber equally across the width so there is no biased created in the fibers during saturation.

i. NOTE: Ensure that the fiber is rolled up and over the top of the take-up roller so that it mirrors how it comes off of the front side roller from the roll of dry fiber.

n. Turn the take-up roller using the handle on the end at a steady rotation to pull the fiber through the Resbox and saturate the roll.

o. Watch the fiber as it is being rolled onto the take-up roller to ensure there are no dry spots and also that it is not overly saturated. The correct gap setting on the squeeze rollers should ensure this is correct.

i. NOTE: There is a drip tray installed on the Resinator to catch any excess resin as it comes off of the saturated roll, but this should be very minimal with the correct gap setting.

p. Continue to roll the fiber until the entire roll has been saturated and is through the Resbox. q. If saturating more than one roll of material, do not pull the entire roll of fiber through the

Resinator unless you will replace the current Resbox. If more rolls are to be pulled through the same Resbox, be sure to connect the next roll of fiber to the end of the first before pulling through the Resbox. This may be done by using tape to connect them or by using a stapler to connect them.

i. NOTE: When pulling the connected section through, be sure to loosen the squeeze rollers as the current gap setting will not allow the double thickness to get through.

r. Remove the take-up roller and pull the core and saturated roll off to be used and installed on the pipe.

s. Clean the Resinator immediately upon completion to ensure any moving parts are not locked in place by cured epoxy. If using it for extended lengths of time, it is recommended to clean periodically before any of the epoxy on the tool is beginning to gel.

iii. Installation - Straight Pipe Installation

a. Hold the end of the roll firmly to the surface of the pipe at the starting point which shall be 1" (2.54cm) within the borders of the Primer layer on either side. Begin the wrap using 100% overlap to assure complete coverage at the starting point.

b. Unroll the tape, keeping it as close to the surface of the pipe as possible. Do not use a long lead of tape. The roll of tape shall always be in an upright position, with the tape being applied from the lower edge of the roll to maintain proper pressure.

c. Apply sufficient tension by pulling on the roll of tape as the layers are being applied in a spiral manner using a 50% overlap.

d. The tape shall be spirally wrapped around the pipe from right to left or left to right using a 50% overlap.

e. Massage and gently tighten the wrap with the flat of your hand or with epoxy roller tool while wrapping to smooth down to be tight on the pipe and do a final smoothing at the conclusion of the first pass of wrapping.

f. Once applied material has been smoothed, apply a 100% overlap leaving 1” (2.54cm) of Primer on the end before reversing the direction of the wrap and continue to apply the Acid-Shield™.

g. As wrapping is continued, continue to massage by hand or with epoxy roller tool as the wrap is applied to ensure no air voids are allowed in the wrap.



ACID-SHIELD

h. Do not reverse the direction of the application without completing an entire wrap along the length of the defined repair area. The length shall be staged in order to allow complete wrapping for the specific length without working time issues arising. Compression Film:

i. The completed Acid-Shield™ application shall be overwrapped by four (4) layers of compression film to lock the resin and protect it while curing.

j. Begin the Compression Film application on the outside of the Primer layer to fully wrap 100% overlap on the pipe itself.

k. Overwrap the entire length of the repair going beyond the other end to fully encapsulate the repair area with the compression film.

l. On the first pass, apply minimal tension just so that there is no slack or wrinkles in the film. m. On the second pass back, apply enough tension to the compression film that you see the

film begin to stretch and get narrower as it is applied which will tighten the repair nicely without putting as many surface blemishes on the wrap.

i. It is an optional step, but the compression film may be perforated using the perforator tool if desired to allow any excess resin to drain from the repair. If this step is taken, use a drop cloth or plastic sheeting below to catch any resin which may drip from the repair.

n. The compression film may be removed when Acid-Shield™ has reached its initial cure time (set hard to the touch).

- Elbow Joint Installation a. Hold the end of the tape firmly to the surface of the pipe at the starting point. The starting

point shall be 1" (2.54cm) within the borders of the Primer layer on either side. Begin the wrap using 100% overlap to assure complete coverage at the starting point.

b. Unroll the tape, keeping it as close to the surface of the pipe as possible. Do not use a long lead of tape. The roll of tape shall always be in an upright position, with the tape being applied from the lower edge of the roll to maintain proper pressure.

c. Apply sufficient tension by pulling on the roll of tape as the layers are being applied in a spiral manner using a 50% overlap.

d. The 50% overlap should be strictly maintained on the outer radius of the elbow and a 75-80% overlap on the inner radius of the elbow in order to keep the wrap perpendicular to the pipe as you proceed through the bend.

e. Massage and gently tighten the wrap with the flat of your hand or with epoxy roller tool while wrapping to smooth down to be tight on the pipe, and do a final smoothing at the conclusion of the first pass of wrapping.

f. Once applied material has been smoothed, apply a 100% overlap leaving 1” (2.54cm) of Primer on the end before reversing the direction of the wrap and continue to apply the Acid-Shield™.

g. As wrapping is continued, continue to massage by hand or with epoxy roller tool as the wrap is applied to ensure no air voids are allowed in the wrap.

h. Do not reverse the direction of the application without completing an entire wrap along the length of the defined repair area. The length shall be staged in order to allow complete wrapping for the specific length without working time issues arising.

