An Introduction to the

Enviropeel System
presented by
Alta Max LLC
distributor for

T H E R M O P L A S T I C S Y S T E M S

OVERVIEW
Understanding Enviropeel
Equipment Description

BACKGROUND
Technical Papers
HSE - Managing Corrosion

CASE HISTORIES
US Mining Industry
North Sea Flange Protection
Australian Mining Industry
Siemens/National Grid
Deluge Test

DOCUMENTS
Sample Method Statement
Tech Data
MSDS
www.ae-sys.com
Understanding Enviropeel
Enviropeel is a unique re-usable thermoplastic
coating system that has been proven to reduce
the costs of corrosion and wear by up to 95%. T H E R M O P L A S T I C S Y S T E M S

A durable, flexible material at normal temperatures, Enviropeel is melted in a specially designed mobile application unit
and sprayed as a liquid on to any size or shape of substrate, cooling to a solid in seconds. Built-in inhibitors are released on
to every surface, providing active protection, penetrating deep into every crevice and flowing round every joint. The
material forms a tough flexible cocoon around the target area providing an impermeable, corrosion-inhibiting barrier that
will protect for the lifetime of the system. Enviropeel is quick
to apply, environmentally friendly, easy to strip, re-usable
and recyclable with no VOCs or harmful chemicals.
Benefits of Use
l Stops corrosion immediately
l Reduces wear & tear
l Prevents ingress
l Long-term active protection
l Reduced labour costs and
maintenance-related accidents
l Extended component life
l Environmentally friendly
l Easy to remove
l Re-usable and waste free

Around the world Multiple Applications

Enviropeel has been used by the mining and oil and gas l Bearing housings
industries offshore and onshore since 1998 - on flanges and l Flanges & Valves
valves in Asia, Europe and the Americas. Applications for
power supply companies in the UK are preventing damage l High-voltage switchgear
from water ingress and, in Australia, Enviropeel is specified l Standby Equipment
for major mining companies, where its use on conveyor
systems has increased equipment life cycles by more than l Gearboxes
500%. Its environmentally-friendly credentials attracted the l Junction boxes
US Coastguard for bolt protection on their vessels and its
ability to protect in ocean-going environments has been l Bolt caps
successfully applied to exposed pipework on LPG tankers. l Dissimilar metal joints
l Replaces petrolatum tape
l Protection of critical spares
Above: Spraying Enviropeel
Left: Protected flanges on an LPG carrier
Bottom: A carbon-steel gear spline after
four years outside in the tropics
 Testing
Enviropeel has undertaken a variety of tests, both in the lab
and in the field, that show how well it performs. In-house and
3rd party ASTM B117 hot salt fog testing showed that areas
within the Enviropeel protection zone stayed in perfect
condition and other tests, including cryogenic, accelerated UV
pinhole and film integrity testing, have shown outstanding
corrosion protection in a variety of aggressive environments.
Field trials for the US Coastguard proved Enviropeel’s
performance on the high seas leading to its adoption for
bolting protection on USCG vessels and on LPG Tankers.
Sample testing during years of exposure to offshore North Sea Above: a range of flange types and sizes encapsulated with
conditions have shown no ill effects on Enviropeel but Enviropeel on a North Sea platform.
provided significant protection for
thousands of flange applications.
Pictured left: Hot salt fog testing for How it works ...
Weatherford on a well-head component. The
Enviropeel coating was cut away from the This simplified cross-section shows two components
upper bolt before testing. The lower bolt was joined by a bolt and protected with Enviropeel.
uncovered after the test.
Enviropeel coating
forms protective layer
Application around substrate

Enviropeel applications use specialized equipment and Steel flange

require licensed, qualified applicators, either supplied as a components
service for specific projects, or trained as part of an equipment
sales or leasing arrangement. A wide range of equipment
Steel bolt
sizes is available, with tank sizes from 30kg/66lb to and nut
10kg/22lb, all built to the highest standards. High capacity,
twin-pump and hazardous area variants are also available.
Inhibitor is
deposited on every
Left: a standard surface within the
18kg/40lb Enviropeel encapsulation,
unit complete with Protective migrating into
removable hose box every cavity
mechanisms ...
Below: the
US-built
10kg/22lb
application unit
is a cost-
ü Passive Protection: Ingress of moisture and
contaminants prevented by perfectly fitting
Enviropeel barrier

ü
effective choice
Active protection: Inhibiting oil coats all
internal surfaces under coating, preventing
corrosion process

Although Enviropeel is
supplied in grey as
standard, it can be
manufactured in a range of
colors to suit any
requirement

www.enviropeelusa.com
 Application Units

CA18
STANDARD
UNIT

CA30 TWIN
PUMP UNIT

A range of Enviropeel equipment is available,

from the simple Slugger to the mighty CA30 .
Every job is different and there is an Enviropeel unit to
built to match - from the twin pump CA30, which can
run two 19-metre (60 ft) hoses at the same time, to the
tiny Slugger repair unit. Zone 2 CA30 & 18 units are
available for offshore and hazardous area use.

MADE TO MEASURE
We can even tailor-make units for specific
purposes. The unit below was specially MA10 COMPACT UNIT
manufactured with twin gas detectors and other
features to meet the needs of a shipping
company for its LPG carriers.

SLUGGER 170 HANDHELD UNIT

T H E R M O P L A S T I C S Y S T E M S

www.ae-sys.com
 COMPARING SYSTEMS
Blasting/Painting Vs Enviropeel Process

Typical Process for Paint Application vs Enviropeel Paint/Coatings Enviropeel

Application
Equipment:
Enviropeel application machine ✔
Compressor 300 to 600CFM capacity ✔
Blasting Pot ✔
Blasting medium, sand or grit ✔
Tarpaulins for protection of blasting medium ✔
Protect sensitive adjacent equipment and personal ✔
Breathing apparatus and blasting protection ✔
Wire brush removal of loose and flaky rust ✔
Blast to SA2.5 and clean up spent abrasive ✔
Mask area not to be affected by paint over spray ✔
1st Stripe coat by hand around nuts and bolts ✔
2nd Coat normally by airless spray ✔
Top Coat ✔ ✔
Allow drying time ✔
Remove masking ✔
Clean up ✔
Wastage Yes 40-60% NONE
Longevity Poor  10 YEARS
Removable ✔
Reusable ✔
10 YEAR WARRANTY NO ✔
Unit Price Comparison Changeout vs. Enviropeel
Independent Customer Provided Figures

Bolt Changeout - 2”nb 150# Flange Bolt Changeout – 12”nb 150# Flange
Cost of replacement gasket $0.65 Cost of Replacement gasket $6.55
Cost of replacement bolts $6.55 Cost of Replacement bolts $32.75
Cost to break joint $49.52 Cost to break joint $226.37
Cost to re-make joint $96.21 Cost to re-make joint $448.49
Total Unit Cost $152.93 Total Unit Cost $714.16

Enviropeel - 2”nb 150# Flange Enviropeel – 12”nb 150# Flange

Cost of product (0.5lb) $22.50 Cost of product (7.7lb) $346.50
Cost of equipment $8.32 Cost of equipment $91.70
Time to clean joint (0.25hr) Time to clean joint (1.0hr)
Time to apply product (0.08hr) Time to apply product (1.0hr)
Cost to complete joint $46.12 Cost to complete joint $137.93
Total Unit Cost $76.94 Total Unit Cost $576.13

Bolt Changeout - 6”nb 150# Flange Comment from commissioning engineer:

Cost of replacement gasket $1.97
Cost of replacement bolts $13.10 “ As can be seen, the application of Enviropeel is
Cost to break joint $108.94 significantly more cost effective than replacing bolt sets.”
Cost to re-make joint $232.03
Total Unit Cost $356.04 “Enviropeel will protect for the mechanical life of your equipment, whereas
unprotected bolting systems may need to be replaced multiple times”
Enviropeel - 6”nb 150# Flange
Cost of product (2.2lb) $112.50 Note 1: As this is an assessment based on a platform under
Cost of equipment $17.58 construction it doesn’t take into account the cost of shutting down
Time to clean joint (0.5hr). parts of the platform to allow the flanges to be unbolted
Time to apply product (0.2hr) Note 2: Assumes low alloy steel bolts – if CRA bolts were specified,
Cost to complete joint $97.80 costs for replacement bolts would be much higher
Total Unit Cost $227.88
ENVIROPEEL TEST REPORT

Author: Barry Windsor Date: 2.8.05

Testing Enviropeel 170 for resistance to a range of chemicals

All in Liquid Form

Test Period

Approximately 6 months

Test Conditions

Individual corked test tubes filled to a depth of 60/70% with liquid.

