Training Manual Plus Cover Rev TD01 Zone 2

GROUP
A LO C I T & E N V I R O P E E L W O R L D W I D E
APPLICATION
TRAINING MANUAL
ZONE 2
A&E SYSTEMS SDN BHD
TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 CORROSION FUNDAMENTALS
2.1 BACK TO NATURE
2.2 BASIC DEFINITION
2.3 THE CORROSION PROCESS
2.4 TYPES OF CORROSION
2.5 SUMMARY
3.0 SAFETY
3.1 REFERENCES CONTAINED IN THE MANUAL
3.2 DANGERS OF HANDLING/OPERATING THE APPLIANCE
3.2.1 DANGER OF BURNS
3.2.2 DANGER OF SPLASHING
3.2.3 ELECTROCUTION
3.2.4 IRRITATIONS OF THE MUCOUS MEMBRANES
3.3 GENERAL SAFETY PRESCRIPTIONS
3.4 SAFETY FEATURES OF THE APPLIANCE
3.5 RESPONSIBILITY OF THE OPERATING COMPANY
3.6 QUALIFIED PERSONNEL
3.7 PERSONAL PROTECTIVE EQUIPMENT
3.8 PROCEDURE IN CASE OF AN EMERGENCY
3.8.1 SKIN BURNS
3.8.2 ELECTRICAL ACCIDENT
3.8.3 EXTINGUISHING APPLIANCE ON FIRE
4.0 ENVIROPEEL SYSTEMS
4.1 ENVIROPEEL APPLICATION UNIT
4.1.1 ENVIROPEEL ZONE 2 UNIT
4.1.2 ENVIROPEEL APPLICATION HEAD AND HOSE
Enviropeel Basic Applicator Training Manual December 2011

Page 1 Revision TJ01
A&E SYSTEMS SDN BHD
4.1.2.1 APPLICATION HEAD
4.1.2.2 HOSE
4.1.3 ENVIROPEEL ZONE 2 PROTECTION SYSTEM
4.1.4 PNEUMATIC AND POWER SUPPLY REQUIREMENTS
4.1.4.1 PNEUMATIC SUPPLY REQUIREMENTS
4.1.4.2 POWER SUPPLY REQUIREMENTS
4.2 ENVIROPEEL MATERIAL
5.0 ENVIROPEEL APPLICATION
5.1 SURFACE PREPARATION
5.2 SPRAYING
5.2.1 ENVIROPEEL THICKNESS
5.2.2 APPLYING TO FLANGES ON VERTICAL PIPES
5.2.3 APPLYING TO FLANGES ON HORIZONTAL PIPES
5.3 POWERING UP AND SHUTTING DOWN PROCEDURE
5.4 WORK PROCEDURE FOR ENVIROPEEL APPLICATION
6.0 MAINTENANCE
6.1 FLUSHING OF THE FILTER
6.2 REPLACING THE FILTER
6.3 CLEANING OF THE HEATING TANK
6.4 SERVICING THE PUMP
6.4.1 REMOVAL OF THE PISTON PUMP
6.4.2 INSTALLATION OF THE PISTON PUMP
6.4.3 STRIPPING THE PISTON PUMP PROCEDURE
6.4.4 REBUILDING THE PISTON PUMP PROCEDURE

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APPENDICES
APPENDIX A : TRAINING SLIDES
APPENDIX B : POOR APPLICATION EXAMPLES
APPENDIX C : ENVIROPEEL E170 TECHNICAL DATA SHEET
APPENDIX D : ENVIROPEEL E170 MSDS
APPENDIX E : ENVIROPEEL PRE-TREATMENT INHIBITOR MSDS
APPENDIX F : POWER DISTRIBUTION & ADMISSIBLE LOADING
APPENDIX G : TOXICITY & FUME ANALYSIS
APPENDIX H : TROUBLE SHOOTING
APPENDIX I : STATUS, PARAMETERS & ERROR MESSAGES
APPENDIX J : JSA SAMPLE

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1.0 INTRODUCTION
The objectives of the 5 day Basic Enviropeel Application Training are to cover the following:
 Understanding corrosion problems.
 Solutions that Enviropeel offers
 Familiarization with Enviropeel equipment and materials
 Enviropeel application techniques
 Basic maintenance of Enviropeel equipment
2.0 FUNDAMENTALS OF CORROSION
Before you can understand why Enviropeel is so successful in preventing corrosion it would be helpful to
understand a little about why corrosion occurs, with particular attention to the effects that you will find on projects
around the world.
2.1 Back to Nature
Corrosion is the disintegration of metal through an unintentional chemical or electrochemical action,

starting at its surface. The driving force that causes metals to corrode is a natural consequence of their
temporary existence in metallic form. The energy that is absorbed and stored during the transformation
into a metallic state from the original ore is gradually released through corrosion, returning the metal to its
original compounds.
These pictures illustrate the similarity in color between pale green malachite, a common copper ore
mineral, and the corrosion products on a brass plate (70% copper) exposed to a humid environment.
Picture 2.1-1 Picture 2.1-2
2.2 Basic Definitions
Some words appear regularly in corrosion descriptions, here are a few definitions to help understand.
Electrolyte: This generally refers to the solution of a chemical compound, such as salt, that dissociates
into electrically charged ions when dissolved in a liquid. The resulting electrolyte (or electrolytic) solution is
an ionic conductor of electricity.
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Atomic structure – the proton, neutron and electron: An atom has a dense central core (the nucleus)
consisting of positively charged particles (protons) and uncharged particles (neutrons). Negatively charged
particles (electrons) are scattered in a relatively large space around this nucleus and move about it in
orbital patterns at extremely high speeds. It is the transfer of electrons during oxidization that lies at the
heart of the corrosion process.
Oxidation, anodes and the galvanic series: In a narrow sense, oxidation means the reaction of a
substance with oxygen. In the case of iron, the reaction with oxygen causes it to be oxidized to rust, as
electrons are transferred from the oxidizing iron to the oxygen. The transfer of the electrons and the
formation of the iron oxide is the basic mechanism that produces loss of metal from the original iron. The
process is referred to as an anodic reaction.
All metals exhibit a tendency to be oxidized, some much more easily than others. The relative strength of
this tendency is recorded in the galvanic series. A metal's position in the series is a key factor in galvanic
corrosion effects, where different metals are in contact with one another. Environmental factors, such as
oxygen and an electrolyte (usually water) also play a significant role in the speed of the corrosion process
2.3 The Corrosion Process
A corrosion cell works like a battery. Exposure of metal to an electrolyte completes a circuit, producing a
current flowing from the anode to the cathode.
The surface of a metal, when exposed to an electrolyte, will have some sites that are more vulnerable to
an anodic reaction, producing electrons that are consumed at other less vulnerable sites by cathodic
reaction. These sites together make up the ‘corrosion cell’.
A Corrosion cell
Picture 2.0-1 Localized corrosion developing on metal in a solution containing oxygen

