NACE 2 CHAPTERS 2-27 STUDY & TEST SET
Creavice Corrosion:
*Occurs on a metal surface that is shielded from full exposure to the environment because of the close proximity of another material that forms a narrow gap between them. *Common in situations where there is metal-to-metal contact.
ASTM D 3359 Method A:
.An X-Cut is made in the coating film. This method is used for coating films thicker than 127 um(5 mils)
Coating Survey Steps:
1. Get a clear Understanding of the scope(objective and goals). 2. Gather the team. 3. Develop a survey plan. 4. Review the standards that may be used for performing required tests. 5. Agree on format to present collected data. 6. Delegate tasks to team members. 7. Evaluate existing coating. 8. Gather additional information per the survey plan. 11. Summarize the data and ensure that the data is accurate, factual and corresponds to the the appropriate standards. 12. Prepare maintenance plans 13. Prepare reports and input data in a database. 14. Submit final survey reports.
Non-Ferrous Substrates Include:
1. Stainless steel 2. Nickel 3. Copper/Nickel alloys 4. Aluminum 5. Aluminum bronzes 6. Copper 7. Bronzes 8. Brass 9. Tin 10. Cadmium 11. Lead 12. Magnesium 13. Zinc
Maintenance Coating Inspection Checklist:
1. Take initial readings of the old coating after surface preparation. 2. Take readings of the surface after coating application in the same location as the first readings. 3. Subtract the initial thickness readings from the final readings to obtain an estimate of the thickness of the newly applied coating.
Steel exposed to high humidity and high levels of atmospheric pollution, such as in an industrial area at a sea coast site, corrodes _ to_ times faster than steel exposed in a rural area of high moisture and low pollution.
15 - 20
Elcometer 106 Scale 6 And Defelsko Positest AT are:
2 Examples of instruments that test adhesion on concrete.
Typical Plant Applied Or Mainline Coatings Include:
2 Layer PE 3 Layer PE Fusion Bonded Epoxy Tapes Coal Tar Enamel Asphalt Insulated Concrete
At or below what relative humidity does corrosion virtually cease:
40%
Corrosion Slows Greatly If the humidity is below__and virtually ceases below __.
40% - 50%
Gamma:
75% Zn 25% Fe
Delta:
90% Zn 10% Fe
Zeta:
94%Zn 6% Fe
Dual Powder:
A 2 layer fusion bonded coating. 2 distinct layers (green & brown or gray) can be seen.
Neoprene Rubber is:
A General-purpose rubber that is resistant to a wide range of chemical and physical conditions: lubricating oils Gasoline Sulfuric acid 50% @80 C(180 F) Strong hydrochloric and hydrofluoric acids at room temperature. Sodium hydroxide (50 to 70%) @93 to 110 C(200 to 230 F) acid slurries.
Who performs coating surveys:
A NACE O-CAT technician or NACE S-CAT technician. A certified NACE coating specialist. A NACE certified coating inspector-Level 3. A coating inspector qualified by field experience. A coating manufacturer's technical representative. A maintenance engineer with extensive knowledge of the plant or facility.
Mandatory Standard is:
A Standard that requires compliance because of a government statute or regulation, an organization internal policy or contractual requirement.
Stoning:
A carborundum brick or other appropriate abrasive block, is used to smooth the surface of the concrete.
Liquid Epoxy:
A coating that cures into a solid film.
Lining:
A coating that is normally used in immersion service.
Repair Patch:
A cross-linked polyolefin sheet coated with a heat-activated adhesive. Designed to seal and protect a damaged pipeline coating system.
Tooke Gage:
A destructive test instrument that is mainly used for measuring the dry film thickness of a coating on a nonmagnetic or nonferrous substrate. Used to measure total coating thickness and the thickness of individual layers of coatings in multi-coat films.
The Standards Engineering Society (SES) Describes A Standard As:
A document that applies collectively to codes, specifications, recommended practices, classifications, test methods and guides, which have been prepared by a standards developing organization or group and published in accordance with established procedures.
Change Control Is:
A formal process used to ensure that changes to any standard are introduced in a controlled and coordinated manner.
3 Layer Polyethylene (PE) Coating:
A green or Red layer of FBE is visible at the cutback area at the ends of the pipe. This FBE layer is applied directly on the steel as the primer in the 3 Layer PE system.
Durometer:
A measure of the hardness of polymers(i.e.Epoxy), Elastomers and rubbers.
WJ-1:
A metal surface after clean to substrate, when viewed without magnification, shall have a matte (dull mottled) finish and shall be free of all visible oil, grease, dirt, rust and Other corrosion products, previous coatings, mill scale and foreign matter.
WJ-2:
A metal surface after very Thourough Cleaning, when viewed without magnification, shall have a matte finish (dull mottled) finish and shall be free of all visible oil, grease, dirt, rust and Other corrosion products except for randomly dispersed stains of rust and Other corrosion products, tightly adherent thin coatings and other tightly adherent foreign matter. The staining or tightly adherent matter shall be limited to no more than 5% of each unit area of surface and may consist of randomly dispersed stains of rust and Other corrosion products or previous applied coatings, tightly adherent thin coatings and other tightly adherent foreign matter.
Coatings Condition Assessment Surveyor:
A person whose knowledge, experience and qualifications mean he is deemed capable to perform a coatings condition assessment.
Vulcanization:
A physicochemical (physical and chemical) change resulting from the cross-linking of the unsaturated hydrocarbon chain of natural rubber (polyisoprene) with sulfur, and the application of heat.
Concrete Cures By:
A process called hydration.
General Corrosion:
A relatively uniform loss of material over the entire surface.
Styrene is:
A solvent that may be harmful if inhaled.
Fluidized Bed Is:
A tank with a false bottom made of porous material. Air pressure is applied from below the porous false bottom to lift the powder above it and force it into suspension
Definition Of A Coating Survey:
A task performed in an organized, rational manner on assets(Bridge, Oil Rig, Chemical Plant, Refinery, Paper Mill etc.) that have been previously paint/coated to gather information on the performance of the installed protective coatings system.
At Pressures Of 140 MPa(20,000 psig):
A uniform matte finish is obtained that quickly turns to a golden hue unless an inhibitor is added or dehumidification is used. Black oxide, paint, elastomeric coatings,enamel, red oxide and polypropylene sheet lining are removed. Chemical contaminants will be removed, but with varying degrees of effectiveness.
At Pressures Of 234 To 248 MPa(34,000 to 36,000 psig):
A uniform matte finish is obtained that quickly turns to a golden hue unless an inhibitor is added or dehumidification is used. Surface materials, including most mill scale, are removed.
At Pressures Of 70 MPa(10,000 psig):
A uniform matte finish is obtained that quickly turns to a golden hue unless an inhibitor is added or dehumidification is used. The black oxide is removed but at a rate too slow to be considered practical.
Butyl Rubber is:
A very pliable and moldable material and generally used in fittings, etc. where sheet lining is not feasible. It vulcanizes easily.
Laitance:
A weak sandy surface, creating a fragile layer of sand and cement.
Standards To Test And Qualify Coatings Are Available From The Following Groups:
ASTM NACE ISO SSPC IMO PSPC
Use The Shore Durometer In Accordance With:
ASTM D 2240
Use the Pencil Hardness Test In Accordance with The Following Standards:
ASTM D 3363 ISO 15184
Tests For The Presence Of Moisture In Concrete Include:
ASTM D 4263: Standard test method for indicating moisture in concrete by the plastic sheet method. ASTM F 1869: Calcium chloride test. Electronic testing: Concrete moisture meter ASTM F 2170-02, Standard test method for determining relative humidity in concrete floor slabs using In "Situ Probes ".
Use The HATE Unit in accordance to:
ASTM D 4541 ISO 16276-1
Use The PATTI Unit In Accordance With:
ASTM D 4541 ISO 16276-1
List The Standards That May Be Used for Dry Film Measurement Of Coatings Over Concrete:
ASTM D6132-97: Standard test method for nondestructive measurement of dry film thickness of applied organic coatings over concrete using an ultrasonic gage. SSPC-PA 9: Measurement of dry coating thickness on cementitious substrates.
Standards that may be used for dry film measurement of coatings over concrete:
ASTM-D6132-97: Standard test method for nondestructive measurement of dry film thickness of applied organic coatings over concrete using an ultrasonic gage. SSPC-PA 9:Measurement of dry coating thickness on cementitious substrates.
Surface Preparation Is Generally Performed On Concrete By:
Abrasive blast cleaning Hand and power tool cleaning High-pressure Water-jetting or blasting Acid etching Stoning Centrifugal Blasting Scarifying
Efficiency of the centrifugal blast wheel(s) depends on several factors:
Abrasive operating mix. Size of the abrasive. Velocity of the abrasive coming off the wheel. Quality and direction of the thrown abrasive. Condition of the feed parts.
Alkyds:
Absorb oxygen from the surrounding atmosphere and uses the O2 molecule to react with the alkyd molecule in the process called oxidation.
Desiccants In Liquid Form Are Called:
Absorbent Desiccants
Cathodic Disbondment Tests Are:
Accelerated procedures to determine how easily a coating loosens from the substrate or develops holidays as a result of normal soil potentials and/or impressed current cathodic protection.
Temperature:
Accelerates the rate of corrosion.
Advantages Of Plural Component Airless Spray Over single Piston Airless Spray System:
Accurate mixing of materials without human element. Ability to spray very thick solvent free materials without thinner. Ability to spray materials with very short pot life.
Rubber Sheet Linings Are Vital In The Storage And Transportation Of:
Acids Certain Alkalis Food chemicals and food products. selected solvents Speciality chemicals and Other corrosive products. Plastic pellets Clay, etc.
Cracks Are Classified As Either:
Active - These are self-made expansion joints, and because they are subject to movement, must be handled like an expansion joint. Static - These do not move, and may be filled or covered without projecting through the top coat.
Sodium Chloride deposited on atmospherically exposed surfaces:
Acts as a hygroscopic material (extracts moisture from the air), which increases corrosivity in non-immersed areas.
National Standards Are:
Adopted by a national standards body (e.g.), American National Standards Institute, Standards Council of Canada and British Standards Institution and made available to the public.