Average ambient test temperature 15 ° C . Stored indoors.

Date of Final Examination 27.6.05

Test Control Coated nails with no test liquid in a sealed tube.

Caveat

NB: Enviropeel 170 is primarily an anti-corrosion coating. As it possesses significant water resistance
(hydrophobicity) it will resist some chemicals, especially those in aqueous solution.

Enviropeel 170 is not designed to be a chemical resistant coating but should perform reasonably well in
conditions of limited immersion, splashes, vapour contact.

Please read the test data and the conclusions drawn.

A&E Systems Limited

3 Charles Wood Road, Dereham, NR19 1SX, UK
Tel: +44 (0)1362 694915 Tel: +44 (0)1362 695350
Company Registration No: 6271390
ENVIROPEEL TESTING TEST PERIOD = 6 months

TEST LIQUID E170 (white)

20% SULPHURIC ACID ; NOT AFFECTED
20% HYDROCHLORIC ACID ; NOT AFFECTED
20% ACETIC ACID ? BLISTERED
SLIGHT SOFTENING
20% PHOSPHORIC ORTHO ; NOT AFFECTED
20% ACETIC ACID ? SLIGHT SOFTENING
TAP WATER ; NOT AFFECTED
DISTILLED/ DEMIN. WATER ; NOT AFFECTED
SYNTHETIC SEA WATER ? SLIGHT SOFTENING
20% SODIUM HYDROXIDE ; NOT AFFECTED
20% SODIUM HYPOCHLORITE ? SLIGHT SURFACE ATTACK
20% AMMONIUM HYDROXIDE ; NOT AFFECTED
WHITE SPIRIT ? SLIGHT SOFTENING
XYLENE : DISSOLVED
METHANOL : DISSOLVED
ETHANOL : DISSOLVED
DIESEL OIL ; NOT AFFECTED
PETROL : EXTREMELY SOFT,SWELLED
METHYL ISO-BUTYL KETONE : DISSOLVED
BUTYL ACETATE : DISSOLVED
AIR-CONTROL ; “OILY” SURFACE INDENTS.

; = suitable ? = needs to be tested case by case : = unsuitable

Conclusions

1. The Enviropeel coated objects must be continuous and pinhole free.

2. Acids: satisfactory with 20% sulphuric acid, 20% hydrochloric, 20% phosphoric but more affected by
20% nitric and 20% acetic.
3. Water: satisfactory (not for potable water contact)
4. Alkalis: satisfactory with 20% sodium hydroxide and 20% sodium hypochlorite (bleach) some reaction
with ammonium hydroxide.
5. Solvents: generally unsuitable.
6. Resistant to diesel but not petrol.
7. Short-term test only - longer testing period may be required for a longer term prognosis
8. Potential permutations involved with chemical testing including type, concentration, temperature,
duration, type of contact etc are truly overwhelming.

If in doubt please consult Technical Services for further assistance.

A&E Systems Limited

3 Charles Wood Road, Dereham, NR19 1SX, UK
Tel: +44 (0)1362 694915 Tel: +44 (0)1362 695350
Company Registration No: 6271390
TECHNICAL BACKGROUND
Since the 1990s A&E has produced many technical papers to
help others understand the power of Enviropeel - and what
makes it work so well. But, before we provide a recent example
of our own work produced for NACE in Houston, it’s worth a
quick look at what one of the world’s largest oil companies said
about us to the Offshore Technology Conference in 2010.

The extract below is from the ConocoPhillips Production Assurance Technology

Division and it describes the background to the application of Enviropeel on
more than 8000 flanges on one of their platforms.

The pictures on the right show, above: a mixed metal flange after 7 years of Enviropeel protection
in the North Sea and below: a group of the many thousands of flanges coated on the platform.

OTC 20317
Offshore Platform Materials Integrity - Remediation Measures
ConocoPhillips, Production Assurance Technology
A platform topsides facility ... deteriorated substantially during the time between installation and the start of
hookup/commissioning due mainly to the substandard coatings and workmanship. This degradation was
exasperated by construction contamination and exposure to the marine environment ... Implementation of
pragmatic solutions to the various issues encountered was required to ensure an on-time start-up. The
required work scope entailed:

1. Bolting remediation with thermoplastic encapsulation

2. Iron and chloride contamination removal
3. Aluminum foil for heat tracing of corrosion resistant alloy (CRA) instrument tubing
4. High dry film thickness (OFT) coating qualification.

Bolting remediation with thermoplastic encapsulation

At this facility, most bolts were manufactured from low alloy carbon steel to provide a good combination of high
strength and reasonable cost. Zinc/nickel electroplating followed by a passivation treatment was specified to
provide corrosion protection. During deck integration, it was evident that a significant quantity of bolting
materials on the platform suffered corrosion due to failure and premature consumption of the electroplated
"protective" coating ... The corrosion product was superficial ... however, considering the potential for future
damage to adjacent contaminated materials, remedial measures were developed.

Therefore, the application of a thermoplastic encapsulation product to prevent water ingress for bolts
operating below 90°C (194°F) was recommended. Encapsulation had been used successfully on other
ConocoPhillips offshore platforms and was thus a recognized, acceptable technical solution for bolt
preservation in the North Sea environment. In addition, this ensured minimized disruption to ongoing
construction; therefore, no further consideration was given to alternative coatings or bolt replacement using
alternative materials/coating systems.

This thermoplastic encapsulation containing corrosion-inhibiting pigments (Enviropeel) is spray applied and
... was applied over bare metal or after preparation

Extract © OTC 2010

 Bolt Corrosion Prevented by Corrosion-Inhibiting Spray-On Thermoplastic

Timothy J. Davison Michael W. Joosten Iain Matheson

A&E Anti-Corrosion Systems ConocoPhillips Company Britannia Operator Limited
LLC Bartlesville Technology Center Royfold House, Hill of Rubislaw
150 Hilden Road, Suite 301 228 Geoscience Building Aberdeen
Ponte Vedra, FL 32081 Bartlesville, OK 74004 United Kingdom

ABSTRACT

Numerous industrial facilities, especially offshore oil and gas installations, are plagued by bolt corrosion
problems. With a limited record of success in prevention or cure, material loss from corrosion is often
factored into maintenance planning, with bolt replacement as a solution when integrity is threatened.

An increasing focus on overall maintenance as an essential part of reducing problems in safety-critical

systems makes the prevention of corrosion effects on basic components such as bolts and fasteners an
increasingly important goal. This paper describes a corrosion-inhibiting sprayable thermoplastic system
that has demonstrated success in the provision of extended corrosion protection on both new and
rusting bolts in extreme conditions.

The system uses purpose-built equipment to spray a thermoplastic material containing inhibiting oils to
encapsulate the substrate. The paper includes a review of current bolt coating systems and describes
the thermoplastic system, together with field case histories showing how this product has effectively
prevented or stopped on-going bolt corrosion issues found in offshore oil and gas production systems
as well as the in mining industry and on LPG tankers.

Keywords: alloy, bolt, corrosion, encapsulation, fastener, flange, gas, inhibiting, offshore, oil, plating,
sprayable, thermoplastic, valve, zinc
 INTRODUCTION

In 2003 Karl Fischer reviewed offshore experiences with bolts and fasteners for the NACE Conference
shortly after a long-term study of bolting materials and their performance in various service conditions
commenced.1 The study was motivated by a need to understand how best to protect bolted systems
from the effects of corrosion without a constant need for maintenance. Material selection and factory-
applied coating systems were the main focus of the study but Fischer was also keen to see what
remedial measures might be available in the event of failure and it was for this reason that the potential
use of a corrosion-inhibiting sprayable thermoplastic system as a post-corrosion treatment was
explored as part of the study.

