1. Understanding corrosion problems and the - - PDF document

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• 1. Understanding corrosion problems and the solutions that

Enviropeel offers

• 2. Familiarization with equipment and material
• 3. Enviropeel application techniques
• 4. Basic maintenance of Enviropeel equipment.
• Fundamentals of corrosion

Advantages of Enviropeel Machine introduction Safety & use of PPE Substrate preparation Recap and test on Day 1 Machine start up Fault/Status codes Application demonstration Practical Training Back Flush Machine shutdown

• Recap and test on Day 2

Trainees start up Machine. Practical training Empty down tank Remove pump & clean out tank

• Recap and test on Day 3

Pump stripping, application head stripping and needle valve adjustment demo Trainees to strip pump, head and adjust needle valve Practical training Final Practical Assessment Course Debrief

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Corrosion is the primary means by which metals deteriorate. Corrosion is a natural process, returning metals to their basic forms Most metals corrode on contact with water or moisture in the air Corrosion specifically refers to any process involving the deterioration or degradation of metal components, of which the best known case (and the one in which we are most interested here) is the rusting of steel. Corrosion processes are usually electrochemical, having the essential features of a battery. Metal atoms exposed to an environment containing water molecules give up electrons, becoming positively charged ions, provided an electrical circuit can be completed. This effect can be concentrated locally to form a pit or crack - or it can extend across a wide area to produce general wastage.

These pictures illustrate the similarity in colour between pale green malachite, a common copper ore mineral, and the corrosion products on a brass plate (70% copper) exposed to a humid environment.

Localised corrosion that leads to pitting may provide sites for fatigue initiation and, additionally, corrosive agents like seawater may lead to greatly enhanced growth of the fatigue crack. Crevice corrosion occurs when water can penetrate but is unable to flow, becoming stagnant Galvanic corrosion can occur when two different metals are placed in contact with each other. The more active, or anodic, metal corrodes rapidly while the more noble, or cathodic, metal is not damaged. In bolted systems, this sacrificial effect can affect bolts, particularly carbon steel bolts in stainless flanges. In this case the bolts, which are more active than the stainless components, suffer from severe galvanic effects, often deteriorating severely within months.

Left: the effect of galvanic corrosion is very clear on these carbon steel bolts, attached to a stainless steel joint. Right: a diagram showing the basic mechanisms of a corrosion cell

Electrolyte

AN ACTIVE ANTI-CORROSION BARRIER The Enviropeel system uses a corrosion-inhibiting sprayable thermoplastic (CIST) to provide an active anti-corrosion barrier for the protection of steel substrates. The system uses a specially-designed heating and pumping unit to spray the Enviropeel E170 on to objects of any size or shape. A STATE-OF-THE-ART APPLICATION UNIT The standard Enviropeel unit is a steel trolley equipped with a computer- controlled heating and pumping unit, a ten-metre hose and an application

• gun. Different equipment sizes and specifications are available.

A CORROSION-INHIBITING SPRAYABLE THERMOPLASTIC Enviropeel E170 is a solid at normal temperatures and is supplied as chips for easy handling. The chips are melted in the heating tank of the application unit and sprayed as a liquid on to the substrate. Cooling almost instantly, the material forms a tight, perfectly-fitting cocoon around the substrate. Corrosion inhibitors are continuously released from the material to provide active corrosion inhibition for the lifetime of the

• system. E170 is strippable, non-toxic, recyclable and reusable, making it

easy to use and environmentally friendly.

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Loading chips into the tank A SHORT VIDEO DEMONSTRATION OF ENVIROPEEL APPLICATION & REMOVAL Applying material to the substrate Trimming and cleaning after application Returning waste material to the tank for re-use Stripping the application from the substrate All clean removed material can be immediately re-used in the application unit

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Environmentally friendly Spray application Built-in inhibitor Strippable Suitable for any substrate High dielectric strength Minimal preparation Flexible & tough Moves with substrate Fits any shape or size Standard colour Grey Available in any colour Re-usable – reduces waste Recyclable Non-toxic Safe use & disposal Bolts & bolted systems Bearing housings Flanges & Valves Gearboxes Junction boxes Dissimilar metal joints Replaces petrolatum tape Protection of critical spares Mothballing Structural

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ASTM G62-87 Pinhole/holiday detection Long term storage of Enviropeel 170 at 80° C. ASTM G62-87 Pinhole/Holiday detection apparatus. Determination of Dielectric strength ASTM B117-97 Hot Salt Fog Test ASTM G53-96 Accelerated weathering Ignition and Deluge Test - DNV-OS-D301 Jan 2001 Cryogenic test in Liquid Nitrogen Long-term testing with DNV

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Acids: satisfactory with 20% sulphuric acid, 20% hydrochloric, 20% phosphoric but more affected by 20% nitric and 20% acetic. Water: satisfactory (not for potable water contact) Alkalis: satisfactory with 20% sodium hydroxide and 20% sodium hypochlorite (bleach) some reaction with ammonium hydroxide. Solvents: generally unsuitable. Resistant to diesel but not petrol. Potential permutations involved with chemical testing including type, concentration, temperature, duration, and type of contact.