Desiccants In Solid Form Are Called:
Adsorbent Desiccants
Wheel Blast Operations Make Use of a variety of blast media including:
Agricultural products. Synthetic products such as glass beads, aluminum oxide and slags.
Primary Reasons Surveys Are Performed:
Aid in planning future maintenance. Work prioritizing. Budgetary purposes. Aid in determining asset's value. Legal compliance.
The Three Main Types Of Antifouling Paints Are:
Albative Self Smoothing Foul Release
Examples Of Convertible Cured Coatings:
Alkyds Epoxy Coatings Polyester/Vinyl Ester Coatings Polyurethane Polyureas Silicone Coatings Inorganic Zinc
A Compound Microscope:
Allows both eyes to see the same image. The image is no different from that of a single monocular eyepiece microscope.
Bluetooth:
Allows remote monitoring and recording. Information can be downloaded for review on mobile devices.
Aluminizing:
Also referred to as aluminum diffusion alloying. A high temperature chemical process in which aluminum vapors diffuse into the surface of the substrate and forms a new metallurgical aluminide alloy.
Heavy Galvanizing:
Also referred to as batch, heavy duty or after fabrication galvanizing. Gives a complete coating of heavy zinc, both externally and internally, if required by the specification.
Light Galvanizing:
Also referred to as continuous, ILG(in-line galvanizing) or zinc electroplated. Application Process is different from the kettle hot dip process. Has a significantly lower level of protection in corrosive environments and often requires supplementary coatings for outdoor exposure.
Poured Concrete Can Be Affected By:
Ambient Conditions: Hot weather causes concrete to cure more rapidly than otherwise, resulting in a greater possibly for voids and a dusty, low strength surface. Applying a curing compound can help mitigate the effects of these conditions. Many entities require a wet burlap curing blanket to be used over freshly placed concrete to prevent this type of "drying out". Vibration: This is done to remove air pockets and can cause the heavy aggregate to sink to the bottom of the form. This results in a weak, Sandy surface, creating a fragile layer of sand and cement known as LAITANCE. This condition can occur both at the upper surface and at the concrete/form surface or interface.
Relative Humidity:
Amount of water vapor in a given volume of air Y 100% ÷ Maximum amount of water vapor ( if air is saturated) at the same temperature.
The Quantity Of The Abrasive Being thrown by the wheel is determined with:
An Ammeter
ASTM D 3359 Method A
An X-Cut is made in the coating film. This method is used for coating films thicker than 127 um(5 mils)
Low Amperage Readings On a centrifugal blasting machine could signify:
An abrasive-starved wheel. A flooded or choked wheel.
Galvanic Corrosion:
An electrochemical action of two dissimilar metals in the presence of an electrolyte and an electron conductive path, which occurs when dissimilar metals come in contact.
A Standard is:
An established norm or requirement that is put together by industry professionals. It is usually a formal document that establishes uniform engineering or technical criteria, methods, processes and practices.
Gas Liquid Chromatograph(GLC):
Analyzes the composition of an organic liquid when it's chemical composition is in doubt.
Sherardizing Process:
Applies a layer of zinc to the metal substrate by heating the object in an airtight container with zinc powder to 300-400 C(572-752 F).
Maintenance Coating Operations:
Applying a coating over a substrate that has been installed in it's final environment and has been placed in service.
Wetting Out:
Applying a paste primer over the surface to displace any remaining moisture and ensure proper adhesion.
Maintenance Coating Operations Are Defined as:
Applying coatings over a substrate that has been installed in it's final environment and has been placed in service.
Semi-hard Rubber Compounds:
Are Affected by temperature changes. Becomes very brittle at freezing temperatures. Are not suitable for some outdoor installations or where there are wide temperature changes.
Cold Applied Tapes:
Are a polyethylene adhesive tape used for corrosion protection on pipelines. It is a polyethylene film, heat laminated, with an adhesive layer of butyl glue.
Silicone Coatings:
Are applied over IOZ(Inorganic Zinc) or applied directly to steel. These materials require a two-step cure process. They react like any solvent-evaporation material, they hardened within a very short time. They don't reach a fully cured state or adhere properly until heated.
Thermosetting Polymers:
Are applied to items that are hard to coat or keep coating on.
People Who Display Steadiness Behavior:
Are extremely predictable and reliable. They are particularly comfortable cooperating with others in carrying out tasks.
Melt Stick:
Are heat activated adhesives supplied as rods for easy application.
Desiccants:
Are substances that naturally have a high affinity for water, so high that they draw moisture directly from the surrounding environment.
Tumbling Mills:
Are systems generally used for batch loads and cleaning parts.
Oven Data Loggers:
Are used in powder coating cure ovens, wet coating ovens, batch ovens and conveyor ovens. Used to measure and record oven temperature profiles.
Polyester/Vinyl Ester Coatings :
Are used in special situations when a chemical or abrasion resistant coating is required. A high degree of surface preparation is commonly specified.
Insulated Pipelines:
Are very easy to identify, because of the readily apparent insulation.
Common Problems Which May Be Noted During The Visual Inspections Of Hot-Dipped Galvanized Items:
Articles in contact Rough coatings Excess aluminum Dross protrusions Lumpiness and runs Uneven drainage Flux inclusions Ash inclusions Dull-Gray galvanized coating Rust stains Wet storage stains
Special Laboratory Test Instruments Include:
Atomic Absorption/Emission(AA/AE) Induction Coupled Plasma (ICP) Spectrophotometer Gas Liquid Chromatographs(GLC) Infrared Spectrophotometers (IR/ and FTIR, FTIR-ATR) Differential Scanning Calorimeters(DSC)
Specialized Test Or Equipment That May Be Encountered By The Coating Inspector, Particularly If Involved In the Investigation Of Coating Failures:
Atomic Absorption/Emission(AA/AE) And Induction Coupled Plasma(ICP) Spectrophotometers. Gas Liquid Chromatographs(GLC) Infrared Spectrophotometers(IR and FTIR and FTIR-ATR). Differential Scanning Calorimeters
A General Description Of Robotic Waterjetting Includes:
Attaches using vacuum, cables or magnets. Vertical, horizontal or overhead surface. Controlled by a single operator. Collects in excess of 95% Of the water, removed coatings and rust (waste generated).
Methods used to cure (vulcanize) rubber are:
Autoclave Internal Steam Cure Atmospheric steam cure (also called exhaust steam cure) Hot water cure chemical cure
Chlorinated Polyether Resins Are:
Available to apply as a powder for dispersion or solution coatings or as sheets for linings. Chlorinated Polyether lends itself readily to dry powder application either by sintering or by the fluidized-bed process.
Bituminous Coatings:
BOTH HOT MELT AND COLD APPLIED COATINGS ARE USED IN THE PIPE COATING INDUSTRY AND AT TIMES FOR INDUSTRIES AROUND THE WORLD. NORMALLY SHOP APPLIED.
Blast pre-cleaning:
Be sure all snow, ice and standing pools of water are removed from work pieces before blast cleaning. Likewise, ensure oil, grease and dirt are removed from the work piece before blasting to prevent contaminating the abrasive.
Several Generic Types Of Coatings May Be Used Over Concrete Including:
Bituminous cutbacks Chlorinated Rubber Vinyl Epoxy Novalac Epoxy Elastomeric polyurethane Sheet materials (e.g.,rubber) Glass-fiber-reinforced plastics Furan resins
ISO 8501-1, Sa 3
Blast-Cleaning to visually clean
Fumes From Bronze, zinc and copper alloys may cause a fever type reaction known as:
Brass Chills
NACE NO. 4/SSPC-SP 7
Brush off blast cleaning. Tightly Adherent mill scale, rust and coating may remain.
Powder Coatings Contain All The same components (except solvent) as liquid-applied coatings:
But it is delivered to the user in powder form instead of liquid. Resins, pigments, additives and the cure are blended together at the powder manufacturer's facility.
Some Various types of synthetic rubber are:
Butyl Rubber Neoprene Rubber Nitrile Rubber Chlorobutyl Rubber Hypalon Types
ASTM F 1869:
Calcium chloride test.
Warm Air:
Can contain or hold more moisture than cold air.
Silicone Coatings Inspection Criteria:
Carefully read the specification and product data sheet. Pay close attention to requirements to slowly and incrementally raise the heat the first time these materials are placed in service.
Epoxy Chalking:
Caused by UV exposure or other radiation.
Epoxy Sagging:
Caused by applying too thickly, over thinning or a too long pot life.
Epoxy Cracking:
Caused by applying too thickly.
Epoxy Pinholes:
Caused by applying too thinly.
The Cause Of Chalking In An Epoxy Coating:
Caused by exposure to UV(sunlight) or other radiation.
Epoxy Failure To cure:
Caused by improper mixing, including a too short induction time, or temperatures above or below the recommended maximum and minimum.
Epoxy Delamination:
Caused from exceeding the overcoat window, coating on a dirty surface or applying over amine blush.
Describe Two Of The Considerations With Regards To "Back Thrust ":
Causes fatigue. Should be no more than 1/3 of the operator's body weight:
Types Of fireproofing coatings:
Cementitious: Made of lightweight cement and can be applied several inches thick. Intumescent: A substance that swells or bubbles up as a result of heat exposure, thus increasing in volume and decreasing in density.
Centrifugal Blast Systems Are Composed Of The Following Elements:
Centrifugal abrasive throwing wheel The blast cabinet (or enclosure) In fixed systems, some type of material handling system Abrasive recycling system A dust collector and vent-pipe system Abrasives
Roto Lining:
Charge a pre-weighed amount of powder into a hollow mold, place the mold into a heated oven, then rotate the mold around two axes while heating the mold and the powder. When the interior metal surface is hotter than the melting point of the powder, the powder melts on contact with the metal.
Powder Coating Inspection Checklist:
Check and record: Ambient Conditions-Air and substrate temperatures, relative humidity and dew point. The dehumidification system-Ensure it performs properly and will "hold the blast ". Fabrication defects-Such as rough welds, skip welds, pits, crevices, particularly in hard-to-reach or even inaccessible areas. Soluble chemical salts. Surface Cleanliness. Surface profile meets specification. Residual abrasive dust.