Corrosion has always had the potential to cause catastrophic failure in infrastructure such as gas
pipelines.2 In the case of bolted systems however, it is more like a death of a thousand cuts, as the
progressive corrosion of fasteners affects the safety and function of the systems they are holding
together.

Fischer enumerated the various bolt materials used in marine environments:

 Low alloy steel

 Copper-based alloys
 Nickel-based alloys
 Stainless-steel alloys
 Titanium-based alloys

Because of the cost and availability of corrosion-resistant alloys, low-alloy ASTM A193 B7 and A320 L7
steel bolting systems make up the majority of marine oil and gas facility fasteners.3 Because of their
lower resistance, some form of corrosion protection will normally be applied. In a Bulletin, Badelek and
Moore speak of their company’s experience in the North Sea, where a number of factory-applied bolt
coating systems for low-alloy steels were evaluated:

 Zinc & Cadmium Electroplate

 Polytetrafluoroethylene (PTFE) Coating
 Sheradising
 Spun Galva nising

Of these, only the spun-galvanised bolts

appeared to offer any corrosion resistance, with
other coatings failing in as little as a few weeks. 4

Similar results were obtained in the initial findings

of the Fischer study, where all but one of a similar
range of coatings exposed in the splash zone
failed in 18 months, despite an exhaustive search
for the most suitable candidates (Figure 1).
Failures in washer coatings and materials were Figure 1: PTFE coated 8 µm zinc electroplated
even more pronounced than those in the low alloy fastener after only 18 months of testing
fasteners. in the splash zone

The zinc/nickel plated L7 bolts shown in Figures 2 to 5 are from a newly constructed platform in the
North Sea before it was commissioned. Typically, in a laboratory salt spray test, a zinc/nickel coating
would be expected to last at least 1,000 hours before ‘red rust’ occurs. 5 An accelerated test such as this
is designed to demonstrate the potential longevity of a coating system on the basis that the test
conditions are so extreme, the lifetime of the coating should, for example, be 10 years under normal
conditions if it could last 1,000 hours in a salt-spray cabinet.

Offshore however, conditions are far from normal; 1,000 hours is only 6 weeks. The bolts in these
photographs have been exposed to constant salt-spray conditions for more than a year.

Figures 2 and 3: zinc-nickel plated L7 bolts on stainless steel flanges

Figures 4 and 5: zinc-nickel plated L7 bolts on a mixed stainless/carbon steel substrate

High levels of bolt corrosion on offshore structures are not uncommon and may be exacerbated by
galvanic and crevice corrosion. In both the illustrated examples, the bolts are carbon steel; in one case
the bolts are fastening stainless flanges, in the other, a combination of stainless and carbon steel. In
such situations, low-alloy bolts are extremely vulnerable to galvanic effects.

For this platform, the client insisted on remedial action before handover - which would normally involve
either blasting and painting or replacement of the one million corroding bolts.6 Because of the potential
costs and delays involved, a review of potential solutions was undertaken which included the use of a
corrosion-inhibiting spray-on thermoplastic (CIST) recommended by the client company as it had been
using it for a number of years on a platform suffering similar failures in PTFE coated bolts.

CIST EXPLAINED

The system involves the application of a thermoplastic barrier coating material that contains corrosion-
inhibiting oils. Although the material is a solid at normal temperatures, when heated to 170°C it
becomes a sprayable liquid which can then be easily applied to any substrate configuration. Substrate
preparation is minimal. Removal of debris and light wire brushing is sufficient. On cooling, the material
returns to a solid state without any loss of its original properties. The result is a rubbery solid,
continuous plastic coating which can encapsulate any size or shape of substrate. Because of the
inhibiting oils, the coating not only provides a barrier to water and oxygen but also actively prevents the
progress of the corrosion process (Figure 6).

Figure 6: diagram of principles

Figures 7 and 8: before and after application

The advantage of such a system is that it works at every level to protect a bolted assembly. Spray
application adapts to any size and produces a coating that conforms to every contour of the substrate.
The resulting outer skin acts as a barrier to the ingress of oxygen and water - and every surface within
the encapsulation is in direct contact with the inhibiting oil as it works into every crevice. This allows
CIST to be applied to substrates where corrosion already exists (Figures 7 and 8) and can prevent
galvanic, pitting and crevice corrosion. Easy to remove and repair, small areas of the CIST material can
be cut away for monitoring or maintenance and reinstated without affecting the overall performance.

CASE HISTORIES

Since 2003, CIST has been in use on North Sea platforms for remedial protection of failing bolted
systems. In the illustrated case the PTFE and electro-plating on low-alloy carbon steel bolts had not
performed well (Figure 9) and a rolling program of CIST encapsulation using an Enviropeel system was
implemented to prevent further deterioration. 7

Figure 9: an area of corrosion affected valves

Over the years both the operator and application engineers have removed sample applications from
flanges to assess their condition. Inspection has shown that further deterioration of the bolts has been
arrested by the CIST application (Figures 10 and 11).

Figures 10 and 11: sample removal shows previously rusting substrate and inner surface of CIST
encapsulation coated with oil

Satisfaction with the performance of CIST on this North Sea platform directly influenced the decision to
use the system for protection on a bridge-linked platform commissioned in 2008. A best practice
specification for the use of CIST for bolt corrosion remediation is being developed by the company. 8

Bolt protection requirements are not just the province of the offshore oil and gas industry. Gas transport
systems in Malaysia and Canada have used CIST systems to protect flanges and bolted systems for
onshore installations and long-term testing in the UK at a major gas terminal was successfully
concluded in 2009 after 4 years of testing. Examination of the substrate following removal of the coating
showed that oil was present on all internal surfaces and no corrosion had occurred (Figures 12 and 13).
The terminal is directly adjacent to the North Sea and, while annual precipitation is low, the installation
is subject to high salt and moisture levels.

Figures 12 and 13: Application in 2005 and following removal in 2009

On LPG carriers, flange bolts required repainting several times a year prior to the use of CIST which is
used to protect flanges and valves on all deck pipework (Figure 14). The use of CIST has eliminated
the need for repainting on such areas for these vessels.

Figure 14: CIST protected deck pipework on LPG carrier

OTHER APPLICATIONS

The combination of inhibition and encapsulation has shown impressive results in other areas too. In the
Australian mining industry the material was used by an engineering company to eliminate corrosion in
stored equipment waiting for installation. Engineers for the client of the engineering firm were intrigued
by the new material and asked for investigations to be undertaken to see if the material was suitable for
use on operating equipment.

These engineers had a particular interest in application to conveyor bearings, where failures in as little
as nine months were commonplace in some areas. As there were many thousands of bearings on
hundreds of miles of conveyor systems, frequent replacement, at $7,000 to $10,000 for each change
out, was a costly and time consuming process.

Before the applications could take place, tests on bearing temperatures and lubrication were
undertaken as there was concern that the encapsulation might affect these areas. No contraindications
were found, but testing did discover that CIST’s lubricating qualities allowed it to be applied directly on
to the bearing shafts without preventing rotation.9 This allowed complete encapsulation of the bearing
housing, combining corrosion protection and particle ingress protection in one application.

Test applications and subsequent field applications over the past five years have shown a 100%
success rate, with no failures in any CIST protected bearings. CIST protection is now mandatory on all
mining conveyor bearings for the two largest mining companies in Australia.

In Figure 15, removal of CIST from trial bearings shows the bearing housing to be unaffected while the
unprotected roller shows clear signs of deterioration.