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The anodes and the cathodes of the corrosion cell are not necessarily fixed in location - they can be
adjacent or widely separated, depending on a number of different factors:
If two metals are in contact, one metal can be the anode and the other the cathode, leading to galvanic
corrosion of the more anodic metal.
Variations in oxygen concentration in the electrolyte can result in the establishment of an anode at sites
exposed to lower oxygen content – this is why stagnant water is a factor in crevice corrosion.
Variations in the homogeneity of the metal surface, due to the presence of inclusions, different phases,
grain boundaries, disturbed metal, and other causes, can lead to the establishment of anodic and cathodic
sites.
The process occurring at the anodic sites is the dissolution of metal as metallic ions in the electrolyte or
the conversion of these ions to insoluble corrosion products such as rust. The flow of electrons between
the corroding anodes and the non-corroding cathodes forms the corrosion current, producing the
destructive process we see as rust.
2.4 Types of Corrosion
There are various types of corrosion, however, below the most common corrosion are list listed below.
Uniform Corrosion: Uniform corrosion occurs over the majority of the surface of a metal at a steady and
predictable rate. Its predictability facilitates easy control, the most basic method being to make the material
thick enough to function for the lifetime of the component. It is responsible for 30% of corrosion failures.
Localised Corrosion: Failures from localised corrosion are far less predictable than uniform corrosion
and, because the failure may occur without warning, have consequences that are far more severe.
Responsible for 70% of corrosion failures, they can occur after a surprisingly short period of use or
exposure. There are a variety of mechanisms for localized corrosion, the most relevant for our training
purposes are:
Galvanic Corrosion: This can occur when two different metals are placed in contact with each other and
is caused by the greater willingness of one to give up electrons than the other. Three special features of
this mechanism need to operate for corrosion to occur:
 The metals need to be in contact electrically

 One metal needs to be significantly better at giving up electrons than the other
 An additional path for ion and electron movement is necessary – an electrolyte.

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Pitting Corrosion: This occurs when a coating breaks down. A small area of exposed metal gives up
electrons easily and the reaction initiates tiny pits with localised chemistry supporting rapid attack. Pits can
be crack initiators in stressed components or those with residual stresses resulting from forming
operations. This can lead to stress corrosion cracking.
Crevice Corrosion: Crevice corrosion occurs when oxygen cannot penetrate a crevice exposed to an
electrolyte and a differential aeration cell is set up. Corrosion occurs rapidly in the area with less oxygen as
electrons flow to more oxygenated areas, causing severe material loss.
2.5 Summary
If we think of corrosion as a natural process which can be affected by a number of factors, we can better
understand how, by interrupting this process, corrosion effects can be reduced or eliminated. In the three
corrosion mechanisms describe above, just by getting rid of the electrolyte, the effects of corrosion would,
for all practical purposes, be eliminated. But, as can be seen in the case of pitting corrosion, localized
coating failure can then lead to accelerated effects when the substrate is exposed to the electrolyte
through a gap in the coating.
In most cases, a good quality coating on a simple surface, such as a steel pipeline, will provide corrosion
protection by preventing exposure to oxygen and water-based electrolytic solutions. It is at the joints where
the problems occur. Here, with multiple components, widely varying in size, and coating issues to do with
assembly and complexity, exposure to corrosion mechanisms is far more likely, and far more difficult to
eradicate. Enviropeel’s combination, of a flexible barrier coating providing passive protection and active
protection from its built-in corrosion inhibitors, is designed to eliminate all possible causes of corrosion.

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3.0 SAFETY
Enviropeel equipment is designed with state-of-the-art technology in order to comply with applicable safety
regulations and to be operated easily and safely by the certified user. Inadequately trained users, on the
other hand, can cause material and personal damage through inappropriate behaviour. This chapter
informs you about safety criteria and other prerequisites which must be met for safe and optimal operation
of the Enviropeel unit.
This chapter must be read and understood by all persons authorized to commission, operate, maintain or
repair the Enviropeel unit.
3.1 References Contained in the Manual
The framed reference boxes in this manual will show you different reference symbols which warn of
possible dangers, situations and precautions which must be observed under all circumstances. Non-
observance may lead to injury, death and/or damage to the product and the environment.
Symbol Signal word Significance and consequences in case of non-observance
Warning of dangerous electrical voltage.

Danger
Risk of injuries including death and destruction of the appliance.
Warning of hot surface and hot material.

Warning
Risk of minor to serious burns.
Warning of high pressure in the hot-melt system.

Warning
Risk of hot material splashes and parts flying around.
Possible inhalation of vapours.

Caution
Risk of harmful vapour levels for persons and environment.
Warning of a general danger area.

