ENVIROPEEL HOT SALT FOG TEST 10,000 HOURS REPORT ASTM B117 ... · ASTM B117 is a standardized test...

Enviropeel ASTM B117 10,000 hr test Copyright © 2018 Enviropeel Holdings, 1128 South West Street, Indianapolis, Indiana 46225, USA Tel: +1 317 631-9100 Email: [email protected]

ENVIROPEEL HOT SALT FOG TEST 10,000 HOURS REPORT

ASTM B117-11 10,000 hours Equivalent to 100 years in marine environment

JULY 2014

TABLE OF CONTENTS


1. EXECUTIVE SUMMARY

2. HOT SALT FOG TEST AND METHODOLOGY

3. SUBSTRATE PREPARATION AND SPECIFICATION

4. RESULT AND OBSERVATION (0-4500 HOURS)

5. CHRONOLOGICAL CORROSION PROCESS OBSERVATION ON CONTROL FLANGE

6. RESULT ANALYSIS AT 4500 HOURS

7. RESULTS ANALYSIS AT 7500 HOURS

8. RESULTS ANALYSIS AT 10000 HOURS

9. CONCLUSION APPENDIX

1. Salt Spray Cabinet Specification

2. Salt Specification


SUMMARY This document reports the findings of a long-term hot salt fog exposure test on Enviropeel corrosion-inhibiting sprayable thermoplastic (CIST), conducted by Enviropeel in-house technical department in accordance with ASTM B117 standards. ASTM B117 ASTM B117 is a standardized test for coatings on steel substrates using a controlled hot-salt mist environment. The test is designed to evaluate the long-term performance of protective coatings by subjecting samples to a super-enhanced corrosion-inducing environment over extended periods of time and is widely regarded as providing a consistent indication of long-term performance in the most severe ‘real-world’ conditions. A standard nickel-plated carbon-steel bolt would be specified at 1000 hours (42 days) of testing - with a life expectancy for the bolt of several years. For this CIST test, three samples were exposed, one for 4,500 hours, one for 7,500 hours and one for 10,000 hours - 416 days - nearly 14 months in total – far longer than most standard tests. ENVIROPEEL CIST Although CIST utilizes a radically different methodology to that of an ordinary passive coating, performance under standard ASTM B117 conditions is a reliable indicator of long-term performance under extreme conditions. CIST is a recyclable non-toxic zero-VOC thermoplastic developed to protect bolted systems such as flanges and valves. The material incorporates a continuously active corrosion-inhibitor and is spray applied as a two-layer coating. TESTING Test flanges were coated with one layer of epoxy zinc primer. Zinc-plated carbon steel bolts were used to join the flanges. All samples were placed in a controlled hot salt fog cabinet at 35oC for the specified period. All but one of the test flanges were coated according to standard procedures with CIST. The remaining flange without Enviropeel coating was also placed inside the cabinet as a control. Throughout the entire exposure period, the control flange became progressively more corroded with heavy pitting and surface corrosion. The unprotected caps of the sample flange pipe also showed severe corrosion. The Enviropeel CIST coated samples showed no sign of deterioration on bolts or surfaces within the CIST encapsulated areas.

Hot Salt Fog Test & Methodology The test was conducted in accordance with ASTM B117-11 ‘Standard Practice for Operating Salt Spray (Fog) Apparatus’. This is designed to provide a controlled corrosive environment for metal or coated metal samples. The Standard covers the apparatus, procedure and conditions required to create and maintain the salt spray environment. The salt spray test cabinet is shown in Figure 1.


Figure 1. Hot Salt Fog Spray Cabinet SALT SPRAY CABINET SPECIFICATION The test parameters for the Hot Salt Fog test are given in Table 1 below.

TEST PARAMETERS

Salinity, IN 5% Salinity, OUT 5%

pH Fog Collection Data

pH in 7.2 Fog Collector 1 2.0 ml/hr/80cm2

pH out 6.5 Fog Collector 2 1.8 ml/hr/80cm2

Temperature Pressure

Saturated Air Temp 47OC Chamber Pressure 1 bar

Chamber Temp 35OC Air Intake Pressure 0.9 MPa

Hygrometer Downtime

Wet Bulb 35OC From -

Dry Bulb 35OC To -

Total Hours


The flanges used in this test are specially made to have closed ends and are coated with one coat of epoxy zinc primer. The flanges were coated with Enviropeel using our standard method of application: two coats of Enviropeel. Figure 2 below shows the preparation of the substrate. Figure 2. Specially made flanges with closed ends, welded, blasted and primed for Enviropeel application

Enviropeel application and specifications are given in Figure 3. All components except bolts and nuts were single coated with primer.

Material: Mild Steel Size: 6”/4” Closed End - depending on available space Coating Spec: Flange - zinc-epoxy prime coat, fasteners - zinc-plated Enviropeel: 2 x layers E170 Test Nos: 6 x identical test pieces (2 for each test duration with different orientation) (Please refer to diagram below)

Figure 3. Enviropeel application specification

Sample welded to the neck with closed ends Blasted sample

Minimum coated single layer and prepared for Enviropeel

application


Results and Observations - Zero to 4,500 hours The following series of photographs show the process of deterioration on the control flange compared with the condition of the Enviropeel coated samples from 0 to 4500 hours

0 HOUR

217 HOURS

513 HOURS


1014 HOURS

2094 HOURS

2182 HOURS


2349 HOURS

2679 HOURS

2846 HOURS


3014 HOURS

3178 HOURS

3418 HOURS


3586 HOURS

3850 HOURS

4090 HOURS


CORROSION EVOLUTION OF THE CONTROL FLANGE 0-4500 HOURS

0 HOUR 217 HOURS 513 HOURS

1014 HOURS 2094 HOURS 2182 HOURS





4517 HOURS


After 4500 hours the control flange and one of the samples were taken out for analysis (the others were left in for continued testing). The following series of photographs show the sequence and observations as the Enviropeel coating is peeled away.