An analysis conducted by the mining companies of performance data from the trial and subsequent
implementation of the CIST protection showed significant direct cost savings as well as reduced
maintenance requirements and lower risk exposure levels.
Figure 15: removing CIST material from trial bearing
shows impeccable condition of protected substrate

CIST PERFORMANCE DATA (2004 to 2009)

On stored conveyor pulleys

• Return for replacement without CIST 44.5%
• Failure rate with full CIST 0%
On operational pulleys
• Average bearing life in original location: 9 months
• Current bearing life in original location with CIST applied: 48+ months
• Resulting component life increase: 500+%
• Resulting saving in pulley changeout costs: 500+ %
• Reduction in maintenance costs: 95 %
• Percentage of CIST costs to rebuild costs: 10 to 15 %
• Percentage of CIST costs to pulley change out costs: 5 to 7 %
• Resulting percentage reduction in risk exposure: 90+ %
• Anticipated increase in component lifetime: 500+ %

ASSET MAINTENANCE

The UK Health & Safety Executive (HSE), an independent regulatory authority charged with oversight
of health and safety issues throughout the UK, issued a redraft of its 5-year Materials and Corrosion
strategy document for the Oil & Gas Industry in September 2010.10 This document is aimed at securing
the life-cycle integrity of offshore installations and refers to the danger from the severe corrosive effects
of the North Sea environment on its ageing infrastructure.

When it comes to external corrosion, its guidance is quite clear: operators are not only responsible for
ensuring the integrity of safety critical areas but must also make sure plans and procedures are in place
to ensure all plant & equipment are in good repair with respect to corrosion. It lists the following as
areas for concern:
  Walkways and stairways
 Cable trays including fittings and brackets
 Bolted connections
 Flanges
 Pipe supports and pipes
 Valves

A variety of solutions exist for remediation of corrosion in these areas and CIST would not be practical
in every category but the list makes it clear that preventing failure in complex assemblies joined by bolts
and fasteners is a priority to meet safety concerns.

Such concerns exist all around the world and many ageing structures are suffering. CIST can provide a
reactive solution to existing problems, with long-term pro-active effects that have eliminated corrosion
entirely for some users and offers the potential to do the same in a wide variety of areas. And, because
it is re-useable, recyclable and toxin-free, it’s better for the environment too!

CONCLUSIONS

1. Long-term evaluations have shown CIST effectively prevents bolt corrosion in aggressive marine
and mining service.
2. CIST provides bolt corrosion control for both existing and new build applications through
encapsulation and inhibiting oil.

REFERENCES

1. K.P. Fischer, A Review of Offshore Experiences with Bolts and Fasteners in Corrosion 2003, Paper
3017: NACE International.
2. For example, the August 2000 rupture of a pipeline in Carlsbad, New Mexico caused 12 fatalities
and widespread damage as a result of corrosion. NTSB Report NTSB/PAR-03/01.
3. ASTM International, ASTM A193 / A193M - 10a, Standard Specification for Alloy-Steel and
Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose
Applications, ASTM A320 / A320M - 10a, Standard Specification for Alloy-Steel and Stainless Steel
Bolting for Low-Temperature Service.
4. Badelek and Moore, Topside Bolting – Corrosion Protection in North Sea Bulletins: BP Amoco,
1999.
5. N. Zaki, Zinc Alloy Plating, http://www.pfonline.com/articles/pfd0019.html
6. As estimated by operating company engineers.
7. Enviropeel is a trademark of the A&E Group.
8. S.P.V. Mahajanam et al, Offshore Platform Materials Integrity – Remediation Measures, OTC 2009,
Paper 20317, Offshore Technology Conference.
9. Vas Dziombak, ‘Engineering Protective System’, West Australian Engineering Excellence Awards,
2005.
10. http://news.hse.gov.uk/2010/09/29/materials-and-corrosion-strategy-2009-2014/?eban=rss-
offshore-oil-and-gas.
How to Manage External Corrosion
Recent UK HSE reports have highlighted the need for dutyholders to monitor asset integrity in non-
safety-critical as well as safety-critical applications, with effective maintenance management
systems for walk and stairways, piping and pipe supports, cable trays and fittings, bolts, flanges and
valves. The 2007 KP3 Report asserted that there had been a failure to adequately monitor asset
integrity and pointed to the need for those with a duty of care to have a better understanding of the
potential impact of degraded, non-safety-critical plant and utility systems on safety-critical elements.
Since 2007 many improvements have been made and
moves for a shift of focus from safety critical elements to
include a greater concentration on overall asset integrity
management - but much remains to be done. A 2009
OSD review concluded that major ongoing efforts were
required, with ageing infrastructure presenting major
challenges. It is with a view to addressing these
challenges that some of the issues raised in the HSE
‘Management of External Corrosion’ document are
examined in the light of what can be done using
Enviropeel to provide prevention and remediation in the
event of corrosion in offshore structures.
AREAS OF CONCERN
The HSE ‘Offshore external corrosion guide’ lists six
areas of concern: corrosion under insulation, firewater Above: a typical view of corroding flanges and valves on a
North Sea platform.
mains & deluge systems, flanges & plant bolting, valves,
Below: a typical flange, perfectly encapsulated with
pipe supports & coatings and threaded plugs. A number
Enviropeel to preserve its integrity.
of accelerating factors are highlighted, including the
presence of water traps, mixed metals and saltwater
conditions.
HOW ENVIROPEEL CAN HELP
Most offshore installations regard a certain amount of
rust as a necessary evil – conditions are such that a good
deal of redundancy is built into systems, allowing for
degradation from corrosion as part of the natural
lifecycle of marine infrastructure. In many cases the
need, for example, to cut bolts off because they are too
corroded to unscrew, is regarded as standard
procedure. Corrosion prevention is HSE’s preferred
option but, where levels of corrosion are allowed to Using Enviropeel to protect vulnerable offshore systems
develop, they insist on verifiable performance standards not only fulfills the HSE’s preferred prevention option
that define the limits beyond which components must be but it provides operators and dutyholders with a long-
repaired or replaced. term solution to the need for constant inspection and
The aim of HSE, of course, is to maintain safety maintenance of both safety-critical and non-safety
standards. Naturally, the inspection and maintenance of critical elements. In most of the areas of concern
offshore structures must be of the highest standard to
ensure safety - but good maintenance is also necessary
for optimum production levels over the lifetime of the
structure. T H E R M O P L A S T I C S Y S T E M S
listed above, a corrosion-inhibiting encapsulation of the
vulnerable components will prevent any degradation of
the substrate, eliminating the need for bolt changes,
equipment replacement or repair.
INSPECTABLE
Although it is well established that bolted systems and
components protected by Enviropeel remain corrosion-
free for many years, it is essential that, when required,
inspection of the substrate can be easily undertaken.
Because Enviropeel is easily removed, all or any part of
the protective layer can be easily peeled away to reveal Above: after two years, an application on a a flange with severely
the target area and, once inspected, the protection can corroded bolts is cut away for inspection. No further corrosion has
taken place and inhibiting oil can be seen on the fastening and in
be reinstated, either by complete reapplication or by
the removed Enviropeel coating.
resealing a specifically removed area. Enviropeel
recommends an annual visual inspection regime with
targeted removals and inspections as part of its 5 and
10-year warranty programmes.
EFFECTIVE
You can be confident that Enviropeel will provide the
protection you need because of the way it works.
Corrosion requires a number of elements to develop.
For aqueous corrosion this would normally be the metal
substrate, oxygen and water. Enviropeel isolates the
substrate by providing an external barrier, preventing
water ingress and coating the surface in an inhibiting oil
Moisture cannot
which prevents the flow of oxygen and the electron penetrate barrier Above: Enviropeel is available
transfer that is essential to the corrosion process. This in a variety of colours and is
isolation process works for galvanic, pitting and crevice suitable for a variety of
Corrosion substrates: pipe supports,
corrosion as well as normal atmospheric corrosion. prevented by flanges, valves, elbows and
The Enviropeel system uses a corrosion-inhibiting, inhibitor layer brackets etc.
sprayable thermoplastic to provide a close-fitting active
Bolt threads protected Left: a simple schematic to
barrier coating on steel substrates of any size or shape
show how Enviropeel protects.
with minimal surface preparation. In red, the outer encapsulation
Active prevents ingress of moisture
FLEXIBLE & ADAPTABLE Inhibitors and, in green, the constant
Not only is the Enviropeel material flexible, allowing it to release of inhibitors coats all
expand and flex with movements in the substrate but the Built-in inhibitors continually inner surfaces, isolating
system itself is very flexible in use, allowing a wide variety released on to substrate components from corrosion.

of solutions on a range of problem substrates. Whether it

is being used to protect bolts, flanges, valves or pipe the environmental impact of materials, it is worthwhile
supports, it provides supremely adaptable protection, noting that Enviropeel does fulfill this objective. The
allowing encapsulation of almost any configuration. material itself can be reused or recycled – waste
material can immediately be used in the application unit
WASTE-FREE, RECYCLABLE AND NON-TOXIC – and no special disposal measures are required as the
While it is not part of a specific safety regime to reduce material is non-toxic and contains no VOCs.