Warning
Risk of minor injuries.
Warning of a general danger area.

—
Danger of material damage to product or the environment.
Application tips or other useful information.

—
No dangerous or harmful situation.
Protection from dangers. Regulation symbols indicating that

gloves, protective goggles or protective clothing must be worn.

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3.2 Dangers of Handling/Operating the Appliance
Enviropeel equipment is built to the highest standards and to comply with all applicable safety regulations.
However, some risk from operating machinery will always exist – and these risks may not always be
obvious - operating personnel should take their own and others’ safety seriously:
3.2.1 Danger of Burns
Danger of burns
There is a danger of suffering burns from exposed hot components when the
unit is in operation and from contact with the melted E170 material
Warning
(temperatures up to 180° C or 356° F).
Heat-resistant protective gloves must be worn for all adjustment or
maintenance jobs on hot parts of the unit or in case of possible contact with
melted E170. Parts of the unit remain hot for some time after the unit has
been switched off. The unit must not be moved while it contains melted
material. Failure to comply may result in injury or damage from melted E170.
3.2.2 Danger of Splashing
Danger of splashing
The E170 in the lines is under a high pressure. There is a danger of hot
Warning
splashes occurring at the application heads or if the pressure system is
breached. If the pressure system has to be opened, the entire appliance must
be relieved of pressure beforehand. Protective goggles must be worn under
all circumstances for all adjustment or maintenance work on parts under
pressure such as pump, distributor block, heated hose or application head.
A label on the rear side of the appliance

warns of the high pressure loads and
temperatures which may occur.

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3.2.3 Electrocution
Electrocution
Operating voltage 240 or 400 volts. Danger of fatality or serious

injury from contact with live components.
Danger Connection of the appliance to the power mains or other work on
the power circuit may only be carried out by persons trained for
the purpose, i.e. electricians or electrical fitters. The protective
covers may only be removed if the power supply to the appliance
is disconnected.
This sticker on the covers on the front and on both

sides warns of unauthorized opening and draws
attention to the correct procedure.
3.2.4 Irritation of the Mucous Membrane
Irritation of mucous membranes by vapours
Even if the prescribed processing temperatures are complied with,

E170 may emit odours and high vapour concentrations might lead to
Caution irritation of the mucous surfaces.
Do not inhale vapours and ensure the unit is operated in sufficiently
ventilated areas. Keep the tank lid closed! Do not exceed the
recommended processing temperature! Read the E170 data sheet
and observe all its recommendations.
3.3 General Safety Prescriptions
The following general safety prescriptions must be observed:

 The unit must only be operated, maintained and repaired by authorized and trained personnel.
 The system must be maintained and only operated in serviceable condition and using the most
recent operating guidelines. If safe operation cannot be assured, the unit should be switched off and
protected against unintentional use until repaired by authorized personnel.
 In addition to the information contained in the operating manual, you must comply with legal
requirements and the provisions on accident prevention and protection of the environment in your
country.
 Do not modify the appliance in any way without receiving written approval from A&E Systems.
 Any major technical issues, deficiencies or abnormal operational stresses are observed during
operation, the user must notify A&E Systems immediately.

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3.4 Safety Features of the Appliance
The units are built to the latest safety standards and feature the following safety systems:
 Appliance switch - interrupts the power supply to the control of the appliance
 External emergency-stop - on the ICS-MAIN board at the clamp X33 an emergency stop contact is
available. If the contact is opened, the feed pump stops immediately.
 Program sequence monitoring - in case of errors all outputs are switched off and the program is
restarted
3.5 Responsibility of the Operating Company
The company operating this unit undertakes to only use suitably trained and authorized personnel. In
addition, operators must be familiar with the generally applicable rules and regulations pertaining to safety
at work, the prevention of accidents and protection of the environment.
The unit may only be operated if it is in safe working order and in compliance with the most recent
operating instructions. If safe operation cannot be assured, the unit should be switched off and protected
against unintentional use until repaired by authorized personnel.
3.6 Qualified Personnel
The unit must only be operated, serviced and repaired by authorized personnel. These personnel must be
familiar with site safety and accident prevention regulations and aware of company internal work
instructions. The owner/operator of the appliance is responsible for all personnel training. The level of
knowledge can be ascertained and intensified with product-specific training by A&E Systems.
3.7 Personal Protective Equipment
Protective clothing covering arms and legs must be worn at all times
when operating equipment!
Gauntlet-style gloves and protective goggles must be worn at all times

when operating, servicing or repairing hot and pressurized equipment.
Danger of hot material splashes and burns!

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3.8 Procedure in Case of an Emergency
Please observe the information below. If an unexpected emergency occurs,

the information below will help you to proceed correctly in keeping the
damage within limits and in preventing possible further damage.
3.8.1 Skin Burns

Contact with hot material or components may cause long-term effects. All burns, particularly on the
face or hands, must be treated by the doctor.
Whenever possible, cool burns as quickly as possible under cold flowing, clean water. Then apply
sterile material, e.g. sterile gauze compresses. Do not use wound powder or oil, ointment or similar.
If no sterile bandage material is available, use freshly ironed handkerchiefs or linens. Do not open or
remove blisters.
3.8.2 Electrical Accident

 Switch the power off immediately (e.g. switch to 0, pull out mains plug, remove fuse)
 If you are affected personally, you must apply all your strength to break free from the power
circuit (push yourself away, drop on the floor, pull out mains plug by walking away, etc.)
 Don't forget to protect yourself in a rescue operation. Stand on an insulated spot, only touch a
person who may still be connected to an electrical current using insulated dry objects (clothes,
wooden handle, etc.), drag or push the victim away from the power circuit.
 Rest the injured person correctly. Give artificial respiration immediately if the person subject to
the accident stops breathing. In case of a circulatory collapse, give artificial respiration and
apply external heart massage immediately.
 Call a doctor right away.
3.8.3 Extinguishing a Fire
In case of a fire, use a CO2 extinguisher. Water can only be used to

control burning E170 material – not on the equipment. All operating
personnel must know the location of the nearest fire extinguisher.
Danger Electrocution
Fire in an Enviropeel Application must never be extinguished with

water! There is a mortal danger from electrocution, danger of burns
from hot water vapours and explosively splashes of hot material.