Examples Of Non-Convertible Coatings:
Chlorinated Rubber Vinyl Coatings Acrylic Coatings Bituminous Coatings
Low-Pressure water cleaning (LP WC):
Cleaning performed at pressures below 34 MPa(5000 psig). Also called "power washing " or "pressure washing ".
High-pressure Water Cleaning (HP WC):
Cleaning performed at pressures of 34 to 70 MBa(5,000-10,000 psig).
Fluxing:
Cleans the steel of any oxidation developed after pickling, which creates a protective coating to prevent oxidation before the steel reaches the galvanizing kettle.
Disadvantages Of Electrostatic Spray Include:
Coating formulation is critical-must be designed for electrostatic spray. Not all coatings suitable for electrostatic spray application. Can only be used on metal or suitable conductive substrate. Usually only one coat of material can be applied due to insulating characteristics of the coatings after application. High voltage safety issues (shock). Equipment costs.
What Is A Polymerization Cured Coating:
Coatings that cure through a chemical reaction.
Gathering pipelines:
Collects raw gas from individual gas wells and moves it to the gas plants where it is processed.
Distribution pipelines:
Collects the gas from the transmission system so utility companies can distribute the gas to end users (i.e the Burner tip).
Custom-Designed Systems:
Come in a wide variety of semi-standard and special automated blast cleaning machines including spinner hanger, monorail, shot peening, straight and skewed roll conveyor, traveling work car and continuous tumbling mills.
NACE NO. 3/SSPC-SP 6:
Commercial Blast Cleaning. 33%
Maintenance Coating Selection Process Should Take The Following Into Consideration:
Compatible with the existing coating system. Condition of the existing coating. Limitations on surface preparation. Manufacturer's recommendation.
Petrolatum Wax Tapes:
Composed of a synthetic fiber filled with a petrolatum compound, fillers and anti-corrosion agents to protect against the corrosive environment of pipelines.
Protect nonferous metals from:
Concrete, cement and mortar, lime mortar and brickwork.
Maintenance Coating Pre-job Conference Topics Should Include:
Condition of the surface to be repaired Plant Shutdown Effect on plant personnel at the site Budget Constraints Use of in-house or contract labor Accessibility to the area Results desired by the owner
The Electrolyte:
Conducts ionic rather than electronic current.
Return Path (Metallic Pathway):
Connects the anode and the cathode and allows electrons generated at the anode to pass to the cathode.
Pitting Corrosion:
Corrosion does not develop uniformly, but primarily at distinct spots where deep pits result.
Disadvantages Of Plural Component Airless Spray Over single Piston Airless Spray System:
Cost is much higher than the cost of single Piston pump. Higher education requirement for the mechanic. High voltage electricity is required for the heaters. Applicator's job is more difficult with multiple hoses.
Wax Tapes:
Creates a solid barrier against water. Excellent strength, very good abrasion resistance as well as good resistance to acids, Alkalis, salts and bacteria.
Additional Benefits Of Dehumidification For Coating Contractors Include:
Crews can begin work earlier in the day and work later. Eliminates contamination of previously applied coatings by the blasting operation. Eliminates overlaps from one coated surface onto another (during daily blast-then-coat routine). All coating is done in ideal conditions. Extended over-coating intervals are avoided. Contractor can guarantee, with reasonable accuracy, the completion time. Extends the coating season by many months. Contractor can control ambient conditions despite weather and atmospheric changes.
Peel Test:
Cut a 1"wide strip in the cool sleeve and pull it from the pipe. Look for the mode of failure. COHESIVE FAILURE IN THE ADHESIVE = PASS ADHESIVE FAILURE TO THE SUBSTRATE = FAIL ADHESIVE FAILURE TO THE BACKING = PASS A destructive testing method mechanically separating a lap joint by peeling.
Round jets are:
Cutters
Inspection Criteria on Vinyl Coatings:
DFT Surface temperature The overcoat window
Acrylic Inspection Criteria:
DFT Surface temperature Wind speed The overcoat window
Inspection Criteria For Chlorinated Rubber Coatings:
DFT, Surface temperature and Overcoat window are all necessary inspection points.
USB:
Data transfers via a high speed data transfer cable to a computer, or in some cases, connects directly to a printer. Connect to a computer or printer via a high speed data transfer cable.
Describe Common Reasons That Wood Might Be Painted:
Decoration Protection sealing Stabilization Preservation Flame Retardance
Concrete May Be Coated For Several Reasons Including:
Decoration Waterproofing Enhancing chemical resistance Protection from freeze-thaw cycles Protection of reinforcing steel Decontamination Surface Sealer Protection against abrasion and erosion Color coding Protective purity of water or other products contained Improving and simplifying cleaning Skid resistance
Thick Film Polyurethane, Polyureas And Their Hybrids Failures:
Delamination: Delamination is caused by an improper specification. Failure To Cure: Generally caused by the failure of the equipment to heat or pump proper amounts of each material to the gun or caused by the gun failing to spray both sides in the proper ratio.
Silicone Coatings Failures:
Delamination: Generally due to an improper heat cure cycle.
Two-Component Thin Film Urethane Coatings Failures:
Delamination: Often due to application after the overcoat window. Color and Gloss Differences: These occur in finished film and are caused by using two or more different batches of material or from using two or more application techniques in adjoining areas. Changes in appearances are also seen if the DFT is uneven across the surface. Blushing: This can be caused by moisture on the surface during the cure. Failure To Cure: This can happen if thinner added during application contains any moisture.
Siloxanes failures:
Delamination: One coat may delaminate from the previous coat; this is caused by application over a non-compatible product. Cracking: This is usually caused by an improper formula and delamination.
During The Coating Operations, The Inspector May Be Required To:
Determine that the specified coating is used. Ensure that the coatings are stored as specified. Observe the mixing and thinning operations. Observe application operations. Monitor ambient conditions. Make a visual inspection of the coated surface after each coat has been applied to check for: Pinholes (detected either visually or with a holiday detector) Bare spots Runs Blisters
Elcometer 106 Scale 6:
Determines the bond strength of coatings applied to concrete surfaces and tests the tensile strength of hardened concrete on site.
Regional Standards Are:
Developed or adopted and promulgated by a regional organization, e.g., European Committee For Standardization (CEN) or Pan American Standards Commission (COPANT).
Consensus Standards Are:
Developed through the cooperation of all parties who have an interest in participating in the development and/or use of the standards
The Three Main Technologies For Charging The Coating:
Direct Charging: An electrode is immersed in the paint supply reservoir or in the paint supply conduit. Tribo Charging: This uses the friction of the fluid as it is forced through the barrel of the paint gun. Post Atomization Charging: The atomized fluid comes into contact with an electrostatic field downstream of the outlet nozzle.
NACE SP0178:
Discontinuity (holiday) testing of new protective coatings on conductive substrates.
NACE SP0188:
Discontinuity (holiday) testing of new protective coatings on conductive substrates.
Foul Release AF's:
Do not contain certain biocides and work on the principle of a nonstick surface.
Dehumidification Inspection Checklist:
Does equipment performance fit the requirements of the intended enclosure. Is the equipment installed by properly certified personnel. Is the enclosure sturdy enough to hold up to intended work activities, potential loads and possible inclement weather. Is the enclosure designed with minimal leakage to ensure the dehumidification system performs efficiently. Is there a backup system available? If not, is there a plan in case Dehumidification is interrupted.
Four Behavioral Styles (DISC Style Description):
Dominance Influence Steadiness Conscientiousness
Describe several benefits of dehumidification.
Dries the air. Lowers the dew point. Permits blasting the entire surface. Holds the blast with dry air. Helps in cleaning the surface. Holds the surface during coating application.
ASTM D 2240:
Durometer is a measure of the hardness of polymers(i.e. epoxy), elastomers and rubbers. "A" Scale is used for softer plastics and the "D" Scale is used for harder materials.
Advantages Of Coal Tar Enamel Pipeline Coating Include:
Ease of application A long life in some environments
Powders Are Applied By One Of The Following Methods:
Electrostatic spray Fluidized bed (dip method) Flame Spray Roto Lining
People Who Display Conscientiousness Behavior:
Emphasize working within existing circumstances to ensure quality and accuracy. Pay close attention to key directives and standards. Concentrate on details. Think analytically. Be diplomatic with people. Check for accuracy. Use subtle or indirect approaches to conflict. Analyze performance critically.
Alkyds Inspection Criteria:
Ensure WFT readings are taken frequently by the applicator. Confirm the applied material is cured before another coat is applied.
Before High-Voltage Porosity Testing (holiday detection) is carried out:
Ensure applied coats are cured. Thickness tested. Visual inspection complete and accepted. Make sure coating thickness is above 150 um(6 mils); coatings below this thickness should be tested with a low-Voltage (wet sponge) unit.
Epoxy Inspection Criteria:
Ensure mixing is done correctly, using the correct equipment, for sufficient time for the type of coating and for the size of the unit. Ensure the entire cure is poured from it's container into the base. Note the time the material is mixed and Mark each can with the time the mixer came out of it. Mark the container with the time it can be used. Monitor the environmental conditions, especially the Dew Point. Check the environmental conditions at least every 4 hours. Know the exact surface preparation required for each project. Ensure the applicator uses a WFT gauge and follows the DFT reading standard specified, as well as check DFT in hard to reach areas. Ensure the specified epoxy is used and applied following all the required steps and conditions for the material and the project.
Thermosetting Resins:
Epoxy Urethane Polyester Acrylic
Materials that can be used to repair FBE:
Epoxy FBE melt sticks Liquid Epoxy Repair Patches Heat Shrink sleeves
DFT Of The Coating On Concrete Can Be Measured By:
Estimated from the WFT. Estimated from quantity of coating used. Verified by a paint inspection gauge (Tooke Gauge). Determined by a modified gauge.
ASTM D 6677:
Evaluating adhesion by knife.
Causes Of Failures Of Acrylic Coatings:
Exceeding the recommend DFT. Applying the material in too hot and/or windy conditions.