The HSE Offshore Division (OSD)seeks a lifecycle management approach which starts with the initial selection of appropriate
For more materials and
information
follows through the lifecycle with effective inspection, maintenance, repair and replacement. For more information on HSE OSD
on Enviropeel go toand corrosion
mitigation you can visit their website: www.hse.gov.uk/offshore/corrosion.htm
www.ae-sys.com
COLONIAL PIPELINE TEST E N V I R O P E E L H O L D I N G S L L C

This test took place at an access well located in Orange, Texas bounded by petrochemical plants
and brackish waters which periodically submerge the substrates during large storms and
hurricanes. The application was completed in October 2016 and followed by a series of
inspections - at 3 months, 8 months and 21 months. During this period Hurricane Harvey caused
the entire area from Beaumont to Houston to be ooded, submerging one of the test anges.
The inspections were to be
accomplished by cutting
away sections of Enviropeel
and resealing after the
inspection. Small areas of
Enviropeel can easily be
removed and resealed for
inspections and testing
without affecting the
integrity of the coating.
Tw o t e s t a r e a s w e r e
completed: a 36” blind
flange and a 12” blind
flange in a soil-to-air
interface.
Test 1: Preparation
and application
The first photos show a 36”
blind flange with visible First inspection on 1/12/17 after 3 months. Enviropeel's built-in
corrosion present on the
A section of the coating remains completely inhibiting oil, which has
flange and fastenings. As
around the abraded area corrosion free and the area arrested all existing
part of the test, a section of
was removed for this of rust previously noted has corrosion and loosened the
the flange and the face of an
inspection. As can be seen receded significantly. This surface rust which could
adjacent nut were abraded
below, the exposed steel was due to the effect of then be wiped away.
to expose the underlying
steel to show how the
application works even
when no coating is present.
The application was
completed on 10/12/16.
Note the extent of the rust
above the abraded patches.
 Cutting and resealing Enviropeel

Following each inspection the removed material was

resealed using a standard electric heat gun to melt the
patch back into the coating - even when heavily
soiled. This is standard practice for inspection and
maintenance on Enviropeel installations where the
ability to easily test targeted locations without needing
to redo the application saves time and money.

Above: the substrate after Below: removal for the third

removal for the second inspection. Externally the
inspection. coating shows dirt from the
muddy environment but
Second inspection on inside everything is in
6/13/17 after 8 months. perfect condition.
The Enviropeel is cut away
from the same location as
well as from the nut of the
bolt which had not been
uncovered since the original
application. As you can
easily see there are no new
signs of corrosion in either
area. Also note that the
external rust has receded
even further.
Final inspection on
7/18/18 after 21 months
The coating is removed from
the same location as
previously after nearly two
years. There are no signs of
new corrosion on the
exposed steel and the rust
staining has faded even
further. Despite evident
external contamination
from flooding and the
environment, inside the
coating is unaffected.
Test 2: encapsulating a almost completely black but,
12” blind flange on when the inspection area
10/12/16 was cut away showed the
Not only was this blind inside of the Enviropeel to be
flange in a soil-to-air in its original condition and
interface, but it was that no further corrosion has
submerged under water occurred on the blind
during Hurricane Harvey for flange, as you can see in the
over a week. For the test, soil photo below.
was cleared away from the
Conclusion
flange to allow access, as
shown above. Enviropeel Not only has the Enviropeel Below right: condition of substrate prior to application.
was then applied to coating completely stopped Below left: inspection reveals substrate to be in original
encapsulate the entire all existing corrosion and condition without any further corrosion despite flooding.
flange and the pipework prevented further corrosion
covered over. After 21 occurring, but it has also
months of rain and flooding reduced rust staining on all
the encapsulation was surfaces.

BEFORE

ALTA MAX, LLC

246 Harbor Circle, New Orleans, LA. 70126

Al Baker 225-287-3062 Kevin Vorisek 817-798-6573

al@altamax.net kevin@altamax.net

AFTER 21 MONTHS
Flange Joint Protection in the North Sea
Enviropeel had been successfully protecting flange bolts on a large gas platform in the
North Sea, operated by two of the world’s largest oil companies, for more than five years.
So, when it came to choosing a system for bolt protection on a new linked platform, the
operators decided that Enviropeel was the best approach to use. Even before
commissioning, the new platform was suffering from the corrosive effects of the severe
North Sea environment on its bolted systems and a new contract for joint encapsulation
across the platform was awarded for the use of Enviropeel.
PLANNING
The original specification called for 6087 flanges on 25 start date of February 2008, ending in August at the time
pipe systems throughout the platform. Following several of the departure of the accommodation platform.
weeks of planning, two survey trips were completed by
Enviropeel personnel using the platform design MOBILISATION
isometrics to identify and tag all flanges that were to be Although a first mobilization did take place in February,
protected. The initial plan was to mobilize a six-man accommodation and commissioning issues delayed the
team per rotation with three machines and an intended second trip and application only began in earnest in mid
June – reducing the time available from 7 months to less
than three.
The reduction in the time available forced a number
of operational changes on the project. Manpower was
increased from 6 per rotation to 8 per shift, with an extra
application unit and full utilization of all machines,
rather than having one or two on standby as originally
intended. Maximum manning was achieved in August
when up to 24 personnel and five application units were
on the platform to complete as many flanges as possible
before the accommodation platform departed.
As well as less time, an examination by the operators
of the schedules used to allocate suitable flanges and
systems determined that an increase in the workscope
was required, with an additional 831 joints to be
completed – a new total of 7123. Unfortunately,
isometrics of the new workscope didn't match those
originally supplied for the two tagging surveys. This, plus

Above left: typical signs of corrosion in bolted systems

on the new platform.
Below: Identifying the systems and joints was one of
the first challenges for the A&E teams - with separate
isometrics for each of 25 systems and a carnival of tags
on every level.

T H E R M O P L A S T I C S Y S T E M S
missing tags lost or removed in the months between the same time as a requirement to maintain strict quality
survey and start of the project, meant a significant control, it took a massive effort by the teams, supervisors
increase in workload surveying and maintaining and client to streamline the identification, recording and
accurate application data. application process, allowing the teams to begin
With pressure for increased joint numbers, at the increasing the numbers of joints completed. Although
equipment servicing issues (arising from the
unprecedented throughput of material), pressure testing
and other operational issues brought delays as the
platform systems went 'live', numbers steadily increased
until up to 200 joints a day became possible. The final

Left: two applicators work from either side of a large

flange joint.
Below left: applications on deck.
Below right: before and after application to a large
joint suffering from bolt corrosion.
Above: the application builds coats in succession, tally, as the team packed for the departure of the
working from underneath, around the sides and finally accommodation platform, was 6231, leaving about
above with two coats to provide maximum protection. 800 joints to be completed at a later date.
The underside is the most difficult are to finish
aesthetically but trimming between and after each CONCLUSION
coat ensures full protection. All trimmings and Overall, a very satisfactory result. Meeting the
drips/spills are collected and recycled. production targets in such a drastically reduced
timescale created challenges that could not be solved by
simply increasing manpower and equipment levels – no
easy task in itself with mobilization dates being put back
week after week. This was the first Enviropeel project to
operate with more than two machines, but tripling the
workforce and adding extra application units did not
have the same effect on the output; working practices
and logistics all had to be revised as the project
developed, to maximize productivity.
Early setbacks were overcome by the dedication of
supervisory and other staff, working with a client that
understood the extra pressures that had been created.
The final result was not just a higher number of joints
completed than the original workscope, but also a
greater understanding of what was required to meet
these new challenges.