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4.0 ENVIROPEEL SYSTEMS
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.
The Enviropeel system consists of the following:

 Enviropeel Application Unit (Zone 2 Unit, Base Unit or Slugger170)
 Enviropeel material (Enviropeel E170 Chipped or Enviropeel 170 Slugs)
Note: Unless otherwise stated, photos in this training manual are of Zone 2 Units and material useage described
is Enviropeel E170 chipped.
4.1 Enviropeel Application Unit
The Enviropeel application unit consists of a heating and pumping unit, a heated hose (standard 10m
length) and spray gun which is constantly controlled and monitored by an in-built microprocessor.
The components are housed in a purpose-built mobile trolley complete with a well-equipped tool drawer for
execution of Enviropeel applications and general maintenance of the application unit.
Picture 4.1-1 General Layout of Enviropeel Application Unit

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4.1.1 Enviropeel Zone 2 Unit
The Enviropeel Zone 2 unit is inspected and certified by DNV, which is suitable for use at offshore
platforms and Zone 2 rated hazardous environments. This unit includes the following:
1) Gas Detector(s) – See Picture 3.1.1-2
2) Emergency Stop Station – See Picture 3.1.1-2
3) Exd Enclosure for ELCB/MCB – See Picture 3.1.1-1
4) Microprocessor Control Panel – See Picture 3.1.1-1
5) IP67 Microprocessor Enclosure – See Picture 3.1.1-1
6) Explosion Proof Microprocessor On/Off Switch – See Picture 3.1.1-1
7) KPC 16 Material Pump (Air Powered) – See Picture 3.1.1-1
8) Heating Tank Lid – See Picture 3.1.1-1
9) Heating Tank – See Picture 3.1.1-1
10) Exd Enclosure for Shutdown Control – See Picture 3.1.1-3
11) Air Pressure Controls – See Picture 3.1.1-3
12) Hose Manifold – See Picture 3.1.1-3
13) Hose Clamps – See Picture 3.1.1-3
14) Hose Heater Cable Junction Box – See Picture 3.1.1-3
15) Locking Wheels – See Picture 3.1.1-1
16) DNV-Certified Lifting Eyes – See Picture 3.1.1-1
17) Up & Over Front Access Door – See Picture 3.1.1-1
18) Tool Drawer – See Picture 3.1.1-1
Picture 4.1.1-1 Enviropeel Zone 2 Unit

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1 10
2
11
14 12
13
Picture 4.1.1-2 Enviropeel Zone 2 Left Picture 4.1.1-3 Enviropeel Zone 2 Right
Door Section Door Section
Note: Pictures 3.1.1-1 to 3.1.1-3 show a modified unit complete with a duel gas detectors and duel output
hose for use on LPG Tankers
4.1.2 Enviropeel Application Head and Hose
The Enviropeel application unit is supplied with a

 10m standard length Hose (Heating Zone 2) complete with an
 Application Head (Heating Zone 3 – not applicable for Enviropeel Zone 2 Unit).
Picture 4.1.2-2 10m Hose

Picture 4.1.2-1 Application Head
Notes: The Heating Zone 3 located at the Application Head is only available in the Enviropeel Base Unit.
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4.1.2.1 Application Head

The application head of the Enviropeel Zone 2 is non-electrical and comprises the
following:
 Needle Valve
 Trigger Mechanism
 Safety Trigger
 Nozzle
4.1.2.2 Hose
Heating elements and heat sensors are located throughout the entire hose. The
temperature of the hose are monitored and controlled by the microprocessor:
The heating elements, heat sensors and material hose are covered with protective, hard-
wearing replaceable sleeves.
4.1.3 Enviropeel Zone 2 Protection System
The protection system consists of a gas detector (item 1 in picture 3.1.1-2); control enclosure (item
10 in picture 3.1.1-3) and an emergency stop station (item 2 in picture 3.1.1-2).
The gas detector has an LCD display for any measured gas concentration together with an integral
alarm and fault relays. The control enclosure is fitted with a power supply used to generate the 24V
DC required by the equipment within the enclosure and the gas detector. It also contains the 32A
four-pole contactor, a 5A four-pole relay and miscellaneous terminals. All the equipment is certified
for use within a flammable atmosphere. The safety system is designed to isolate all power to non-
EX rated components making it perfectly safe in a flammable atmosphere even though the unit
remains connected to the power system.
As soon as the unit is connected to a power supply the gas detector will monitor for flammable gas
before allowing start-up. The unit cannot be started if either flammable gas is detected or the
emergency stop button has been activated. Once both of these conditions have been cleared, then
power may be applied to the main machine by pressing the green ‘Start ’ button, energising the
contactor within the EX control enclosure, allowing supply to be available at the terminals within the
power distribution enclosure.
Upon detection of a flammable gas or upon activation of the emergency stop button, the contactor
will de-energise, isolating the power supply. Any fault within the detector system will also cause the

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power to be cut-off. Power can only be reapplied once the level of flammable gas has dropped
below the alarm level, the stop button reset or the fault has been corrected.
4.1.4 Pneumatic and Power Supply Requirements
4.1.4.1 Pneumatic Supply Requirements

To operate the Enviropeel application unit, it requires 7-10 bar of clean pneumatic air.
The pneumatic air is supplied to the material pump and to the nozzle at the application
head to achieve the required spray pattern during application.
Picture 4.1.4.1-1 Pneumatic System Picture 4.1.4.1-2 Schematic Diagram of