Mastic Fillers:
Excellent adhesion capabilities. Non-shrinking. Remains flexible. Excellent water resistance.
Some Of The Properties Of Concrete Are:
Extremely durable Inorganic Hard Has good compressive strength Improves with age
Polyester/Vinyl Ester Coatings Failures:
Failure to cure.: Hardness testing may be required to determine if the proper cure is achieved before returning the surface to service. Blisters can form if surface is not totally oil and contaminant free. Wicking can be a problem if glass fiber is included in the coating mixture. Wicking causes underfilm corrosion, blistering and/or delamination.
Epoxy Failures:
Failure to cure: Caused by improper mixing including a too short induction time or temperatures above or below the recommended maximum and minimum. Cracking: Caused by applying too thickly. Pinholes: Caused by applying too thinly. Sagging: Caused by applying too thickly, over thinning or too long a pro-life. Delamination From Previous Coat: Caused from exceeding the overcoat window, coating on a dirty surface or applying over amine blush. Chalking: Caused by UV exposure or other radiation.
Solvent-Borne Inorganic Zinc Coatings Failures:
Failure to cure: Caused by overcoating too soon. Mud Cracking: Caused by an excessively thick application, typically over 125um(5 mils).
Water-Borne Inorganic Zinc Coatings Failures:
Failure to cure: Caused by overcoating too soon. Mud Cracking: This is caused by applying an excessively thick coating, typically over 125 um(5 mils).
Water-Borne Coatings Failures:
Failure to cure: Caused by the water evaporating too rapidly due to excessive heat on the surface or excessive air flow over the surface.
Acrylic Failures:
Failure to fully cure. Failure to adhere when used as a primer.
Advantages Of Electrostatic Spray Include:
Fairly complete coverage of odd shapes. Uses liquid or powder coatings. Efficient transfer of liquid coatings (minimal loss due to overspray). Very uniform film build.
Advantages Of Waterjetting And Wet Abrasive Blasting On Concrete Include:
Fast cutting of the surface. Washing dust away. Reducing abrasive and concrete particles in the air.
Standard Industry Terms For Reinforced Plastics Are:
Fiber Reinforced Lining (FRL) Glass Reinforced Plastic.(GRP) Fiberglass Reinforced Plastic (FRP)
Two Basic Types Of Plural Component Spray Equipment:
Fixed Adjustable ratio
The Different Methods Of Thermal Spray Application:
Flame Spraying Arc Spraying Plasma Spraying High-Velocity Oxyfuel
Bituminous Coatings Inspection Criteria:
Follow the inspection criteria for the particular product and the facility applying it. Pay close attention for holidays, especially on the bottom side and the areas where the application equipment has difficulty reaching
Normal Requirement For Surface Preparation For A lining:
For new surfaces cleaning in accordance to SA3/NACE 1/SSPC-SP 5 white metal blast cleaning. For maintenance work you may see the requirement for SA2/NACE 2/SSPC-SP 10 near white blast cleaning. Waterjetting is only used for lining work when a surface profile already exist. You may see a requirement to water wash or jet to remove soluble contaminants and then abrasive blast. You may find it necessary to abrasive blast a surface then wash it and blast it again, this could be repeated several times before an acceptable result is achieved.
Coating Thickness On Concrete Can Be Derived By:
From WFT readings. By calculations based on the quantity of coating applied to a given area. Sometimes by core sample. Electronic devices based on ultrasound are also used to determine the DFT of a coating on concrete. In some cases, a Tooke Gauge is specified to obtain an accurate spot determination of DFT. In this case, a repair procedure is usually specified as well.
Some Of The Most Common Hazards Associated With Specialized Application Are:
Fumes and dust inhalation. Electrical shocks. Burns. Falling objects. Explosions. Environmental contamination.
The Usual Galvanized Coating Consists Of Three Distinct Iron-Zinc Compounds:
Gamma(75% Zinc and 25% iron) Delta(90%Zinc and 10 % iron) Zeta(94% zinc and 6% iron) Eta(outer layer)(100% Zinc)[not considered a separate layer]
Two Broad Classifications Of Corrosion can be described as:
General Localized
Standards Developing Organization (SDO):
Generally refers to the thousands of industry or sector-based standards organizations which develop and publish industry specific standards.
Steps In The Process For Performing A Simple Coating Survey:
Get a clear understanding of the scope(objective and goals). Gather a team(If needed). Develop a survey plan. Review standards that may be used for performing required tests. Agree on a format to present collected data. Delegate various tasks to team members if necessary. Evaluate the existing coating(overall and by"paintable items) Gather additional information per the survey plan. Summarize the data and ensure the data is accurate, factual and corresponds to the appropriate standards. Prepare plans to perform the maintenance work required, based on the survey results(If required). Prepare reports and input data in a database. Submit final survey reports.
Soft Rubbers Have:
Good resistance to a number of corrosive chemicals . Excellent abrasion resistance. Good temperature resistance up to 140 F(60 c)
Nitrile Rubber:
Good resistance to aliphatic solvents such as kerosene, naptha, mineral spirits, etc., as well as animal, vegetable and mineral oils. It has relatively poor resistance to acids.
Describe The Proper Safe Accurate Operating Procedure for a low voltage holiday detector:
Ground cable is attached directly to substrate. Sponge saturated with a solution of tap water/wetting agent. Maximum rate of 30 cm/2(1 linear ft/s). Used on coatings up to 500 um(20 mils). May be used on concrete.
Solvent Evaporation Cure(non-Convertible) coatings:
Harden as the solvent evaporates.
Solvent-Evaporation Cure(non-Convertible) Coatings:
Hardened as the solvent evaporates.
Fusion Bonded Epoxy:
Has been one of the primary coatings used on pipelines for many years.
Chlorobutyl Rubber:
Has very low permeability and excellent chemical resistance.
Zinc Rich Epoxy:
Has zinc added to it. Supplied as either a two-component material with zinc already in the base or as a three-component material with the zinc to be added by the applicator at the time of mixing. Use this material only as a primer.
Heat-Shrink Sleeves:
Have a cross-linked polyethylene backing and a heat-activated adhesive.
Multi Table Machines:
Have a series of independent revolving work tables mounted on a rotating platform or "spider". The individual tables rotate as they move beneath the blast from the abrasive throwing wheel.
Humidity (wetness) and time of wetness:
Have a strong impact on initiating and accelerating corrosion rates.
Vinyl Coatings:
Have same issues as chlorinated rubber coatings. Vinyl Coatings are commonly used in water tanks and as interior linings in water pipes.
Polyethylene Polymers:
Have temperature resistance to 93 C(200 F). Good low temperature flexibility. Have excellent resistance to chemicals. They are resistant to creep. Have high impact resistance. Excellent tensile strength. High electrical resistivity. Are insoluble in organic solvents. Do not stress crack.
All Finely Divided Metal Particles:
Have the potential to ignite.
Pipeline Coatings Field Joints Include:
Heat Shrink sleeves Insulation half shells Field foam Liquid Epoxies Cold Applied Tapes Hot applied tapes FBE field joints Petrolatum (wax) tapes
Melt Sticks:
Heat activated adhesives supplied as rods. Should not be used on FBE field joints. Flexible Solvent free No mixing or measuring Quick setting Excellent moisture resistance
Reasons Coating Surveys performed:
Helps plan future maintenance. Easier prioritization of work. Budgetary concerns. Helps determine valve of assets. Legal compliance.
Practical Considerations For Abrasive Blast Cleaning Of Concrete Include:
Hold the blast nozzle somewhat farther from the work than when blast cleaning steel. Use pressures lower than those used on steel. Move the blast nozzle as rapidly as practicable, consistent with the specified surface profile. Avoid gouging the surface or exposing large areas of bare aggregate. Use a finer-size abrasive than is used on steel; coarse abrasives can remove too much concrete.
Destructive Tests For Heat-Shrink Sleeves Include:
Holiday detection (if the voltage set too high) Peel Test. A 25 mm(1") wide strip cut and pulled from the pipe.
ISO 1461:
Hot Dip Galvanized coatings on fabricated iron and steel assemblies specifications and test methods.
CAN/CSA G 164:
Hot Dip Galvanizing of irregularly shaped articles.
AS/NZS 4680-1999:
Hot Dip galvanized (Zinc) Coatings on fabricated ferrous articles.
A few safety issues the inspector should know when working around Hot Dip Galvanizing Are:
Hot-Dipped articles stay hot and to make sure the article is cool before touching it. Molten metal can splash out of the kettle and travel some distance. Nascent hydrogen may off in the air above the kettle.
Wheel Blast Shop Systems, Equipment And Applications Generally Differ Only In:
How work is conveyed through the blast. Type of abrasive used.
Elcometer 108:
Hydraulic Adhesion Tester (HATE) Unit.
WJ-1(visual cleanliness)Is comparable to which blast cleaning standard:
ISO SA 3
The Normal Standard For Surface Preparation Of New Surfaces For Linings is:
ISO Sa 3 or NACE NO.1/SSPC-SP 5
The Normal Standard For Surface Preparation For Maintenance Work is:
ISO Sa2 1/2 or NACE NO. 2/SSPC-SP 10
Curling May Occur:
If a maintenance coating to be applied is incompatible with the existing coating system.
Caustic Cleaning:
Immerses steel in a caustic solution to remove the dirt, oil and grease from it's surface.
Pickling:
Immerses the item in an acid tank, filled with either hydrochloric or sulfuric acid, to remove oxides and mill scale.
The two primary types of cathodic protection are:
Impressed Current. Galvanic (sacrificial).
Use The Positest AT:
In accordance with national standards and international standards including: ASTM D 4541/D 7234 ISO 4624/16276-1 AS/NZS 1580.408.5
Pollutants And Acid Gases:
In addition to the effect of a direct chemical attack, these materials reduce the electrical resistance of the electrolyte.
Some Of The Causes Of Failure With Rubber Linings May Be:
Incorrect product selected for the intended service. Using rubber after the shelf life has expired. Using rubber lining that was not properly stored. Rubber must be kept cool in storage because, with heat, it can vulcanize and roll. If this occurs, the material should be discarded. Incorrect application process.