Compression Film: i. Install in same manner as straight pipe with same considerations as on elbow wrapping.

- Tee Joint Installation

NOTE: Due to the increased installation time by nature of the geometry, it is important to work quickly and efficiently to ensure the material is applied and cures properly for successful performance.



ACID-SHIELD

a. Cut the Acid-Shield™ roll into strips long enough to wrap the full circumference of the pipe with 4-6" (10.2-15.2cm) of overlap.

b. The number of strips shall be determined by the diameter of the branch stem and should be enough to extend past the tee branch.

i. For example, if it is a 4” tee and you have 2” wide strips, you should have at least 6 strips, which will allow you to apply these at a 50% overlap and cover the stem area below. Having extra will not hurt the application.

c. Wrap the first 2 strips around the main line on either side of the branch in a ribbon format using a 50% overlap and ensure that the entire pipe surface around the branch is covered, taking care to achieve complete coverage of the inside radius of the branch. Press firmly but evenly onto pipe. Use a gloved hand or epoxy roller tool to smooth the wrap as it is being applied to work out any air pockets.

d. Apply the remaining strips around the main line onto the branch with a 50% overlap of the previous strip.

e. Hold the end of the tape firmly to the surface of the pipe at the starting point. The starting point shall be 1" (2.54cm) within the borders of the Primer layer.

f. Begin the wrap using 100% overlap to assure complete coverage, then proceed using 50% overlap working towards the tee.

g. When you reach the tee, wrap at an angle across the tee to transition across the branch area to reach the opposite side of the main line. Continue wrapping using a 50% overlap until reaching 1" (25.4mm) from the Primer layer edge.

i. NOTE: It is important that no tension is applied when crossing over the branch piece to the other side. Pulling tension will cause the wrap to wrinkle in the bend and will be very difficult to fix. Simply lay the material onto the pipe and smooth with a gloved hand or epoxy roller tool until you reach the other side and complete at least one full wrap around the pipe on the other side.

h. Use a gloved hand or roller to smooth the wrap as it is being applied and to work out any remaining air pockets as you wrap. Waiting to try and remove trapped air at the end of the wrap will be difficult, if possible.

i. At the end of the first wrap along the main line, apply a 100% overlap. The roll may now be cut at this point if desired or needed. Do not reverse the direction of the application without completing an entire wrap along the length of the repair area.

j. Proceed to wrap the branch section of the tee beginning at 1” (2.54cm) from the Primer layer edge and using 100% overlap to assure complete coverage, then proceed using 50% overlap working towards the tee.

k. Once the tee joint is reached, the material may be transitioned onto the main pipe if needed to secure the end.

l. Repeat all steps starting with cutting of the strips then proceeding in the same manner as before. Cover any areas which may have been missed on the first pass (i.e., going back-side of the tee if the first past went front-side, etc.)

Compression Film: m. Install in same manner as straight pipe with same considerations as on tee wrapping. n. On Tee Joints, it is helpful to apply a piece of folded over film or rags in the “triangle” area

where compression is not achieved to help provide the pressure on that point of the tee joint for uniform results.



ACID-SHIELD

CHAPTER 7: INSTALLATION INSPECTION & VERIFICATION This chapter will outline the inspection and validation process for Quality Control Records that should be completed by the site inspector or supervisor (depending on who is assigned this role by the client). This is the final step to ensure that the installation was completed successfully and to the proper specifications as defined by the Repair Specification for the repair which was carried out. CSNRI provides a detailed document for use in the final inspection and QC hold points to help facilitate this process entitled, Acid-Shield™ Quality Control Records. This chapter does not go into full detail and the Quality Control document may be used to record all hold points and measurements, or the site-specific documents may be used provided they meet the minimum required documentation as outlined by CSNRI.

NOTE: It is recommended that the client’s official personnel be the final inspector of the installation provided that they have completed the proper training to perform the inspections. If the final inspection is completed by the contractor, it is required that the client’s official personnel attend the inspection and sign off on the completed job to close out the proper paperwork.