Pneumatic System
Picture 4.1.4.1-3 Legend of Schematic Diagram

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4.1.4.2 Power Supply Requirements

Enviropeel application units (Zone 2 and Base) use the following power supply.
US Power Specifications
Electric Supply: 220VAC, 50-60Hz, 32Amps, 3 phase and Earth connections, 4-core
wire
The power distribution and admissible loading of Enviropeel Zone 2 unit can be found in
Appendix E.
For other power requirements, please refer to our respective offices.
4.2 Enviropeel Material
The Enviropeel E170 material is a thermoplastic containing built-in corrosion-inhibiting oil. Solid at normal
temperatures, it is heated to form a liquid for application, after which it rapidly returns to its normal solid
state - encapsulating the substrate within a perfectly fitting anti-corrosion barrier. It is supplied as chips to
speed melting and make handling easier.
Picture 4.2-1 Enviropeel E170 Grey Chipped

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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. Please refer to Appendix C and D for the Technical Data Sheet and Material
Safety Data Sheet for more information.
The following are the characteristics of Enviropeel E170:

 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
 Does not contains any VOCs
 Safe use & disposal

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5.0 ENVIROPEEL APPLICATION
5.1 Surface Preparation
Unlike any painting system, the Enviropeel coating system can be applied on minimal surface preparation.
Although any loose flaking rust or paint should be removed from the surface, this can easily be achieved
by means of a wire brush and/or a scraper.
Picture 5.1-1 Surface Preparation Using Wire Brush on Flange
For effective corrosion prevention, the surface of the substrate MUST BE DRY prior to the application of
Enviropeel.
It is important that severe contamination of the substrate, ie rust flakes, loose coatings, petrolatum, heavy
grease, etc. should be removed prior to Enviropeel application as this prevents contact of the Enviropeel
film with the substrate. Under certain circumstances it may be necessary to pressure wash the substrate to
remove contamination. After pressure washing, the surface can be dried using compressed air.

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Picture 4.1-2 Pressure Washing to Remove Heavy Grease
5.2 Spraying
Before application of Enviropeel on the substrate, there are many factors to consider:
 Orientation of the flanges
 Surface condition of the flanges and bolts and nuts
 Gaps or voids between flanges
5.2.1 Enviropeel Film Thickness
For the Enviropeel System to work effectively, film thickness and continuity during application is of
prime importance.
The average minimum thickness of the Enviropeel after cooling on the substrate should be 4mm.
However, if the substrate is subject to extreme UV exposure, the thickness should be at least 6-
8mm as high UV exposure may dry inhibitor on the surface of the Enviropeel. This will only affect
the top 2mm. By increasing thickness to 6-8mm, the performance of the corrosion inhibitor under
the remaining 4-6mm thickness will not be affected.

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5.2.2 Applying to Flanges on Vertical Pipes
Before applying on the flanges, set the high and low air pressure (see Pic 4.1.4.1-1) and the pump
pressure to a comfortable setting. Pressure settings may vary from applicator to applicator.
However, as a general guideline, the pressure settings are set but not limited to the following
settings:
 High air pressure set at approx 2 bars
 Low air pressure set at approx 0.5-1.0 bar
 Pump pressure set at approx 3.0-4.0 bars
When applying to flanges on vertical pipes (after preparation) the following steps should be
followed:
1. Install matrix tape round the pipe on the upper neck of flange.
2. Spray/apply Enviropeel Pre-Treatment Inhibitor into flange gap and corroded surfaces.
3. Apply 1st coat to the bottom section of the flange at about 90o angle to the flange using high
air pressure.
4. Inspect to ensure Enviropeel covers the flange, bolts and nuts.
5. Trim off excess Enviropeel at the bottom.
6. Apply 2nd coat to the bottom section of the flange at about 90o angle to the flange using
high air pressure.
7. Trim off excess Enviropeel at the bottom.
8. Wipe the overlapping area.
9. Apply 1st coat from the upper neck of flange covering the matrix tape using low air pressure
by toggling the pressure switch (see Pic 4.1.4.1-1).
10. Install mechanical strap on the first coat after the first coat is touch dry.
11. Wipe the overlapping area.
12. Apply 2nd coat over the 1st coat covering the mechanical strap completely using low air
pressure.
13. Trim off excess Enviropeel.

A&E SYSTEMS SDN BHD
5.2.3 Applying to Flanges on Horizontal Pipes
Before applying on the flanges, set the high and low air pressure (see Pic 4.1.4.1-1) and the pump
pressure to a comfortable setting. Pressure settings may vary from applicator to applicator.
However, as a general guideline, the pressure settings are set but not limited to the following
settings:
 High air pressure set at approx 2 bars
 Low air pressure set at approx 0.5-1.0 bar
 Pump pressure set at approx 3.0-4.0 bars
When applying to flanges on horizontal pipes the following steps should be followed:
1. Install matrix tape around flange gap if necessary.
2. Spray/apply Enviropeel Pre-Treatment Inhibitor into flange gap and on corroded surfaces.
3. Apply 1st coat clockwise on both sides of the flange at approximately 11 o’clock direction
(looking towards pipe direction) covering the bolts and nuts until 6 o’clock position using high
air pressure.
4. Trim off excess/dripping Enviropeel
5. Apply 1st coat anti-clockwise on both sides of the flanges at approximately 11 o’clock direction
covering the bolts and nuts until 6 o’clock position high air pressure.
6. Trim excess dripped Enviropeel.
7. Inspect to ensure Enviropeel covers the flange, bolts and nuts and that there are no holiday
8. Wiped the surface of Enviropeel before applying 2nd coat.
9. Repeat steps 5 to 9 for 2nd coating.
5.3 Powering Up and Shutting Down Procedure
Connect both pneumatic and power supply and observe the following sequence:
1. Ensure the melting tank is filled to the required level.
2. Turn on the switch at power supply source.
3. Turn on the explosion proof switch on machine (item 6 in Pic 4.1.1-1)
4. Press green button on emergency stop switch (item 2 in Pic 4.1.1-2). The red light on the emergency
switch should not illuminate. If the red light is on, pull the red switch and press the green button again.
5. All indicating lights will illuminate for 2 seconds followed by LED “Tr<Tn”. This indicates that the
machine is in starting up phase.
6. Select required parameters by pressing the up and down button (Pic 5.3-2)
7. Select the Parameter to 22 by pressing the up and down button (Pic 5.3-3)
8. Press all 4 buttons (Pic 5.3-4) simultaneously to release the “loc” mode
9. Change the value to 1.1.1 by pressing the “-“ button (Pic 5.3-5).
Note: the value is automatically reset to 1.2.3 after reaching the set temperatures