Right and above: A review of the finished applications

shows the high standards maintained throughout the
project.
MINING INDUSTRY - WA T H E R M O P L A S T I C S Y S T E M S

Robil Engineering of Port Hedland in Australia is a company that works extensively

providing engineering services for the mining industry. They first came across Enviropeel in
a UK chartered publication. Following a visit to the Enviropeel UK head office, an initial
machine was purchased to provide an engineering solution to problems experienced with
corrosion on machined surfaces and also stored equipment.

Initial results on a variety of components and equipment were

extremely positive and, with the addition of two extra
machines, Robil set about revolutionising their approach to
component protection. In order to provide added value to
their refurbished assemblies, Robil undertook trials with the
protection of the bearing and seal systems on various sized
conveyor pulleys from BHP Billiton, coating around the
complete bearing housing and seal assemblies after rebuild.
The material was sprayed over the housings and seal areas,
up to and completely around the shaft. This doubled the
effectiveness of the barrier, providing corrosion protection
and an additional barrier against contamination ingress,
effectively an ‘extended labyrinth’, on to the shaft.
With proven success on stored equipment, the next logical
step was to trial the same system on operational machinery.

Left: Australia can be an extremely severe environment as the

condition of the illustrated equipment shows.
Below: At first the refurbished bearings were coated with
Enviropeel ready for storage.
 Left: Spraying Enviropeel on a pulley housing.
Above: An unprotected pulley housing - and a similar pulley after refurbishment.
Below: With the Enviropeel removed from a pulley housing after use, it is clear how
good the performance of the Enviropeel is. The roller in the background shows clear
evidence of corrosion whereas the protected pulley is as good as new.
Enviropeel bearing housing
protection has produced a huge
increase in bearing life.
Previously, bearings in this
location were lasting an average
of nine months before they
required urgent change out but,
in 2007, four years after the first
applications, no pulleys with
Enviropeel-coated housings had
shown any sign of failure. All of
the bearings that Robil have
trialed and tested in service so far
at both BHPB and Dampier Salt
were chosen from particularly
severe areas, with high spillage
in dirty and salty environments.

Conclusion
Enviropeel has proved itself in
many parts of the world and Results from BHP Billiton/Rio Tinto
under a wide variety of ON STORED CONVEYOR PULLEYS
conditions, but perhaps, it is in Average return rate for replacement on inspection
Australia where the adaptable prior to installation on pulleys without Enviropeel . . . . . . . . . . . . . 44.5%
nature of the system has shown Failure rate with full Enviropeel protection (improved
itself most clearly. It provides after early testing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0%
users with the ability to extend ON OPERATIONAL PULLEYS
component life, avoid expensive Average bearing life in original trial location . . . . . . . . . . . . . . . . 9 months
double handling, significantly Current bearing life in original location with
reduce maintenance as well as Enviropeel applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48+ months
down-time costs and Resulting component life increase . . . . . . . . . . . . . . . . . . . . . . . . 500+%
Resulting saving in pulley change out costs . . . . . . . . . . . . . . . . . 500+%
dramatically reduce the exposure
Reduction in maintenance costs . . . . . . . . . . . . . . . . . . . . . . . . . 95%
of people to risks associated with Percentage of Enviropeel costs to rebuild costs . . . . . . . . . . . . . . . 10-15%
working with this type of Percentage of Enviropeel costs to pulley
equipment. Enviropeel coating of change out costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7%
bearing housings has been Resulting percentage reduction in risk exposure . . . . . . . . . . . . . . Approaching 500%
Improvement in safety relating to pulley
adopted as standard practice by
change out operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approaching 500%
BHP Billiton and Rio Tinto in
Australia for their conveyor It is expected that the minimum component lifetime increase should be 500+%
systems.
POWER SUPPLY
INFRASTRUCTURE
A nation’s power supply infrastructure has to
be maintained to the highest possible
standards and Enviropeel was identified by
Siemens as being a far better way of
preventing water ingress than the system
they were using.
So, in 2011, Enviropeel started an intensive programme of
application on gas insulated switchgear and other power
transmission infrastructure.
In most cases, the substrates do not require corrosion protection
as they are constructed from a light alloy and use stainless steel bolts.
However, the substrates have to be extremely lightweight and
consequently can be vulnerable to damage resulting from water
ingress between joint surfaces. Enviropeel proved to be very
successful in trials and adoption across the UK is growing apace.
Needless to say, the Enviropeel application team had to undergo
considerable training to be able to work in such hazardous locations!

T H E R M O P L A S T I C S Y S T E M S

Pictured above and below: Applications at various UK

sites, including at a nuclear plant in yellow, specially
ordered for the site.
Mid right: an Enviropeel application engineer working from
a mobile platform
PROTECTING THE EDGES - HOW
MOISTURE INGRESS IS PREVENTED
USING ENVIROPEEL T H E R M O P L A S T I C S Y S T E M S

Typically, Enviropeel is applied to flanges either on

a horizontal pipe or a vertical pipe, the pipe would
be expected to have an intact protective coating as
in the example shown in Fig 1. Here we can see that
the flange edges and bolts are corroded but that
the main pipe coating is in good condition.

A standard Enviropeel application, as shown in Fig

2, encapsulates all the vulnerable areas and
continues the coating until a reasonable area of
intact coating has also been covered.

Fig 3: unpainted carbon

steel testpiece after 3000 Fig 1: typical substrate prior to use of Enviropeel
hr ASTM B117 hot salt Fig 2: typical Enviropeel application
fog test.

Slight ‘blending’ between unprotected and protected

areas can be seen after removal of encapsulation.

Although, on the unpainted steel test substrate in

Fig 3, a small margin can be detected where Fig 4: a mixed stainless and carbon steel joint
moisture meets the inhibitor, on a painted substrate with carbon steel bolts with Enviropeel
the effect is completely insignificant. All the encapsulation removed after more than 6 years
vulnerable areas are locked in a moisture-free,
inhibitor rich environment, away from any
potential ingress. The example in Fig 4, shows a
substrate which, without encapsulation, would
have bolts failing within 18 months because
carbon steel bolts in a stainless substrate suffer
badly from galvanic corrosion. As can be seen, no
corrosion has occurred within the encapsulation.

On a vertical pipe, there would seem to be more

potential for problems but the right application
techniques will prevent ingress even in the worst
possible circumstances. In long-term salt-water
deluge tests, shown overleaf, the ability of
Enviropeel to prevent corrosion in these areas is
clearly demonstrated.
ABRADED AREA
For the test, an uncoated carbon steel pipe and
flange test piece was placed in a stream of 20% salt
water. To emulate splash zone conditions, the flow
was turned on and off on a 12 hour cycle.

To ensure no protection of any kind was on the

substrate, a 15cm strip was abraded with an angle
grinder (to remove mill scale etc) along the whole CABLE TIE
length of the pipe.

The test was run over three months, following which

the Enviropeel was cut away to reveal the results.

Fig 5 above: substrate and Enviropeel encapsulation shortly

after the beginning of the trial. On potentially vulnerable
edges, cable ties provide extra security.

Fig 6 left: two weeks into the trial, the circular water
delivery system can be seen at the top of the photo.

Fig 8 below: intially, strips of Enviropeel are removed from

the substrate.

Fig 7 right:
substrate after
three months,
just prior to
removal of
Enviropeel
Fig 9 above: the removal of the mill scale is clearly visible

Fig 10 above right: following removal of all the Enviropeel

material from the joint, the level of protection is clearly
visible.

Figure 11 below: cutting through the sealing tie reveals a

sharp line between the protected and unprotected areas of
the substrate.

Because Enviropeel cools and contracts on to the

substrate, with a constant release of inhibiting oils,
moisture is prevented from entering the interface.
Where there is likely to be substantial or sustained
water pressure, extra material is applied and cable
ties are employed to provide extra security. Sealing
upper edges securely is particularly important as
these are the areas that are subject to rain and
water flows.