Chemical Salts:
Increase the rate of corrosion by increasing the efficiency (conductivity) of the electrolyte.
Describe two ways to reduce the relative humidity of the boundary layer Of air:
Increase the surface temperature. Reduce moisture content by dehumidification.
Oxygen:
Increases the rate of corrosion.
Moisture Cured Urethane Inspection Criteria:
Inspection technique requires an extra careful watch on the relative humidity during the cure cycle.
Zinc Rich Epoxy Inspection:
Inspectors must know the proper mix ratio and ensure all of the zinc supplied in the kit is used. verify it is constantly agitated to keep the zinc in suspension.
Inspection Criteria For Zinc Rich Epoxy:
Inspectors must know the proper mix ratio. Ensure all the zinc supplied in the kit is used. Verify the pump is constantly agitated to keep the zinc in suspension. Ensure all mixing and application criteria in the specification are followed.
National Standards Body (NSB):
Is Generally used to refer to the one-per-county standardization organization, which is that country's member to ISO.
A PH Range Of 0.00 to 7.0:
Is acidic
A PH Range Of 7.0 to 14.0:
Is alkaline
Steel Grit:
Is best for etching, i.e., creating a surface profile prior to coating or plating or for cleaning hard alloys, brightening Non-Ferrous parts, mill rolls, heat treated parts or any application where a roughened grit blast surface is required or desired.
Hypalon:
Is chlorosulfonated polyethylene, but is regarded by industry as a form of synthetic rubber. The material is very resistant to weathering. It is resistant to oxygen, ozone, heat, flame, tear abrasion, oil and grease. Hypalon has gained wide recognition in handling chronic acid (10%), hydrogen peroxide (30%)and sulfuric (50 to75%). It is resistant to temperatures to 93 C(200 F).
Feathering:
Is performed at the repaired area by working the edges of the repaired area back to achieve a fairly smooth transition from the repair area to the sound coating.
Moisture Cured Urethane Failures:
Is prone to failure to cure if used in areas of low humidity. Moisture-Cured Urethane will blister and delaminate if applied to surfaces not cleaned in accordance with the specification.
Attenuated Total Reflection Infrared(ATR-IR) Spectroscopy:
Is used to analyse the surface of materials.
Chemical Cure:
Is vulcanization at ambient temperatures. A liquid vulcanizing agent is topically applied to the surface of the rubber. Use supplemental heat to reduce cure time. Cure takes place from the rubber surface downward. This cure method produces less adhesion than other methods.
Robotic Waterjetting:
It Is A vehicle that attaches itself, using vacuum, cables or magnets to a vertical, horizontal or overhead surface. It is controlled by a single operator.
Coating Survey:
It is done to gather information on the performance of the previously coated protective coatings system in an organized, rational manner on assets such as bridges, offshore platforms, chemical plants, refineries, paper mills, etc.
NACE NO. 6/SSPC-SP 13:
Joint surface preparation standard for surface preparation of concrete.
Fireproofing Has Two Basic Functions:
Keep fire away from living or working spaces. Protect a building or facilitie's structure from the extreme heat fires generate.
Describe The Difference Between Laitance And Efflorecence:
LAITANCE is a weak surface layer of water-rich cement mixture on the surface of the fresh concrete caused by the upward movement of the water. EFFLORECENCE is caused by moisture passing through the concrete and carrying soluble concrete salts with it to the surface. The salts react with carbon dioxide in the atmosphere creating a fluffy white crystalline deposit on the surface.
ISO 8501-1, Sa 1:
Light Blast Cleaning
Bitminous Coatings Failures:
Long periods of sunlight exposure cause embrittlement, cracking and delamination. Holidays are the most common problem when they are shop-applied.
Liquid Epoxy Coatings:
Look like FBE. They are identifiable by their distinct colors usually light blue, green or gray.
At Pressures Lower Than 70 MPa(10,000 psig):
Loose rust, debris and material in depressions and pits are removed, but the black iron oxide Fe304 (magnetite) remains. A matte finish not achieved.
Flame Spray:
Low air pressures blow thermoplastic powder particles through a high temperature, open flame torch similar to an oxyacetylene blowtorch. Simultaneously, particles melt and the coating surface is heated.
When Using Solvent Borne Inorganic Zinc, What Would Be One Common Reason For A Failure To cure:
Low humidity. These coatings cure by solvent evaporation and chemical reaction by absorption of moisture from the surrounding atmosphere
Materials Requirements:
MRs
Measure The Coatings Thickness Of Hot Dipped Galvanized Items With One Of Four Methods:
Magnetic thickness gauge (Magnetic DFT gauge). Stripping Weighing(before and after galvanizing process) Optical Microscopy
Moisture Cured Urethane:
Materials are used in areas of high humidity where other materials generally cannot be used. Are frequently single package materials but must be applied in strict accordance with the owner's and manufacturer's requirements.
Liquid Epoxy Coating:
May be applied using a plural component pump. They are base and cure mixed at the spray nozzle, resulting in a film coating from 10 mils up to 60 mils. Temperature rating 80 C(176 F) to 150 C(330 F)
Steel Shot:
May be the best blast cleaning, peening or de-scaling abrasive available.
Eddy-current instruments are used for:
Measure Dry Film Thickness of non-conductive films applied over conductive substrates.
ASTM D 4138:
Measurement of dry film thickness of protective coating systems by destructive means.
Defelsko Positest AT:
Measures the force required to pull a specified test diameter of coating away from it's substrate using hydraulic pressure.
Three Methods To Apply Polyethylene In Current Use Are:
Melt the resin then extrude it onto the article to be coated. Flame Spray the polyethylene directly onto a metal surface. This method requires special equipment and operator expertise. Heat the object to be coated to a temperature above the melting point of the polyethylene then immerse the object in a fluidized bed of powder. Flame Spray the polyethylene directly onto a metal surface. This method requires special equipment and operator expertise.
Sherardizing:
Method of galvanizing also referred to as vapor galvanizing.
-0.85 V:
Minimum requirement for cathodic protection.
Additional Inspection Concerns For Waterjetting Includes:
Monitor the clean up of the Waterjetting area. Ensure that the water run-off from jetting operations is collected, treated and/or disposed of according to applicable regulations. Document carefully (with photographs, if necessary) each phase of the Waterjetting.
Some Of The inspection concerns during centrifugal blasting include:
Monitor the dust collector. Monitor the amperage of the wheel motors/Low amperage. Monitor the handling and loading of the conveyor line for contaminates/possible discontinuities in the steel. Monitor the speed of the line. Inspect the steel as it leaves the production line.
When planning enclosures, the following minimum requirements should be considered:
Must be large enough to contain the whole area. Not larger than the performance capabilities of the dehumidification equipment. Be sturdy enough to hold up to intended work activities, potential loads and possible inclement weather. Have minimal leakage to maintain proper environmental conditions and ensure the dehumidification system operates efficiently.
Surface Preparation For Thermal Spraying Generally Requires A Minimum:
NACE NO. 1/SSPC-SP 5 or ISO Sa 3 With an angular profile.
Individuals Who May Be Qualified To Perform Coating Surveys:
NACE-CERTIFIED Offshore Corrosion/Coating Assessment Technician(O-CAT). NACE-CERTIFIED Shipboard Corrosion/Coating Assessment Technician (S-CAT). Certified NACE coating specialist. NACE-CERTIFIED Coating Inspector-Level 3 Coating manufacturer technical representative with adequate field experience. Maintenance Engineer with extensive knowledge of the plant or facility.
Explain The Difference Between:
National Standards Body (NSB): Used to refer to the one-per-county standardization organization which is that country's membership to the International Organization For Standardization(ISO) Standards Developing Organization: Refers to the thousands of industry or sector-based standards organizations that develop and publish industry standards.
Two Major Classes Of Rubber:
Natural: Derived from latex obtained from Hevea trees and is coagulated with acetic or formic acid. Unsaturated hydrocarbon known as polyisoprene. Synthetic: Any one of a group of manmade elastomers with one or more of the properties of natural rubber.
NACE NO. 2/SSPC-SP 10:
Near White Metal Blast Cleaning. When viewed without magnification the surface shall be free from visible oil, grease, dust, dirt, mill scale rust, coating, oxides, corrosion products and Other foreign matter. Random staining shall be limited to no more than 5% of each unit area of surface and may consist of lightshadows, slight streaks or minor discolorations caused by stains of rust, stains of mill scale or stains of previously applied coatings.
Anions:
Negatively charged ions.
Degrees Of Flash Rust:
No flash rust: A carbon steel surface that, when viewed without magnification exhibits no visible flash rust. Light flash rusted surface: A carbon steel surface that, when viewed without magnification, exhibits small quantities of a rust layer though which the carbon steel substrate may be observed. The rust or discoloration may be evenly distributed or present in patches, but it is tightly adherent and not easily removed by lightly wiping with a cloth. Moderate flash rusted surface: A carbon steel surface that, when viewed without magnification, exhibits a layer of rust that obscures the original carbon steel surface. The rust layer must be evenly distributed or present in patches, but it is reasonably well adherent and leaves light marks on a cloth that is lightly wiped over the surface. Heavy flash rusted surface: A carbon steel surface that, when viewed without magnification, exhibits a layer of heavy rust that hides original carbon steel surface completely. The rust may be evenly distributed or present in patches, but it is loosely adherent, easily comes off and leaves significant marks on the cloth that is lightly wiped over the surface.
Repair Patches:
No special tools or equipment required. Excellent abrasion resistance. Inert to common acids, Alkalis and solvents.
Two Categories Of Curing And Their Definitions:
Non-Convertible: no chemical change during the cure cycle. Convertible: Some chemical change during the cure cycle.
Wind speed monitor common operator errors include:
Not facing into the wind. Not holding the instrument away from the body.
Safety Rules Applicable To Thermal Spray Are In:
OSHA standard subpart Q_welding, cutting and brazing of CFR 1910.
Localized Corrosion:
Occurs at discrete sites on the metal surface and often occurs in areas that are difficult to inspect. Frequently causes the need for unplanned maintenance.