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High temperature from material and equipment Compressed air Electricity – High / Low Voltage Fumes – Non-toxic but could cause irritation Strains, bumps, slips trips and falls A duty of care towards: yourself, co-workers, the general public and the environment Maintain equipment Use common sense

Enviropeel equipment is designed to operate reliably and safely but, as with all industrial equipment and processes, precautions must be observed to ensure the safety of those operating the equipment and for

• thers in the work area.

The most obvious risk factor associated with Enviropeel relates to the fact that the material is heated, so the material and parts of the equipment can be too hot to touch. Care must be taken not to direct the flow of material towards anyone, and users must be aware of the risks of operating electrically-powered equipment as well as more general risks associated with trailing cables and hoses.

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EYE PROTECTION

Minimum requirement is safety glasses but in many cases a full face visor is advisable

HEAT & OIL RESISTANT GLOVES

Gauntlet type to protect wrists

LONGSLEEVE COVERALLS

To protect against accidental exposure to hot material

ENCLOSED FOOTWEAR

On any work site feet should be protected at all times – steel toe- capped boots are mandatory

SITE SPECIFIC REQUIREMENTS

REGULATORY: This could include colour-coded helmets, special footwear, high-visibility workwear etc SPECIAL CIRCUMSTANCES: Enclosed spaces, for example, may require the use of an inorganic respirator. Operators should risk- assess every situation to make sure they are correctly equipped.

WEARING THE CORRECT PPE IS MANDATORY Site Inductions and site specific requirements

A site induction will always be required. Other site specific requirements could include training/certification for special areas, such as confined spaces or offshore and hazardous areas

JSA/Risk assessment

No project can commence without a full assessment of the likely hazards – and a fully implemented procedure for dealing with them

Minimum 4m safety zone

A safe perimeter must be established to prevent the entry of unauthorised personnel

Permit to work (hot work)

All necessary permissions and paperwork must be in place before work can commence

Tool box talk - start of shift and change of location

Although a full risk assessment will be in place, situations may arise that require modification because of unforseeable circumstances, feedback from crews, location changes etc. A daily talk and feedback session allows procedures to reflect changed requirements

MSDS and Method Statements

Full documentation covering material, equipment, safety and technical procedures must be available for inspection by site authorities.

Safe working practice/s

These are outlined in the risk and method statements. However, these cannot cover every possible

• circumstance. Personnel should check for potential hazards and make sure others are aware of any
• risks. Use common sense, follow procedure and be aware of your surroundings at all times.

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Remove all loose material - paint flakes, rust layers Remove oils, grease and chemicals The substrate MUST be dry prior to application Flange gaps to be injected with pre-treatment inhibitor and covered with matrix tape Depending on situation, pre-treatment inhibitor to be used externally on bolts/connectors and other suitable sections of substrate

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1) Gas Detector(s) 2) Emergency Stop Station 3) Exd Enclosure for ELCB/MCB 4) Microprocessor Control Panel 5) IP67 Microprocessor Enclosure 6) Microprocessor On/Off

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1 3 4 5 6 7 8 9 10 10 11 11 12 12 1 2 10 10

7) KPC 16 Material Pump (Air Powered) 8) Heating Tank Lid 9) Heating Tank 10)Exd Enclosure for Shutdown Control 11)Air Pressure Controls 12)Hose Manifold

13 13 14 14

13) Hose Clamps 14) Hose Heater Cable Junction Box 15)Locking Wheels 16)DNV-Certified Lifting Eyes 17)Up & Over Front Access Door 18)Tool Drawer

15 15 16 16 17 17 18 18 LEFT SIDE DOOR CLOSED RIGHT SIDE DOOR OPEN

Height: 1220 mm Width: 613 mm Length: 1111 mm Nett Wt: 350 kg Gross Wt: 500 kg

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1 2 1) ELCB/MCB

Interior showing circuit-breakers

2) MICROPROCESSOR COMPARTMENT

Open to show main pc boards and control panel pc board

3) SHUT DOWN CONTROL BOX

Open to show control electronics

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Euro Spec: 380-420 volt 3-phase Neutral and Earth 50/60Hz or US Spec: 200-240 volt 3-phase and Earth 50/60 Hz

Max 25A at nominal voltage +/- 10% Use mains/extension cables which have a sufficient power rating.