A&E SYSTEMS SDN BHD
10. To set the temperature settings of the tank, select LED light to Tank by pressing the left button (Pic
5.3-4). Now select to Tnorminal (Pic 5.3-2) and set the temperature to 175oC.
11. To set the temperature settings of the hose, select LED light to hose by pressing the left button (see
Pic 5.3-4). Now select to Tnorminal (see Pic 5.3-2) and set the temperature to 180oC.
12. The machine is ready for use when the overall status shows “A11” and the LED “Ready” is lit.
13. To start the pump, press the pump button and the green LED on the pump button will light; the overall
status remains blank.
Picture 5.3-1 Microprocessor Control Panel
Picture 5.3-3 Picture 5.3-4

Picture 5.3-2
Picture 5.3-5

A&E SYSTEMS SDN BHD
5.4 Work Procedure for Enviropeel Application
1. Remove any oil, grease, loose rust and other contamination as much as possible from the surface
substrate, for the longest possible service substrate should be coated with an Alocit primer after
surface preparation.
2. When the substrate surface condition is so badly corroded that it may require replacement, the client
should be called in to verify the integrity of the joint/substrate. The substrate should not be coated
with Enviropeel until verification has been received from a client authorised engineer.
3. Where significant corrosion is apparent on all surfaces, a pre-coat with Enviropeel Pre-Treatment oil
should be applied.
4. Enviropeel Pre-Treatment Inhibitor should be sprayed into the flange gap area to maximize
corrosion protection. Where the gaps between flanges are sufficiently large, a matrix tape shall be
used as a “bridge” to reduce wastage of Enviropeel being sprayed into the gaps.
5. The continuity of electrical cables for the Application Unit and the power source must be checked
and confirmed prior to hook up. Application Unit must be operated according to specification.
6. The E170 in the melting tank must be adequately heated and melted to ensure that the material is
fluid for spraying.
7. The Operator should set the air and material pressure to suit ambient conditions and perform trial
before actually coating the substrate. Only trained and qualified Enviropeel operators are allowed to
operate the machines.
8. The substrate surface MUST BE DRY and free from water or moisture prior to the application of
Enviropeel.
9. The Dry Film Thickness should be monitored regularly to ensure sufficient amount of material is
deposited as per specification.
10. Upon completing the coating work, all edges shall be trimmed and an acceptable finish must be
ensured.
11. Safety at work must be treated with utmost importance and any unsafe situation/condition in the
work area should be notified to the client immediately.
12. Where possible, photographs shall be taken prior to application as well as after application.
13. Wind breaks should be erected during windy days to facilitate application.
14. All outside work must stop during rain or thunderstorms to protect personnel and equipment.

A&E SYSTEMS SDN BHD
6.0 MAINTENANCE
Contamination and foreign objects in the Enviropeel application unit are the most frequent reason for
stoppages. This is why the entire system must be kept clean at all times and why the following
maintenance jobs must be carried out under all circumstances.
Problems with the Enviropeel application unit (e.g. clogging) may occur if the
maintenance work is not carried out at all or incorrectly. Such problems usually
occur at irregular intervals and are often difficult to localize.
The maintenance intervals apply to one-shift operation. In case of a higher workload the unit needs more
frequent maintenance.
Prior to the operation of the Enviropeel application unit, ensure that all pneumatic and power supply
connections are securely fastened.
The piston pump is the most common item requiring servicing or maintenance as it is the only moving part
on the Enviropeel application units. To service the pump, please see Section 6.4. During servicing of the
piston pump, ensure that all seals are intact and in good condition. To avoid frequent servicing of the
piston pump, it is imperative NOT to recycle any contaminated E170.
Throughout the operation of the Enviropeel application unit, always wipe down the machine to remove oil
residues and practise good housekeeping around the working area. By having a clean working
environment, there will be less contamination included with the collected E170 during application which in
turn reduces the wear and tear on the piston pump.
6.1 Flushing of the Filter
Contamination within the Enviropeel application unit accumulated in the filter is flushed out through
the drain opening. Removal of the filter is not necessary. Flushing of the filter should be done at
least once every 2 hours or as when required.
Note: The appliance must have reached its operation temperature before flushing can commence.
1. Set the pressure controller at the piston pump back to 0 bar.

2. Place a temperature-resistant container under the drain opening (1) at the valve block.
3. Open the drain bolt (2). Hot Enviropeel will now flow from the drain opening (1).
4. Increase the pump pressure and drain Enviropeel until no more visible contamination flows out of
the drain opening.
5. Close and tighten the drain bolt again. Exchange the filter cartridge if it is heavily contaminated.

A&E SYSTEMS SDN BHD
Picture 6.1-1 Draining of contamination
6.2 Replacing the Filter

Replacement of the filters should be done every end of the work shifts or as when required.
Note: The unit must have reached its operating temperature before flushing can commence. The tank
does not need to be empty.
1. Set the pump pressure at the controller to 0 bar.