As this test shows, despite the high salinity and

constant flow of water, no corrosion or penetration
of any kind can be seen within the Enviropeel
encapsulation.
SAMPLE METHOD Two copies of this document must supplied to all
personnel prior to mobilisation, one to be retained, one

STATEMENT signed and returned to the local admin team

Method Statement for Encapsulating Joints at a Nuclear Electric Substation

Reference: A&E Ref: CA1423

Siemens Ref:

Produced By: Safety Officer Date: 18.07.11

Accepted By: Senior Manager Date: 18.07.11

Work Scope
This method statement covers the application of Enviropeel within Substation
Compound to all Gas Insulated (GIS) flange and hatch covers to prevent water ingress plus
procedures for joint encapsulation.

Exact Location

Substation Compound
All flanges

Access & Egress

Note: There must be no access/egress across site or any other route not agreed with the
SAP / Site Safety Manager / Engineer.

All operatives will have attended the Site Induction Training

All operatives will log their attendance on site by signing the site attendance register
located in the site office.

All personnel will have their certificates of competence and operator’s licenses checked and
copied before access into the compound is permitted.

All vehicle movements will be along approved, designated routes and supervised by the
site supervisor.

The flanges and covers will be accessed by a MEWP driven by an authorised operator. The
flanges immediately leaving the building will be accessed by Scaffolding. Great Care will
be taken when working on pressurised GIS equipment especially Small bore pipework.

Objective

To negate further degradation of substrate due to corrosion and prevent water ingress for
all designated areas.
In order to ensure good practice and minimise disruption:

1. Daily site reports to be kept and copies filed for Enviropeel records
2. All incidents (Enviropeel or others) must be reported in accordance with the appropriate
reporting chain. This reporting chain will be briefed to all Enviropeel personnel
prior to work commencing.
3. Plan ahead for site services and notify accordingly
4. Liaise with operator and other contractors to avoid work conflicts
5. Confirm equipment checks and certification are complete before commencing work

Pre-work documentation.

Prior to preparing a site for / carrying out Enviropeel operations an Enviropeel Pre
Operations Risk Assessment must be carried out by Project Manager / Project Supervisor to
identify and eliminate any unforeseen hazards during survey.
The Project Manager / Project Supervisor will carry out a “tool box talk” prior to the
commencement of working operations.

Preparation

Using wire brushes, remove loose material such as paint and rust particles and brush or
wipe down as necessary to remove and avoid contamination of Enviropeel material. All
debris to be collected in a suitable receptacle or by laying a tarpaulin or similar sheeting
under the application area and disposed of in accordance with site regulations.

Application Equipment

Enviropeel Application Unit CA30. All equipment to have pre-mobilisation safety check
prior to mobilisation and confirmed on site each day prior to work commencement.

Application procedure and specification:

Locate 415V power supply within vicinity and safety check any supplied extension cables.
Locate the application unit within the application radius of the supplied hoses (between 10
and 19 metres).
Set up safety signs and barriers.
Sheet off where necessary for weather protection.

1. Load the heating tank with the Enviropeel chips.

2. Switch on the unit and set the heating tank temperature control to 170°c.
3. Monitor the heating up phase until the ready light illuminates.
4. All flanges/joints, as identified in work pack , will be coated with E170 Grey to a
minimum thickness of 4mm; two coats will be required to attain this thickness
 5. By means of application through the spray gun, apply the first coat to the underside
of the joint then apply to the top section to complete first stage of the encapsulation.
6. Once coating of the substrate has been completed all excess material will be
trimmed and recycled for later use. Any heavily contaminated material to be
disposed of into hazardous waste bags and placed in the relevant skip.
7. Repeat the second coat in the same manner as the first coat.

Quality control

1. All applications must be two coats, with a minimum average DFT of 4mm. Coating
thickness to be checked using Elcometer 355 or similar dry film thickness gauge
with 5mm+ capacity.
2. Every application must be checked visually for any holidays (holes) in the coating
using inspection mirrors where necessary for inaccessible areas. If any are identified
the application must be removed, material recycled in the unit heating tank and the
application repeated.
3. All relevant data (joint number, material batch number, dates and operative) to be
recorded on daily work sheet report for quality control purposes.
4. Shift Supervisor is responsible for quality of all applications on his/her shift.
5. Random daily checks to be carried out by Project Supervisor on all work undertaken
6. All failed applications must be immediately removed and marked for reinstatement
7. Reasons for any application failures must be reviewed and addressed with retraining
if necessary

Health & Safety

Objective:

To ensure the safe working environment at site for other contractors and Enviropeel
personnel on site whilst the above stated work is carried out, also to minimise the
disruption to site personnel and other contractors.

Related documents

 Risk assessment – Enviropeel

 Work scope – Siemens
 Training certificates – Enviropeel
 Material MSDS and COSHH sheets – Enviropeel
 Application Machine certification – Enviropeel
Safety equipment

Standard Personal Protection Equipment (PPE) - hard hat, safety glasses, flame retardant
high visibility overalls, ear protectors (for use when required) and safety boots.

Extra PPE required for Enviropeel application – Eye and face protection – normally a full
face visor but a face mask may be used where access is restricted, Kevlar gloves when
using knives, heat and oil resistant gloves when operating application unit.

Safety considerations

 Ensure all work is executed in accordance with the SAP / Safety Managers
instructions.
 Erect safety barriers and signs. Observe existing ones
 Ensure all walkways are kept clear of tools and equipment. Protect hoses and cables
that cross the walkways.
 Make sure isolations are in place (see below)
 Adhere to safety distances when working near to adjacent live circuits
 Erect tarpaulins in windy conditions.
 Where it is unavoidable to have spray hose crossing walkways use walkway ramps
to negate any tripping hazard.
 Maintain a clean work area. Good housekeeping is high priority.
 Liaise with other work forces working nearby and plan accordingly to ensure a
smooth and safe work pattern is achieved.
 Take time after each break to assess any ch ange in conditions i.e. review the risk
assessment and log any new hazard or changes identified.

Isolation of Site equipment

To only be carried out by Siemens / NG employed Senior Authorised Persons.

Training requirements

 All Enviropeel operatives are approved for the application of Enviropeel

 Enviropeel personnel must attend a site induction
 All personal are required to have BESC, EUSR Persons and CCNSG Safety Passport.

E170 storage and MSDS docs

E170 is non-hazardous and will be stored in plastic buckets each containing 10 kg, which
in turn will be stored in a secure and dry location. All health and safety data sheets will be
available at all times.
Signing on Register
I, the undersigned, have read, discussed and fully understand the above method Statement
and Risk Assessment on encapsulating joints at the Nuclear Electric Compound and will
adhere to all its method of working and conditions set down.

PRINT NAME COMPANY SIGNATURE DATE

NOTE: - All personnel in the work party must read, agree and sign the above prior to
commencing the work.

If during the course of the work there are any changes to the method of work, the work
must stop and a new R.A.M.S. produced in line with the method / conditions of work.
 ENVIROPEEL E170
MATERIAL TYPE ENVIROPEEL Thermoplastic Corrosion-Inhibiting Barrier Coating
High-build, solvent-free strippable and re-usable thermoplastic
polymer, can be used in conjunction with Enviropeel Pre-treatment
Inhibitor.
RECOMMENDED USE For the anti-corrosion protection of steel and other metals,
especially flanges, pipework etc, transit protection of machinery
and components, long and short-term protection of stored
machinery and components. Speedy stripping and re-application
for inspection and maintenance on site.
ENDORSEMENTS ASTM B117 10,000 hr - hot salt fog compliant
APPLICATION TYPE Enviropeel Application Unit / Slugger 170 hand unit
COLOR Standard Grey - Any color on request
FLASH POINT Greater than 200°C/392°F
% SOLIDS 100%
V.O.C. No volatile organic compounds or other harmful by-products
TOXICITY Non Toxic & Non Hazardous
RECOMMENDED THICKNESS Minimum 4mm/160 mil (two coats)
PRACTICAL Continuous application at DFT of up to 4000 microns/160 mil per
APPLICATION RATES coat is achievable.
DRYING TIMES Touch dry - 1-2 minutes - handling time 15 minutes.
SPECIALISED Substrate temp down to -15°C/5°F without ice/frost/moisture. Apply
APPLICATION
CONDITIONS
in a continuous operation.
Humidity is not a factor as long as substrate remains dry
Low ambient temp (below 6°C/43°F) may require special measures
Max substrate temp 80°C/176°F.
RESISTANT TO UV and a wide range of aqueous solutions including sea water as
well as some chemical solutions.
PACKAGE DETAILS 10 Kg/22lbs plastic containers (re-usable).
SHELF LIFE Minimum 36 months in original container stored at 20°C/68°F
MELTING TEMPERATURE 120°C/248°F NB - Oil separation may occur during heating
- avoid by mixing regularly. Material levels in
APPLICATION TEMPERATURE 160-175°C/320-347°F tank should be kept at or near maximum
MAXIMUM TEMPERATURE during use to prevent degradation etc.
180°C/356°F
SURFACE PREPARATION Minimum surface preparation required - use wire brush to remove
loose flaking paint and rust particles.
Can be applied to existing rust. For substrates with heavy rust,
Enviropeel Pre-treatment Oil should be used to prevent undue
absorption of inhibitor from E170
EQUIPMENT CLEANING Although there is no need to remove or clean out equipment after
use, periodic cleaning to prevent build-up of residual solids is
recommended. Use Enviropeel Solvent-Free Equipment Cleaner.