Swing-table blast cleaning equipment:
Offers a high degree of work handling flexibility and can accommodate very large and heavy work pieces of up to 9000 kg.(10 tons). The work table rotates under the blast of one or more abrasive throwing wheels and swings out with the door as the door is opened.
PIG:
Often called the Tooke Gage.
The Three Main products that are transported through pipelines are:
Oil Gas Water
Plural Component Spray Equipment Have Two Types Of Feed Mechanisms:
One type that blends the components in a manifold and mixes them in an inline static mixer. One type that mixes the components at the spray gun tip.
Describe The Following Factors And how they affect corrosion:
Oxygen: Oxygen increases the rate of corrosion. Temperature: Corrosion usually accelerated with increasing temperature. Chemical Salts: Increases the rate of corrosion by increasing the efficiency of the electrolyte. Humidity (or wetness): The wetter the environment, the more corrosion is likely to occur. Pollutants and Acid Gases: Acid rain, chemical byproducts and chlorides all promote corrosion.
ASTM STP 500:
Painting Test Manual
Fireproof Coatings Fall Into Two categories:
Passive: They protect based on insulating the surface from the heat of the fire. Intumescent: They build a thicker film when exposed to fire, thus insulating the surface.
Water-Borne Inorganic Zinc Coatings Inspection Criteria:
Pay close attention to the curing cycle of these materials. Inspector must ensure they are fully cured prior to overcoating or packaging.
Solvent-Borne Inorganic Zinc Coatings Inspection Criteria:
Pay close attention to the curing cycle of these materials. The inspector must ensure they are fully cured prior to overcoating or packaging.
Three Factors Affect The Properties Of The Vulcanizate (vulcanized product):
Percentage of sulfur and accelerator used. Temperature of the curing process. Time of cure.
Polyester/Vinyl Ester Coatings Inspection Criteria:
Perform all of the standard tests for these products and possibly a hardness test if required.
Centrifugal Blasting Conveyor Systems Are Commonly Used For Cleaning Of:
Plate Rolled structural Shapes Large Trusses Girders
PATTI Unit:
Pneumatic Adhesion Tensile Testing Instrument
Some Common Resins Used In Reinforced Linings Include:
Polyester Epoxy Vinyl Ester
Thermoplastics:
Polymeric sheet materials made of polyethylene (PE),polyvinyl chloride (PVC), polypropylene (PP)and fluoridated plastics such as the brand name Teflon.
Thermoplastic materials:
Polyvinyl Chloride (PVC) Polypropylene Kynar Halar polyethylene Teflon
Polymeric sheet materials include:
Polyvinyl chloride (PVC) Polyethylene Polypropylene KYNAR(PVDF) HALAR(ETCFE) TEFLON (FEP and PTFE)
Caitons:
Positively charged ions.
Inspection Checklist:
Pre-job conference. On-site pre-job inspection. Obtain specifications and data sheets. Read, understand, discuss and compare. Pre-inspect equipment for obvious excessive wear (excessive wear creates a dust hazard as well as improper blast). Check materials for proper shot/grit mix according to the specification. Calibrate equipment daily before use. Monitor ambient conditions. Perform visual inspection of the blasting/coating operation and Machinery. Perform required tests on blasting/painting operations. Record all the functions performed. Report to the client as required.
Tape Coating application:
Preheat pipe to the specified temperature. Abrasive blast clean the surface to a NACE NO 3/SSPC-SP 6(commercial blast). Heat the pipe after blast cleaning to the required temperature. Apply the primer to the substrate. Begin application of the spiral wrap tape. Stencil (size, length, storage, pre-positioning). Cut back the coating; The standard is 15.2cm(6") or less, or remove protective end covering.
Surface Preparation For Liquid Epoxies:
Preheat the pipe to the specified temperature,if required. Grit or shot blast the area to NACE NO. 3/SSPC-SP 10(near white). Cut back the coating; The standard is 3" or less or remove protective end caps.
FBE Application Process Includes:
Preheat the pipe to the specified temperature. Grit or shot blast the area to NACE NO. 2/SSPC-SP 10(near white blast). OPTIONAL: Pre-Treat the area with an acid bath. Heat the pipe to the specified temperature before applying FBE. Apply the FBE Coating (single layer FBE or dual powder). FBE is applied in powdered form by electrostatic spray. Cure the FBE Coating. Quench the coating in a fresh water bath. Stencil (to track and position in line).
ASTM D 1730:
Preparation of aluminum and aluminum alloy surfaces for painting
ASTM D 1731:
Preparation of hot dip aluminum for painting.
ASTM D 1732:
Preparation of magnesium surfaces for painting.
Application Process for Coal Tar Enamel Includes:
Prime the pipe. Apply the coal tar dope. Wrap the application with a glass fiber mat. Apply a second layer of CTE dope. Wrap the application with a second layer of glass fiber mat. Apply an outer wrap of coal-tar impregnated glass fiber felt. Cool the application.
A Well Balanced operating mix (working mix) of various sizes will:
Provide consistency of the finish on work being cleaned. Ensure uniform abrasive coverage of the work. Ensure conditioning of the abrasive for optimum cleaning. Minimize lowest abrasive and machine part-wear and reduce downtime for maintenance.
Rubber Linings Are Used Most Commonly in:
Railroad tanks cars. Truck Tanks. Barge Tanks Membrane behind an acid brick lining system.
Impressed Current Power Sources Include:
Rectified commercial power Solar cells Generators Fuel cells Wind power cells Thermoelectric cells
While Oxidation Occurs At The Anode:
Reduction occurs at the cathode.
Name Some Of The Post Treatments That May Be Performed And Why:
Reduction of coating thickness by reducing the amount of molten metal adhering to the article as it leaves the bath. This may be done by rolling, wiping, centrifuging or air blasting. These operations must be done while the coating is still molten. Improvements of the properties of the appearance of the coating may be accomplished by such treatments as chromating, phosphating, light rolling and roller leveling. Change in the properties of the coating. Hot-Dipped zinc coatings are sometimes annealed to convert the whole of the coating into an alloy. Aluminum coatings intended for heat resistance may be converted into an alloy in the same way. Aluminum can be anodized and dyed attractive colors.
Types of dehumidification equipment include:
Refrigeration and Desiccant
Thermosets:
Reinforced Plastic materials (FRP) are polyester, vinyl ester, epoxy and novalac epoxy resins applied as part of a system applied in conjunction with woven and non-woven reinforcement materials such as glass, Kevlar and nylon materials.
Electronic Hygrometers Can Be Used To Determine:
Relative Humidity Air Temperature Dew-point Temperature
Dehumidification:
Removes moisture vapor from the air to lower the dew point.
Methods For Checking Surface Profile:
Replica Putty
Acrylic Coatings:
Resins are commonly blended with other resins because of their excellent resistance to UV degradation. Additionally, they are used as the main or singular resin, in Water-Borne Coatings with very low VOC.
Cutting Tip 2X:
Resolution of reticle 25 microns/1 mil.
Cutting Tip 10X:
Resolution of reticle 5 microns/.2 mils.
1X Cutting Tip:
Resolution of reticle 50 microns/2 mils.
Standard Practices:
SPs
Benefits Of Cold Applied Tape:
Safe to apply. Environmentally clean. Very good insulation characteristics. Good anti-corrosion barrier. Good mechanical strength Low water absorbsion rate. Long service life. Easy to apply.
Fan Jets Are:
Scrapers and/or pushers
Sacking:
Scrubbing a mixture of cement mortar over the concrete surface using a cement sack, gunny sack or sponge rubber float.
People Who Display Influence Behavior:
Shape the environment by bringing others into the alliance through persuasion.
People Who Display Dominance Behavior:
Shape the environment by overcoming opposition to accomplish results.
Portable Centrifugal Blasting Systems Can Be Used On:
Ship Decks, hull sides and bottoms. Storage Tanks Concrete Floors Highways and Bridge Decks
High-pressure hoses, hose connections and all other equipment, including the nozzle control valve, lance and nozzle:
Should have a minimum burst strength of 2 1/2 Times the capacity of it's maximum-rated operating strength.
Polyethylene (PE) Can Be Extruded by:
Side extrusion for large diameter pipe. Crosshead extrusion
60% Humidity:
Significantly decreases iron's corrosion rate.
Chlorinated Rubber Coatings:
Single package coatings. Were once commonly used in both the chemical processing industry and the marine industry because of their excellent petro chemical, water and UV resistance.
The Binder In An Albative AF:
Slowly dissolves in seawater, so it constantly presents a fresh layer of copper on the surface.
Finish requirements for galvanized coating include:
Smooth, continuous, lustrous, free of gross imperfections: Cracking Peeling Bare spots Lumps Blisters Flux Ash or Dross inclusions.
The Three Categories Of Natural Rubber Are:
Soft Semi-hard Hard
IR:
Some models print information directly to a portable infrared printer. Print information immediately via a portable infrared printer (IR).
Service environments with permeation Issues and Some Situations In which Permeation May Occur Include:
Sour crude storage tanks. Cooling Towers Fertilizer Plants
NACE NO. 12/AWS C2.23M/SSPC-2300:
Specification for application of thermal spray coatings.
With Regards To Maintenance Coatings All Parties Should Agree On:
Spot repair requirements. Feathering Appearance of repaired area
Special Substrates That Have Tightly Adherent Oxide Films Include:
Stainless steel Nickel Tin Cadmium
Data Logger:
Stand alone instruments that automatically measure and store environmental data.
ASTM D 4262:
Standard method for testing pH of chemically cleaned or etched concrete surfaces.
ASTM D 4259:
Standard practice for abrading concrete.
ASTM D 4260:
Standard practice for acid etching concrete.
ASTM D 5064:
Standard practice for conducting a patch test to assess coating compatibility.
ASTM D 4787:
Standard practice for continuity verification of liquid or sheet linings applied to concrete substrates.
ASTM E 376:
Standard practice for measuring coating thickness by magnetic-field or eddy-current examination methods.
ASTM D 6386:
Standard practice for preparation of coated iron and steel products and hardware surfaces for paint.
ASTM A 780:
Standard practice for repair of damaged and uncoated areas of hot-dip galvanized coatings and touch-up procedures for coating bare spots on an existing hot-dip galvanized product.