2. Drain the system pressure. A temperature-resistant container should be placed under the drain opening
(1) at the distributor block to collect molten Enviropeel material. Open the drain bolt (2) far enough for
material to emerge. System pressure is released once material flow stops. Fully open the drain bolt (2).
3. Remove the screw plug (3). The filter cartridge is still seated in the bore.
4. Screw an M5 bolt (5) or the special filter key into the thread of the filter cartridge (4) and pull the filter
cartridge (4) including the O-ring (6) from the bore.
5. Clean the bore with a lint-free rag and slide the new filter cartridge with O-ring into the bore.
6. Turn the screw plug (3) back in again.
7. After the filter change there will be air in the system. Increase the pump pressure slightly so that the air
can escape through the drain opening (1). Once air flow ceases and only material flows out, close the
drain bolt (2). The appliance is now ready for operation again.
Picture 6.2-1 Replacing the filter cartridge

A&E SYSTEMS SDN BHD
6.3 Cleaning of the Heating Tank
During constant use, the Enviropeel application unit heating tank must be cleaned at least once per month
or as necessary depending on work load.
Make absolutely sure you wear working clothes covering

arms and legs, protective goggles and heat-resistant gloves
for cleaning work.
1. Empty the tank to a level 10mm/0.25” below the top of the heating vanes by pumping out excess
material.
2. Leave the Enviropeel in the tank to solidify overnight.
3. In the morning turn on the unit and set the tank heat to 150° C/302° F and hose and gun to OFF
4. When the E170 has melted around the edges, turn OFF the unit.
5. Remove the pump and clean out the piston pump (see Section 6.4).
6. Using a slotted head screwdriver, remove the E170 from the tank in blocks, ensuring that the sides of
the tanks are NOT scraped by the tips of the screwdriver.
7. Clean the tank filter of any E170 or contamination.
8. Replace and clean filter cartridge (see Section 6.2).
9. Clean away as much of the remaining E170 or any contamination in the tank with a lint free cloth.
10. Replace the cleaned piston pump and the tank filter.
11. Fill in the tank with new E170 and it is fully melted, the system should be cleaned and ready for use.
6.4 Servicing the Piston Pump
Picture 6.4-1 Removing and Installation of the Piston Pump

A&E SYSTEMS SDN BHD
6.4.1 Removal of the Piston Pump

1. Heat the unit to operating temperature to ensure the E170 around the piston pump is melted.
2. Remove the cover (1) after loosening the union nut. Pull out the plug (2) of the pump control
and the air hose (3).
3. Fully loosen the fastening nut (4) counterclockwise using a hook spanner.
4. Full the piston pump vertically upwards and out of its holder.
6.4.2 Installation of the Piston Pump

1. Visually check to ensure all O-rings are in good conditions.
2. Insert the journal of the piston pump in the bore at the tank base.
3. Tighten the fastening nut (4) with a hook spanner.
4. Plug in the connector (2), connect the pneumatic hose (3) and place the pump cover.
6.4.3 Stripping Piston Pump Procedure
Picture 6.4.3-1 Exploded View of Piston Pump (KPC12)

A&E SYSTEMS SDN BHD
Referring to Pic 6.4.3-1, use the following sequence to strip the pump:
1. Unscrew material feed nozzle (196) from lower end of pump using 18 mm spanner.
2. Remove lower suction ball housing (195).
3. Remove upper and lower solenoids (110) by removing 14 mm nuts and pulling away from
the air hose.
4. Remove the front cover assembly (120) by removing the four allen screws (125) and nylon
washers (300), solenoids and power lead will come away with the cover assembly.
5. Remove the air regulator (100) from the upper manifold (10) by unscrewing the banjo bolt
(90) using a 14 mm spanner.
6. Unscrew four allen bolts (75) and remove the manifold.
7. Pull out air feed tube (65).
8. Remove the magnet guide tube (15).
9. Unscrew the magnet assy. (35) retaining nut (45) and lift off the magnet assembly.
10. Take note of orientation of lower manifold block (5) to pump body (185) for reassembly.
11. Remove four allen bolts (180) and lift off lower manifold block (5).
12. Lift off the pump retaining collar (210) and spacer (205).
13. Using circlip pliers remove circlip (225) and nylon washer(220) from the piston shaft (190).
14. Push the piston shaft (190) down and remove it from the lower end of the pump body (185).
15. Unscrew the two allen screws (250) and washers (255) from the top of the pump body (185)
and remove the brass washer (200), this will expose the main piston sealing ring (270).
16. To access the upper suction ball (230), unscrew the piston shaft end cap (215) and the
suction ball can be removed from the piston shaft
6.4.4 Rebuilding the Piston Pump Procedure
Referring to Pic 6.4.3-1, use the following sequence to rebuild the pump:
1. Insert the suction ball (230) into the piston shaft and refit the piston shaft end cap (215).
2. Insert the piston shaft (190) into the pump body (185) from the bottom and push the shaft up
and through the body.
3. Slide the brass washer (200) over the top of the piston shaft and locate it in the recess at
the top of the pump body (185).
4. Refit the two allen screws (250) and washers (255) and tighten down.
5. Slide the nylon washer (220) over the top of the piston shaft and seat it on the shaft
shoulder, using circlip piers refit the circlip (225) ensuring it locates in its slot completely
above the nylon washer.
6. Sit the pump retaining collar (210) and the spacer (205) in their position on top of the pump
body (185).
7. Ensuring orientation is correct, slide the lower manifold (5) over the piston shaft until seated
squarely onto the spacer (205) and secure with the four allen bolts (180).
8. Place magnet assembly (35) onto the top of the piston shaft ensuring the green paint mark
on the magnet is facing upwards and secure it down with the 13 mm nut (45).
A&E SYSTEMS SDN BHD
9. Ensuring lower sealing washer (20) is in position, place the magnet guide tube (15) over the
magnet assembly and seat it on the lower manifold (5).
10. Place air feed tube (65) into its position on the lower manifold (5).
11. Carefully placing the upper sealing washer (20) on top of the magnet assembly guide tube,
seat the upper manifold (10) onto the guide tube ensuring the air tube (65) lines up with the
corresponding hole on the upper manifold.
12. Secure upper manifold into position using the four Alan bolts (75).
13. Refit the air regulator (100) by placing the Banjo bolt (90) through the upper manifold and
connecting it to the regulator, ensuring that there is a sealing washer (95) either side of the
manifold, tighten the banjo bolt using a 14 mm spanner ensuring the regulator is in the
vertical position.
14. Place the front cover assembly (120) in position and secure using the four Alan screws (125)
placing the nylon washers (300) between the cover and the manifolds.
15. Place the upper and lower solenoids (110) on their respective air pipes and secure using the
14 mm nuts.
16. Refit the lower suction ball housing (195) into the base of the pump.
17. Refit material feed nozzle (196) to the base of the pump.