Hour meter reading: 4517 hours Arrangement of samples in Salt Spray Cabinet

Control flange was carefully taken out from the chamber

The flange was put on the stand for comparison

Side view of the Enviropeel coated sample Side view of the control flange. Note: Corrosion at the end cap. A single layer of primer is not able to protect

the weld joint.


Angle view of the Control Flange Angle view of the Enviropeel coated flange

Side by side comparison on stands Side by side comparison

Commencing cutting off Enviropeel coating from the substrate

Enviropeel coating was cut in section to reveal the substrate underneath


Side by side comparison on stands Enviropeel has been completely peeled off revealing substrate in perfect condition

Close up on the protected flange The bolt was opened to inspect the condition of the thread

The bolt was loosened by hand The thread shows no sign of corrosion


Side by side comparison: After 4500 hours with and without Enviropeel protection

Close up comparison

Comparison against the control flange


Conclusion at 4,500 hours After 4,500 hours of exposure the control flange has significantly deteriorated with high levels of corrosion whereas the Enviropeel coated sample is completely unaffected - preserved in its original condition. Bolt threads, nuts and all encapsulated surfaces are seen to be corrosion-free. The test has proven Enviropeel’s effectiveness in eliminating corrosion with the protected substrate showing no signs of deterioration and inhibitor levels in the Enviropeel after 4500 hours remaining satisfactory. Testing continues until 7500 hours and ultimately 10000 hours with the same configuration and some minor improvements.

Close up shot showing the condition of the bolts and nuts after severe exposure of salt environment for 4500 hours which equivalent to 45 years in real time.


Result Analysis at 7500 Hours

No sign of any corrosion in the E170 protected area Enviropeel E170 coating has been completely removed

Side-by-side comparison Peeling away the E170 coating reveals the substrate and bolts to be in pristine condition

The 7500 hour sample was taken out and placed on a stand for evaluation

Condition of the control flange after 7500 hours in the salt-spray cabinet


Bolts comparison: top - control flange, Bottom - 7500 hour sample & right - 4500 hour sample

Side-by-side comparison of the 7500 hour sample and the control flange

Side-by-side comparison: left - control flange, middle - 4500 hour sample & right - 7500 hour sample

Close-up shot of the bolt and nut A close up side-by-side comparison of the 7500 hour sample and the control flange

Comparison showing the underside of the flanges.


Conclusion at 7,500 hours Previously, after only 4,500 hours of exposure the control flange had already significantly deteriorated with high levels of corrosion, whereas the Enviropeel coated sample had remained completely unaffected – preserved in its original condition. Bolt threads, nuts and all encapsulated surfaces were completely corrosion-free, proving Enviropeel’s effectiveness in eliminating corrosion. The protected substrate showed no signs of deterioration and inhibitor levels in the Enviropeel after 4,500 hours remained satisfactory. After 7,500 hours, the control flange has suffered even greater deterioration, whereas both the 4,500 and 7,500 hour protected samples still showed no changes with the encapsulated substrates fully protected. There were no signs of discoloration in the E170 material and the level of inhibitors in the coating and on the substrates was satisfactory. The test will continue until 10,000 hours with the same configuration and some minor technical improvements.

CONTROL 4500 HRS

7500 HRS

EDGE OF

ENCAPSULATION

EDGE OF

ENCAPSULATION

The contrast between the control sample and the Enviropeel-protected samples is clear to see in the photo above.


Final conclusion at 10,000 hours In the last two stages of the test (4500 & 7500 hours), Enviropeel was found to have successfully eliminated corrosion despite the extreme conditions. The test was continued to 10,000 hours and the outcome was equally conclusive. Not only were the bolts and nuts preserved in their original condition, but the whole encapsulated area was in pristine condition without any traces of corrosion or water ingression. All three samples remained in exceptional condition. The test has not only proven Enviropeel’s effectiveness in eliminating corrosion but inhibitor levels in the Enviropeel, even after 10,000 hours remaining satisfactory, indicating continuing high levels of protection. The outer material was found to have hardened slightly from exposure to the test environment but remained acceptable without any significant discoloration. The control flange, however has suffered even greater deterioration providing further confirmation of Enviropeel’s powerful protective abilities.

4500 hrs 10000 hrs 7500 hrs Control


APPENDIX 1

HOT SALT FOG TEST CABINET SPECIFICATION MODEL: HD200

CAPACITY: 200 L


APPENDIX 2

SALT SPECIFICATION: SUPPLIER: MERCK GROUP

BRAND: EMSURE ORIGIN: GERMANY

ENVIROPEEL HOT SALT FOG TEST 10,000 HOURS REPORT ASTM B117 ... · ASTM B117 is a standardized test...

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