ASTM D 4258:
Standard practice for surface cleaning concrete for coating.
ASTM D 4261:
Standard practice for surface cleaning concrete unit masonry for coating.
Name And Define The Three NACE Standards Classifications:
Standard practice(SP) Test Method (TM) Materials Requirement(MR)
ASTM A 123A/123M:
Standard specification for Zinc Coatings on iron and steel products.
ASTM A 153A/153M:
Standard specification for Zinc coating on iron and hardware, fasteners and small products that are centrifuged after galvanizing to remove excess zinc.
ASTM A 767A/767M:
Standard specification for Zinc-coated steel bars for concrete reinforcing steel or rebar.
ASTM B 6:
Standard specification for Zinc.
ASTM F2107-02:
Standard test method for determining relative humidity in concrete floor slabs using In Situ Probes.
ASTM F 2170-02:
Standard test method for determining relative humidity in concrete slabs using In Situ Probes.
ASTM D 2583:
Standard test method for indentation hardness of rigid plastics by means of a Barcol Impressor.
ASTM D 4263:
Standard test method for indicating moisture in concrete by the plastic sheet method. A segment of a 1 mm(4 mils) thick, clear polyethylene sheet approximately 457 x 457 mm (18"x 18") is taped over the concrete to be tested so that the concrete is tightly sealed from the atmosphere and sunlight. The patch is allowed to remain a minimum of 16 hours.
ASTM D 3359:
Standard test method for measuring adhesion by tape test. Adhesion by tape pull off test (Methods A&B).
ASTM D 6132-10:
Standard test method for nondestructive measurement of dry film thickness of applied organic coatings over concrete using an ultrasonic gage.
ASTM D 4541:
Standard test method for pull-off strength of coatings using portable adhesion testers.
ASTM D 7682-10:
Standard test method for replication and measurement of concrete surface profiles using replica putty.
ASTM G 8:
Standard test methods for Cathodic Disbondment of pipeline coatings.
Voluntary Standards Are:
Standards established generally by private-sector bodies and that are available for use by any person or organization, private or government.
Construction materials include, but are not limited to:
Steel Aluminum Stainless Plastic
Construction materials may include but not be limited to:
Steel Aluminum Stainless Plastic
Typical Surface Preparation Requirements:
Steel shall be new, full-weight steel,free from Structural defects. Steel plate shall be flat with no appreciable warp or buckle. Steel plate should have a minimum thickness and weight as specified. Vessel must be braced to avoid bulging. All welds to be continuous, peened and ground to remove sharp edges and high spots. Edges and corners should be ground to a minimum radius as specified. All weld spatter should be removed. Blast cleaned to NACE NO. 1/SSPC-SP 5 white metal with a surface profile of 38 to 64 um(1.5 to 2.5 mils).
AS/NZS 1397-2001:
Steel sheet and strip - hot dip zinc coated or aluminum/Zinc coated.
The Main Feature That Reinforcing Adds To A Resin Is:
Strength
Disadvantages Of Coal Tar Enamel Pipeline Coatings Include:
Subject to corrosion and damage from soil stress. Environmental and exposure concerns. Use of coal tar is regulated in some locations.
Epoxies Applied Underwater Are:
Subject to temperature limitations during application.
Major Stages Of The Hot-Dip Process:
Surface Preparation Fluxing Dipping Post treatments Inspection
Major Concerns For Spray Metalizing Inspection Are:
Surface Preparation(cleanliness and profile) Substrate pre-heating Moisture free substrate verification Application procedures and techniques Application of sealers and topcoats when specified DFT measurements (DFT gage) Handling and storage of finished products
Waterjetting Is Effective For Removing:
Surface oil and grease. Rusty Concrete (shot-crete) spatter. Existing coatings Water-soluble contaminants that cannot otherwise be removed by abrasive blasting. An underwater unit used to clean barnacles or other micro-organisms for ship hulls or off-shore platform legs.
Faying Surfaces:
Surfaces that depend on friction to hold the structural elements in place should not be Hot-Dip galvanized because this treatment greatly reduces the possible coefficient of friction between the surfaces.
NACE Test Methods:
TMs
ASTM D 5402:
Test method for measuring solvent resistance of organic coatings.
Pull Adhesion Tests:
Tests using portable adhesion testers: Elcometer 106, Defelsko Unit, HATE Unit & PATTI Unit.
The Negative Effect Reinforcing Has on a resin is:
The Ability of a liquid to travel along the fibers path (wicking). Cause corrosion to the substrate. Blisters. Delamination of the system.
A typical Waterjetting team consists of:
The Nozzle Operator. The Pump operator. Additional Operators Or Workers.
Non-Visible contamination (NV) is:
The Presence of organic matter, such as very thin films of oil and grease and inorganic and/or soluble ionic materials such as chlorides, ferrous salts and sulfates that remain on the substrate.
Boundary Layer:
The air only a few millimeters away from the steel.
Air turns:
The air turnover principle eliminates air stratification or layering, in large open spaces by recirculating the hot air that becomes trapped in the higher spaces. The number of times it does this per hour is called air turns.
Hot spot:
The concentrated area of the blast.
The Corrosion Process Is:
The deterioration of a substance, usually a metal, or it's properties because of a reaction with its environment.
Hot Water Cure:
The equipment is filled with water and steam is injected to boil the water. The temperature and water level are maintained for the required period of time.
Curling:
The expansion, lifting, softening or other deformation of the existing coating in reaction to the applied coating.
AF Coating Inspection Concerns:
The film thickness of each coat of AF is very important to the life of the coating system, more so than with most typical coatings.
Powders Applied To A Heat Source Pass Through Four Distinct Stages:
The flow stage, which occurs when the particles of powder begin to flow, but are not fully liquid. Wetting Stage, which occurs when the particles of powder absorb more heat, fully liquefy, and wet the surface. Gel Stage, which occurs when the particles of powder begin to gel, converting to a solid. Curing Stage, allows for further changes to take place, permitting the powder to cure completely.
Passivation:
The formation of a protective oxide film on the surface reducing it's chemical activity and ability to corode.
Information That Should Be Included When Providing Samples For Laboratories:
The identity of the materials to be analyzed. The inspector should ensure that the samples are properly packed and labeled. A Chain-of-Custody form should accompany the samples. A copy of this should be retained by the inspector. The type of analysis required. Examples include: Leachable lead in spent abrasive; Type and concentration of retained solvents in coating chips; Generic identification of coating type. Expected concentrations or concentrations of interest. Examples include: Lead in paint is of interest in Parts per million(in potable water this changes to parts per billion). This allows the lab technician to select the best instrument for the job.
The Anode Is:
The location on the mettalic surface where oxidation occurs.
Water-Borne Coatings:
The major concern is preventing freezing during shipping and storage.
The Cathode Is:
The more noble region on the electrode where electrons are consumed.
2-Layer Polyethylene (PE) coating:
The most commonly used coating for pipelines. It is usually yellow in color.
Epoxy Two-Component(Co-Reactive) Coatings:
The most widely used industrial/marine coatings.
Electrostatic spray:
The powder is conveyed under pressure into the gun in fluidized form. This spray method is based on the principle that negatively charged objects are attracted to positively charged objects.
Internal Steam Cure:
The pressure vessel is used as it's own autoclave. Workers close off all openings and fill the vessel with steam under controlled temperature and pressure.
Hot-Dip Galvanizing:
The process of coating iron or Steel with a thin zinc layer, by passing the steel through a molten bath of zinc at a temperature of around 820-860 F(460 C).
Flow And Flood Coating:
The process of pumping material over the top of an item and allowing it to cover the item as it flows down the surface.
The life of any coating system on a steel substrate depends significantly on:
The quality of the surface preparation.
Self Smoothing AF:
The rate of ablation is controlled and the surface of the coating system becomes smoother during use.
Cathodic Protection Is:
The reduction or elimination of corrosion by making the structure to be protected a cathode by means of an impressed current or attachment to a galvanic anode.
Autoclave (vulcanizer) Cure:
The rubber lined equipment is placed in an autoclave and subjected to controlled steam under pressure. This method is preferred because of better heat transfer and shorter cure cycle. This method results in the highest rubber-to-metal adhesion and yields the highest lining density useful for more corrosive media.
Cathodic Disbondment:
The separation of the coating from the surface through hydroxyl (OH-) formation due to increased (made more negative) potential.
Life Cycle Of A Coating System Can Be Affected By:
The steel in question. Costs The service atmosphere Product Maintenance
To Determine The Coating System Life Cycle Costs, The Following Should Be Considered:
The steel to be coated and it's condition. The Coating System chosen(benefits and drawbacks) The service environment The initial material costs The initial labor costs Time until the first maintenance coating Maintenance intervals Maintenance costs over the life of the coating system The length of time the coating system will last The yearly maintenance costs Evaluating the coating system
Disadvantages Of Waterjetting Include:
The surface must have a profile (Waterjetting leaves no profile). Equipment is very expensive. Danger of UHP hose breaking. Danger of injection into the skin or serious cuts. Collecting and disposing of the contaminated water. Proficient operators.
Linings Protect:
The surface they are applied to. The cargo being carried or contained.
Ways To Tell If Heat Shrink Is Fully Shrunk:
The tape shrinks down tightly to conform to the pipe surface. The adhesive flows out from the edges.
820-860 F(438-460 C):
The temperature range the galvanizing kettle is operated at.
Elcometer 110 Pneumatic Adhesion Tensile Testing Instrument (PATTI) Unit:
The tester uses a pneumetically operated piston to apply a tensile force along the axis of a pull stub that has been glued to a coating.
Waterjetting:
The use of "water only ",without the addition of solid particles such as sand or garnet in the water stream.
The Abrasive Blast Machine Cleans Best With:
The use of a range of abrasives.
ASTM D 4138 Method C:
The use of a specific angle-tip drill bit to cut a conical cavity in the coating. A Saberg Drill. Multiply the number of reticle divisions by 0.79 to give the coating thickness in mils. Multiply the number of reticle divisions by 20 to give the coating thickness in microns.
Visible Surface Cleanliness (VC) is:
The visible condition of the substrate when viewed without magnification and after cleaning.