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EXAMPLE CA18 EURO

Power Voltage L1(A) L2(A) L3(A) CA18/1

Max per phase <10A

4,500 watt 400 volt

L1+L2+L3

6.5 6.5 6.5 10m ATEX EExe HOSE

Max per phase <16A per zone <9A

1,180 watt 230 volt

1 Line

5.13

• 19m ATEX EExe HOSE

Max per phase <16A per zone <9A

1,980 watt 230 volt

1 Line

8.60

• Loading with 10m

ATEX EExe HOSE 11.63 6.5 6.5 Loading with 19m ATEX EExe HOSE 15.1 6.5 6.6 TOTAL LOADING 10M 24.63 TOTAL LOADING 19M 28.10

HEATING TANK (Heating Zone 1) 12,18 or 30 kg capacity 3 heating elements Teflon coated Stainless steel lid with heat deflector

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PUMP 12:1 or 16:1 Pneumatically operated Pressure limit 6bar Air regulator

REAR VIEW FRONT VIEW, LID OPEN FRONT VIEW, TANK & PUMP CLOSE UP OF KPC 16 PUMP

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HOSE (Heating Zone 2) 10m standard length – up to 19 metres available Protective, hard-wearing replaceable sleeve Temperature controlled from microprocessor Heat sensors throughout

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APPLICATION HEAD Non-electrical (heated by transfer) Needle valve Safety trigger Nozzle Display overall system status (“A” codes) Display heating zones status (“H” codes) Set and monitor system controlling parameters

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Set and control temperatures in all zones Detect faults and display relevant error codes (“E” codes) Control pump interlock This is the computer within the system. Its main functions are to:

The microprocessor is housed in a water and dust-proof IP67 box. The control panel is accessed via a lift-up protective window for programming during operation

1) Main air in 2) High/low change-over switch 3) High Pressure regulator 4) Low pressure regulator 5) Air out to pump and hose 6) Optional Slugger air regulator 7) Slugger air out

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3 4 5 6 7 2

Air powers the material pump and is also supplied to the hose nozzle for use during application. The illustration is of the magnetic remote air board which duplicates the controls found within the Enviropeel unit Air supply requirement: 12/18kg unit: 7.5cfm minimum 30kg unit: 16cfm minimum for twin hose operation

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• APPLICATION OVERVIEW

Number of coats: 2 Minimum thickness per coat: 2mm Total minimum film thickness: 4mm Identify target substrate and assess for optimum coverage, taking into account access, substrate condition and complexity. Prepare substrate, cleaning off loose particles and other contaminants Apply continuous film of Enviropeel, starting from the underside – there must be no pinholes Keep gun at right-angles to substrate where possible to avoid overshooting Check behind and around bolt heads and other protrusions for gaps in coating Always make sure joins are properly sealed with extra application time to allow fusion between film layers from the additional heat input. Trim and waste material to be collected in clean trays to avoid contamination –check carefully for cable ties and

• ther material before re-entering into tank

Wait for material to melt properly before using machine Keep machine topped up and agitated – but DO NOT OVERFILL – tank lid must not be prevented from fully closing Back flush periodically Turn down pump regulator when changing or checking in-line filter Keep machine running log up-to-date Do not operate machine without correct PPE Do not leave machine on while not in use Avoid placing contaminated material back in machine – when recycling, always visually inspect material for material or objects likely to clog the filters – do not recycle large clumps of waste material Do not transport unit with hot melted material in tank Do not spray towards any person or animal Use common sense and exercise caution at all times The Enviropeel application machine is engineered to high standards and has very few moving parts therefore, as long as care is taken and good housekeeping observed, minimal maintenance is required.

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Keep a clean working area at all times Keep machine free from debris and wipe down after use Visually check leads and all electrical connections Check all pneumatic systems Visually inspect unit and hoses for integrity Back flush filter Clean nozzles Drain water separators Complete operating log

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Status codes are electrical and temperature related codes which are displayed by the microprocessor via sensors and temperature limiter switches built into the system. They display the overall status of the equipment (codes beginning with A), heating zone status (codes beginning with H) and may display error codes (codes beginning with E) if a malfunction or other problem develops. During the start up process you would normally see A2, A11 and A15 as the various zones heat up, followed by the lighting of the ‘Ready’ indicator. Heating zone status messages display on request and occasionally you may see an error message such as the examples below:

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EO1 Temp limiter switch opened (Max temperature reached) EO2 Temp sensor circuit interupted (fuse, disconnected hose etc) EO5 Insufficient heating (temp <5° C within 10 mins) (fuse defective, sensor not in contact with heater, power supply etc) NB: A full list of status and error codes is displayed in your course manual

SLUGGER 170 – Hand-held Unit

• Used for repairs and small-scale applications
• Heat and spray up to 3.5kgs of material an hour
• Uses Enviropeel E170 in slug form
• Requires compressed-air supply
• Non EX only - available in 230 and 110 volt variants

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CA5 – Luggable Unit

• Non EX only - designed as a back-up unit for the

base application unit

• Used for demos and training and in poor access

areas for repairs and small-scale applications

• Heat and spray up to 5kgs of material an hour
• Requires compressed-air supply
• Available in US and Euro variants