A&E SYSTEMS SDN BHD
APPENDIX A
TRAINING SLIDES

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A&E SYSTEMS SDN BHD
APPENDIX B
POOR APPLICATION EXAMPLES

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A&E SYSTEMS SDN BHD
APPENDIX C
ENVIROPEEL E170 TECHNICAL DATA SHEET

Revision 0
A&E SYSTEMS SDN BHD
APPENDIX D
ENVIROPEEL E170 MSDS

Revision 0
A&E SYSTEMS SDN BHD
APPENDIX E
ENVIROPEEL PRE-TREATMENT INHIBITOR MSDS

Revision 0
A&E SYSTEMS SDN BHD
APPENDIX F
POWER DISTRIBUTION & ADMISSIBLE LOADING

Revision 0
A&E SYSTEMS SDN BHD
APPENDIX G
TOXICITY & FUME ANALYSIS

Revision 0
A&E SYSTEMS SDN BHD
APPENDIX H
TROUBLE SHOOTING

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A&E SYSTEMS SDN BHD
APPENDIX I
STATUS, PARAMETERS & ERROR MESSAGES

Revision 0
A&E SYSTEMS SDN BHD
APPENDIX J
JSA SAMPLE FORM

Revision 0

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GROUP

2.0 CORROSION FUNDAMENTALS

2.1 BACK TO NATURE

2.2 BASIC DEFINITION

2.3 THE CORROSION PROCESS

2.4 TYPES OF CORROSION

3.1 REFERENCES CONTAINED IN THE MANUAL

3.2 DANGERS OF HANDLING/OPERATING THE APPLIANCE

3.2.1 DANGER OF BURNS

3.2.2 DANGER OF SPLASHING

3.2.4 IRRITATIONS OF THE MUCOUS MEMBRANES

3.3 GENERAL SAFETY PRESCRIPTIONS

3.4 SAFETY FEATURES OF THE APPLIANCE

3.5 RESPONSIBILITY OF THE OPERATING COMPANY

3.6 QUALIFIED PERSONNEL

3.7 PERSONAL PROTECTIVE EQUIPMENT

3.8 PROCEDURE IN CASE OF AN EMERGENCY

3.8.1 SKIN BURNS

3.8.2 ELECTRICAL ACCIDENT

3.8.3 EXTINGUISHING APPLIANCE ON FIRE

4.0 ENVIROPEEL SYSTEMS

4.1 ENVIROPEEL APPLICATION UNIT

4.1.1 ENVIROPEEL ZONE 2 UNIT

4.1.2 ENVIROPEEL APPLICATION HEAD AND HOSE

Enviropeel Basic Applicator Training Manual December 2011

4.1.2.1 APPLICATION HEAD

4.1.3 ENVIROPEEL ZONE 2 PROTECTION SYSTEM

4.1.4 PNEUMATIC AND POWER SUPPLY REQUIREMENTS

4.1.4.1 PNEUMATIC SUPPLY REQUIREMENTS

4.1.4.2 POWER SUPPLY REQUIREMENTS

4.2 ENVIROPEEL MATERIAL

5.0 ENVIROPEEL APPLICATION

5.1 SURFACE PREPARATION

5.2.1 ENVIROPEEL THICKNESS

5.2.2 APPLYING TO FLANGES ON VERTICAL PIPES

5.2.3 APPLYING TO FLANGES ON HORIZONTAL PIPES

5.3 POWERING UP AND SHUTTING DOWN PROCEDURE

5.4 WORK PROCEDURE FOR ENVIROPEEL APPLICATION

6.1 FLUSHING OF THE FILTER

6.2 REPLACING THE FILTER

6.3 CLEANING OF THE HEATING TANK

6.4 SERVICING THE PUMP

6.4.1 REMOVAL OF THE PISTON PUMP

6.4.2 INSTALLATION OF THE PISTON PUMP

6.4.3 STRIPPING THE PISTON PUMP PROCEDURE

6.4.4 REBUILDING THE PISTON PUMP PROCEDURE

Enviropeel Basic Applicator Training Manual December 2011

Enviropeel Basic Applicator Training Manual December 2011

2.0 FUNDAMENTALS OF CORROSION

2.1 Back to Nature

Corrosion is the disintegration of metal through an unintentional chemical or electrochemical action,

Picture 2.1-1 Picture 2.1-2

2.2 Basic Definitions

2.3 The Corrosion Process

Picture 2.0-1 Localized corrosion developing on metal in a solution containing oxygen

Enviropeel Basic Applicator Training Manual December 2011

2.4 Types of Corrosion

 The metals need to be in contact electrically

Enviropeel Basic Applicator Training Manual December 2011