To ensure a safe work place, Before Commencing The Job, the Waterjet team should Ensure that:
The work area is properly barricaded. Electrical equipment protected from the water. Electrical connections are not allowed to sit in water. All fittings and hoses are in good condition/proper pressure rating. Nozzles free of obstructions. System is flushed clean and air removed. The dump system and all control systems are operational Proper LOTO provisions/confined space entry requirements.
Flourpolymer coatings are best known for:
Their non-stick feature. Excellent chemical resistance. High temperature resistance.
Powders fall into two broad curing categories:
Thermoplastic: Materials that soften when heated and return to their original hardness when cooled. Thermosetting: Materials that harden when heated and retain their hardness when cooled.
Siloxanes:
These can come as single-package or two-component materials and normally blended with other resins such as acrylic, epoxy or polyethylene.
Solvent-Borne Inorganic Zinc Coatings:
These coatings cure both by solvent evaporation and chemical reaction from absorbing moisture from the surrounding atmosphere. These can be used as pre-construction primers, but must be applied at only 19um(.75 mils).
Water-Borne Inorganic Zinc Coatings:
These coatings cure by water evaporation and absorbing carbon dioxide from the atmosphere. The cure may take days, but the coating appears to cure within minutes of application. Has a use as a pre-construction primer if applied at 19um(.75 mils).
Infrared Spectrophotometer:
These instruments analyse the composition of a coating or identify many chemical compounds using infrared radiation that interacts with the material analyzed.
Stand alone wind data logger:
These instruments may record wind speed, gusts and direction as well as time, date, temperature and Other important wind parameters.
Atomic Absorption/Emission(AA/AC) And Induction Coupled Plasma Spectrophotometers:
These instruments quantify concentrations of metallic compounds.
Thick Polyurethane, Polyureas And Their Hybrids:
These products are applied by heated plural airless spray. They have a short pot life, sometimes as short as 9 seconds. Inspectors must understand how the specialized spray equipment works and understand the unique mixing at the tip of the gun.
Two-Component Thin Film Urethane Coatings:
These products are most commonly used as topcoats over Epoxies due to their good-to-excellent UV resistance and their wide availability in different colors.
Differential Scanning Calorimeter:
They measure the degree of cure for chemically-cured coatings such as Epoxies. Are quality-control instruments for powder coatings such as fusion-bonded Epoxies. Measures heat gained or lost in a chemical reaction.
Atmospheric Steam Cure:
This is vulcanization without pressure, using atmospheric steam. The temperature of the steam and the steel skin are closely monitored.
ASTM D 6132:
This test method covers the use of ultrasonic film thickness gauges to accurately and non-destructive measure the DFT of organic coatings applied over a substrate of dissimilar material.
ISO 8501-1, Sa 2:
Thorough Blast Cleaning
It Is A Good Practice To Require Every Waterjetting Operator:
To carry a medical alert card to present to medical personnel prior to any treatment.
The Functions Of The Centrifugal Blasting Machine Separator Include:
To control the sizing of the abrasive mix. To remove sand, spent abrasives(fines), rust, dirt and any other contaminants from the abrasive stream. To control abrasive consumption.
The Purpose Of Antifouling (AF) Paints Is:
To either make the hull of the ship so distasteful that biofouling larva reject it or the coating makes the hull so slick the larva cannot adhere.
Performance And Pre-Qualification Tests Are Done:
To verify that it meets certain physical and performance characteristics.
ASTM D 4138[Method A]:
Tooke Gage
Flourpolymer coatings:
Trade names include: Teflon, Xylan, Solar, Coraflon. Have excellent chemical and high-temperature resistance and thus are used as linings in the chemical processing industry. Require heat to cure. Inspectors must know the heat cure cycle and ensure it is followed.
Transmission pipelines:
Transports larger quantities of gas from storage facilities to different markets across the country.
Midstream pipelines:
Transports the gas from gas plants to storage facilities.
Tapes:
Treat tape as a standalone coating on water lines or as part of an insulation system; the same as 2 LPE.
Basic Centrifugal Blast Setups Include:
Tumbling Mill Multi Table Plain Table Swing Table Custom design systems
Chemically Induced Polymerization Coatings:
Two compounds are mixed together to form another compound.
Hardness Readings By A Given Test Method Are Affected by:
Type of coating, Sheet or filled material Cure Ambient temperature Thickness of material to be tested Size of the sample
FBE Field Joints:
Typically green or red
Common Characteristics Of FBE Include:
Typically green or red and looks like a painted finish. May be a single layer or a 2 layer "dual powder ". DFT from 250-500 microns(10-20 mils)
Advanced environmental testing instruments have the ability to store data that can be transferred to a computer or other devices. Transfer methods include:
USB IR Bluetooth
Two-Component Thin Film Urethane Coatings Inspection Criteria:
Use The required standard inspection techniques. Closely watch the DFT. Ensure that if any thinner is used, the coating supplier approves in writing.
ASTM D 3359 method B:
Use a cross hatch cutter or razor-sharp knife to score through the coating down to the substrate. Make a series of cuts at right angles to each other to form a grid of small squares. For coating films less than 5 mils.
Steel Troweling:
Use a steel trowel to move mortar over the surface to fill holes and to provide a reasonably pore-free surface to apply coatings.
Thermal Spray Safety Practices For Operators Include:
Use hoses rated for high pressure. Never clean powder off equipment or clean spray cubicles with compressed air. Do not use compressed air to clean clothing. Do not supply plant compressed air to a breathing apparatus. Reduce compressed air to less than 30 PSI for cleaning purposes.
Water-Borne Coatings Inspection Criteria:
Use standard inspection criteria, paying particular attention to surface temperatures if high heat is expected, particularly to the tops of structures in full sunlight.
Concrete Coating Characteristics Include:
Used in conjunction with other coating such as FBE. Used to reduce buoyancy so pipe will sink. Can be applied in many thicknesses. Can be applied to any diameter of pipe.
A"Tri-Ply" lining construction is:
Used to form a sandwich which is semi-hard or hard rubber between two layers of soft rubber.
Ultra sonic thickness gauges:
Used to measure the thickness of coatings on nonmetal substrates (plastic, wood, etc.) without damaging the coating.
Centrifugal Spray Equipment:
Uses a rapidly spinning disc, brush or other device to atomize coatings.
A Digital Microscope:
Uses optics and a charge-coupled device (CCD) camera to output a digital image to a monitor
Hot Spray Systems:
Uses the combination of a drum heater to preheat the product with an inline heater built into the pump mechanism to ensure the product reaches the required temperature.
Stereo Microscope:
Uses two separate optical paths with two eyepieces and two objectives to provide slightly different viewing angles for the left and right eye. This view prospective produces a three-dimensional visualization adding "depth of field " to the image.
Optical Microscope:
Uses visible light and a system of lenses to magnify images of small samples
ISO 8501-1, Sa 2 1/2:
Very through Blast-Cleaning
Non-destructive Tests For Heat-Shrink Sleeves Include:
Visual inspection Physical inspection Holiday detection
Which 4 Standards Replaced NACE NO. 5/SSPC-SP 12:
WJ-1 WJ-2 WJ-3 WJ-4
Coal Tar Enamel(CTE):
Was used in North America through the 1970's and is still used in some International locations. Advantages: Ease of application & a long life in some environments. Disadvantages: Subject to corrosion and damage from soil stress. It's used resulted in environmental and exposure concerns as well. Coal Tar is regulated in some locations.
Ultra High Pressure Waterjetting (UHP WJ):
Waterjetting performed at pressures above 210 MPa(30,000 psig).
High-pressure Waterjetting (HP WJ):
Waterjetting performed at pressures from 70-210 MPa(10,000 to 30,000 psig).
Thermal Spray Applicators And Others In The Area Should:
Wear No. 6 green welding lenses in appropriate goggles.
Cavitation-Corrosion:
When a metal is exposed to cavitation (formation and collapse of vapor bubbles in a liquid).
Impingement Attack Or Corrosion Erosion:
When a metal is subjected to high velocity liquids
The dew point temperature is:
When air is cool enough to be saturated and capable of producing dew.
Fretting Corrosion:
When two metals are in contact and there is slight relative movement.
WJ-4:
When viewed without magnification, shall be free of all visible oil, grease, dirt, dust, loose mill scale, loose rust and Other corrosion products, and loose coating. Any residual material shall be tightly adherent to the metal substrate and may consist of randomly dispersed stains of rust and Other corrosion products or previous applied coating, tightly adherent thin coatings and other tightly adherent foreign matter.
WJ-3:
When viewed without magnification, shall have a matte finish (dull mottled) finish and shall be free of all visible oil, grease, dirt, rust and Other corrosion products except for randomly dispersed stains of rust and Other corrosion products, tightly adherent thin coatings and other tightly adherent foreign matter. The staining or tightly adherent foreign matter shall be limited to no more than 33% of each unit area of surface and may consist of randomly dispersed stains of rust and Other corrosion products or previous applied coating, tightly adherent thin coatings and other tightly adherent foreign matter.
NACE NO. 1/SSPC-SP 5:
White metal blast cleaning.
DeFacto Standards Are:
Widely accepted and used, but lack formal approval by a recognized standards developing organization.
Waterjetting advantages include:
Worker safety. Worker air quality: Respiratory requirements may be less stringent. No dust contamination or clean-up. Friendly to the environment. Relatively cost efficient. It requires less clean up.
Alkyds Failures:
Wrinkling and/or a soft film. Caused from the applying the coating too thickly. Putting the coating into service before it has time to fully cure.
SSPC-PA 9:
measurement of dry coating thickness using ultrasonic gages.
O-CAT:
offshore corrosion assessment technician
Guniting:
process of spraying or slinging shotcrete onto a surface as a coating to restore concrete to its original grade.
S-CAT
shipboard corrosion assessment technician
ASTM D 3363:
standard test method for film hardness by pencil test.
ASTM D 4752:
test method for measuring MEK resistance of Ethyl Silicate Zinc-Rich primers by solvent rub.
Acid Etching:
uses a dilute acid solution to remove laitance and roughen the concrete surface.