7.1. Inspection of Engineering Documentation

a. Engineering Review

i. Confirm the Repair Specification provided for the repair matches the repair location and note the following items:

- Repair Specification ID Number - Pipe Diameter - Operating Conditions - Length of Repair

b. Material Review

i. Confirm all product Lot Numbers were recorded prior to usage ii. Confirm proper quantities were utilized as per the required material estimates as a minimum

7.2. Inspection of Surface Preparation

a. Surface Preparation Review

i. Confirm Surface Preparation methods were followed as instructed ii. Note any deviations which were mandated or allowed on site iii. Confirm surface profile measurements were taken and recorded

7.3. Inspection of Composite Repair

a. Composite Repair Installation Review

i. Confirm each hold point during the installation was followed and documented ii. Confirm the calculated repair length was met at a minimum iii. Confirm the calculated number of layers was met at a minimum

b. Composite Repair Inspection

i. Take photos of the completed repair for record keeping purposes ii. Inspect the composite repair for visible defects including, but not limited to:

- Delamination at ends of repair - Cracks in the matrix resin - Foreign objects within the repair system - Wrinkles - Noticeable color changes or swirling



ACID-SHIELD

- Dry spots or fiber fraying out of resin iii. Measure and record the Shore D Hardness of the Primer layer to ensure it is fully cured for service (required

values are found on the Quality Control Records document) iv. Validate cure schedule time and temperatures have been met for ECR System v. Measure and record the Shore D Hardness of the Composite Wrap to ensure it is fully cured for service

(required values are found on the Quality Control Records document)

7.4. Completion and Filing of Paperwork

a. Final Inspection Records i. Complete the Acid-Shield™ Quality Control Records document (or approved equivalent) to submit. ii. Documentation is not complete until it has been duly signed by the installation supervisor and the approved

client representative. iii. Final copies of the paperwork should be supplied to each of the following for record keeping:

- The client - The contractor - CSNRI



ACID-SHIELD

CHAPTER 8: ADDITIONAL INSTALLATION CONSIDERATIONS

This chapter will provide some useful information for some typical application scenarios which may be outside of the scope of normal operation as defined in the previous chapters of this installation guide. It is critical that any of these which may be noted for a specific repair application is communicated to CSNRI prior to the engineering design process so that all proper considerations may be given throughout the whole process.

8.1. Additional Considerations

a. For Vertical Installations i. Begin the wrapping portion of the installation at the bottom of the repair area and proceed upwards.

b. For Splash Zone Installations i. The area of the splash zone being repaired must be in dry conditions while the repair is carried out. ii. Compression Film must be used immediately to prevent any contact and potential disruption of the curing

process by the sea water and waves.

c. For Impact or Abrasion Resistance for the Installation i. Additional layers of Syntho-Glass® 24 or Syntho-Support™ over the Acid-Shield™.

d. For Non-Buried Installations i. The Acid-Shield™ repair must be coated with a UV-stable and environmentally resistant topcoat. ii. CSNRI has Syntho-Glass® UV and Syntho-Coat™ 500 which have both been approved for use with the

system as topcoats. - Note that the topcoat options above are not equal in chemical resistance and used only as a UV

protection as needed for the Acid-Shield system.

e. For Buried Installations i. The repair may be coated with an approved coating system should the usage require it. ii. If the pipeline is inspected by ILI, marker bands may be installed at each end of the repair area to indicate

that a composite repair has been installed.

f. For Cold Weather Installations i. Keep all components in a climate-controlled environment at room temperature or higher for at least 24 hours

before using on site and continue to keep them warm on site until use. ii. Once the initial setting has occurred, a heat blanket may be applied over the repair length (do not put on

uncured resin or it will bond to the pipe) to ensure the curing is achieved. - The Acid-Shield™ composite system will not cure by itself at temperatures below 40°F (5°C) and

will require an external heat source to ensure the curing process is completed. Do not heat to a temperature above the maximum cure profile temperature for more than 2 hours.

g. For Hot Weather Installations i. Keep all components in a climate-controlled environment at room temperature for at least 24 hours before

using on site and continue to keep them cool on site until use. ii. Keep epoxy in a cooler on ice at the job site prior to mixing.



ACID-SHIELD

CHAPTER 9: WARRANTY/D ISCLAIMER STATEMENT

9.1. Warranty/Disclaimer Statement:

All proposed repairs to pipeline and piping systems using the Acid-Shield™ system must be installed by or supervised by properly trained and experienced technicians. Syntho-Glass® 24, and Syntho-Glass® UV are registered trademarks; and Acid-Shield™, Syntho-Support™, and Syntho-Coat™ 500 are trademarks of CSNRI. CSNRI, the Manufacturer of Acid-Shield™ (and other aforementioned products) will replace at no charge to the purchaser any product proved to be defective. Responsibility of the Manufacturer and the Distributor is limited to replacement of the product only. Neither the Manufacturer nor the Distributor shall be liable for consequential or incidental damage or loss of any kind as they do not have any control over the conditions under which these products may be used or over the methods of application. Installers of Engineered Composite Repair Systems such as Acid-Shield™ must be fully trained and qualified in order to be compliant to industry standards. Users should test the product for their particular need and suitability. Users should consult with the Manufacturer or the Distributor for all proposed repairs using the Acid-Shield™ system. Written procedures for specific repairs are available upon request from the Manufacturer or Distributor. Acid-Shield™ is not an approved coating system. Failing to coat composite system per standard procedures can lead to atmospheric corrosion damage or environmental degradation of the Acid-Shield™ system. Apply protective coatings per company standards.

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