AUSTRALIA: A&E Systems PTY Ltd +61 (0)8 94183688 : aus@ae-sys.com

EUROPE: A&E Systems Ltd +44 (0)1362 694915 : uk@ae-sys.com
MALAYSIA: A&E Systems Sdn Bhd +60 (0)3-5569 4277 : mal@ae-sys.com
USA: Enviropeel USA +1 985 373 9091, info@enviropeelusa.com www.ae-sys.com
SAFETY DATA SHEET:
ENVIROPEEL 170
1 IDENTIFICATION OF THE SUBSTANCE/PREPARATION

PRODUCT NAME: Enviropeel 170 PART NO. EP170

2 COMPOSITION/INFORMATION ON INGREDIENTS

INGREDIENT NAME: CAS NO. CONTENTS HEALTH (Class) RISK(R NO.)

Incorporated Inhibiting Oil
(Hydrotreated Heavy Naphthenic Distillate): 64742-52-5 5-10% Not Classified Not Classified

COMPOSITION COMMENTS: Base Oil <3% DMSO extract by IP346

3 HAZARDS IDENTIFICATION

Not regarded as a health hazard under current legislation.

4 FIRST AID MEASURES

GENERAL: As supplied the product does not present any hazard. However, when in use at elevated
temperatures any hazard will be from hot material in contact with the skin or the eyes. There
could be an inhalation hazard from concentrated vapours.

INHALATION: Provide rest, warmth and fresh air. Get medical attention if discomfort continues..

INGESTION: DO NO INDUCE VOMITING! NEVER MAKE AN UNCONSCIOUS PERSON VOMIT OR DRINK

FLUIDS! Drink plenty of water. Get medical attention. Provide rest, warmth and fresh air.

SKIN: Remove affected person from source of contamination. Remove contaminated clothing. Wash
the skin immediately with soap and water. Get medical attention promptly if symptoms occur
after washing.

EYES: Make sure to remove any contact lenses from the eyes before rinsing. Promptly wash eyes
with plenty of water while lifting the eye lids. Continue to rinse for at least 15 minutes and get
medical attention.

5 FIRE FIGHTING MEASURES

EXTINGUISHING MEDIA Use: Water spray, fog or mist. Alcohol resistant foam, Dry chemicals, Dolomite,
Carbon dioxide (CO2). Do not use water jet.

SPECIAL FIRE FIGHTING Cool containers exposed to flames with water until well after the
PROCEDURES: fire is out. Avoid breathing fire vapours.

HAZARDOUS DECOMP- Fire creates: Toxic gases/vapours/fumes. Carbon monoxide (CO).

OSITION PRODUCTS: Carbon Dioxide (CO2)

PROTECTIVE Wear self-contained breathing apparatus and appropriate protective clothing.

MEASURES IN FIRE:

6 ACCIDENTAL RELEASE MEASURES

ENVIRONMENTAL: Do not allow to enter public sewers and watercourses.

PRECAUTIONS

SPILL CLEANUP METHODS: Wear necessary protective equipment. Sweep up and place into METHODS:
appropriate sealed containers. Floors may become slippery.
7 HANDLING AND STORAGE

USAGE PRECAUTIONS: Avoid spilling, skin and eye contact. Provide good ventilation.

STORAGE PRECAUTIONS:Keep in cool, dry, ventilated storage and closed containers. Do not store above 40°C.

8 EXPOSURE CONTROLS AND PERSONAL PROTECTION

INGREDIENT NAME: CAS No. STD LT EXP (8hrs) ST EXP (15min)

3
INHIBITING OIL: 64742-52-5 OES 5mg/m (Oil Mist) 10mg/m3 (Oil Mist)

INGREDIENT COMMENTS: OES = Occupational Exposure Standard.

Exposure risk from Oil Mist not present when incorporated into
E170 base polymer as ingredient

PROTECTIVE EQUIPMENT:

VENTILATION: Provide adequate general and local exhaust ventilation.

RESPIRATORS: Respiratory protection not be required for material at ambient temperatures or for short-
term exposure to heated vapours in well-ventilated areas. When vapour or mist is
generated by heating or handling, use an organic vapour respirator with a dust and mist
filter. All respirators must be certified to NIOSH or equivalent standards.

PROTECTIVE GLOVES: Use protective gloves

EYE PROTECTION: Use approved safety goggles or face shield.

HYGIENIC WORK: DO NOT SMOKE IN WORK AREA! Promptly remove any clothing that becomes
contaminated. Wash promptly with soap and water if skin becomes contaminated.
Wash at the end of each work shift and before eating, smoking and using the toilet.
No eating or drinking while working with this material.

9 PHYSICAL AND CHEMICAL PROPERTIES

APPEARANCE: Solid COLOUR: Translucent/Grey/White/Red/Yellow/Blue

ODOUR/TASTE: Characteristic SOLUBILITY DESCRIPTION: Insoluble in water
MELTING POINT(°C) Initial @ 120 SPECIFIC GRAVITY (Water=1) 0.97
pH-value, CONC N/A FLASH POINT (°C) 200
AUTO IGN. TEMP. (°C) 225

10 STABILITY AND REACTIVITY

STABILITY N
: ormally stable.

11 TOXICOLOGICAL INFORMATION

INHALATION: Gas or vapour is harmful on prolonged exposure or in high concentrations.

INGESTION: May cause discomfort if swallowed.

SKIN: Prolonged contact with the skin may cause severe irritation.

EYE: Particles in the eyes may cause irriation and smarting.

12 ECOLOGICAL INFORMATION

MOBILITY: Absorbs to soil and is not mobile.

BIOACCUMULATION: Low potential for bioaccumulation.

DEGRADABILITY: Not readily bio-degradable.

WATER HAZARD CLASSIFICATION: WGK 2 (Company)

13 DISPOSAL CONSIDERATIONS

DISPOSAL METHODS: Dispose of in accordance with Local Authority requirements.

14 TRANSPORT INFORMATION

HAZARD CLASS (ADR) Not classified for Transportation.

15 REGULATORY INFORMATION

RISK PHRASES: Not classified SAFETY PHRASES: Not classified

16 OTHER INFORMATION

REVISION DATE: 10/08 Replaces all previous versions

All information is based on results gained from experience and tests and is believed to be accurate but is
given without acceptance of liability for loss or damage attributable to reliance thereon as conditions of use
lie outside our control. Users should always carry out sufficient tests to establish the suitability of any products
for their intended applications. No statements shall be incorporated in any contract unless expressly agreed in
writing nor construed as recommending the use of any product in conflict of any patent. All goods are sup-
plied subject to A&E Systems Ltd General Conditions of sale.

ALL INFORMATION IS GIVEN IN GOOD FAITH BUT WITHOUT WARRANTY

Protecting ALTA MAX, LLC.

Industry From Corrosion 246 Harbor Circle, New Orleans, LA. 70126
Distributor for
Alfred Baker
Cell: 225-287-3062 or Office: 504-948-8625
Email: al@altamax.net

Website: www.altamax.net

T H E R M O P L A S T I C S Y S T E M S

www.corrosion