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2.What is chemical reacition? Combination of elements
3.What is the Formula of hydrous iron oxide (rust) fe++
+2OH
fe (OH)2
4. Three elements for corrosion? anode cathode
electrolyte
5.
6.Does Corrosion occur at the cathode or at the anod?
Anod
7.Name the three factors needed for corrosion to occur.
Anod, cathode and electrolyte
8.What is the meant by the term electrolyte? An
electrolyte is a substance which will conduct a current
and broken down by it.
9.What is the corrosion? Degradation of a metal by
chemical or elector chemical means.
10. In the corrosion circuit do electrons flows from anode
to cathode. yes
11. Which gas is released at the cathode when the
electrolyte is water? Hydrogen
12. Which is the more noble metal, steel or aluminum?
Steel
13. Which is more elector negative? Aluminum
14. If steel and copper were in a contact in an
electrolyte which would corrode? Steel
15. Name 2 common Hygroscopic salts. Chloride ,
sulphates
16. Name 3 metals used as sacrificial anodes an a steel
pipeline. Magnesium, zinc and aluminum
13.
What is meant by the term burnishing? Polishing,
and a smooth shiny area
14.
What would be the equivalent to st2 in Sa grades?
Sa1
15.
What is the natural figure on the pH scale? 7
16.
How is the pH measured. using Ph indicator strip
17.
Why are inhibitors sometimes added to water in wet
blasting?
Retard the formation of corrosion products
18.
Name two typical areas where needle guns might be
used? Heavy rust and grease
19.
What is the Duplex process for surface preparation?
A passivation process using posporic /chromic acid with
a small percentage of iron filling.
20.
Which pH range covers acids? 0 to 7
21.
Which pH range covers alkalies? 7 to 14
22.
What is the meaning of pH? Potential of Hydrogen
23.
Name three disadvantages of wet blasting. Wasting
of water, slurry, and inhibitors
24.
Name two areas on a structure where flame cleaning
cannot be done? Oil Plant and Gas Plant
25.
Which three basic operations are performed during
flame cleaning? Expansion, Dehydration and Heat
penetration
26.
How does BS 7079 define Flame Cleaning standards?
AFI, BFI, CFI, DFI
27.
What is the Jasons Hammer?
It is a power tool
used (for chipping) for tend to leave coarse profile.
28.
What is meant by St2 and St3? Thorough Hand
power cleaning and very Thorough Hand power cleaning
29.
Two alloys are used to render wire brush spark free,
what are they? Phosphor Bronze and Beryllium bronze
30.
Why should Burnishing be avoided? Does not
provide good adhesion
31.
Name tow major disadvantages of using a needle
gun. Lack of surface profile and sparking
32.
After phosphating, what would be a typical pH
requirement prior to coationg? 4.5 to 7.0
33.
What is understood by the term Knock out pot?
Vapour traps which is on the main air line and use for
reduce the amount of water and oil in the compressed
air.
34.
If a operator was blasting with a nozzle pressure of
80psi. what would be approximate efficiency? 70%
35.
Which solvants are commonly used for degreasing?
Hydrocarbon solvent e.g: Xylene (**pickling)
36.
What is a `Dead mans Handle? It is a Handle under
direct operator control for safety.
37.
Why is carbon impregnated into blast hoses To
reduce the chance of electric shock by static.
38.
How is abrasive cleansed in a wheel labrator
system?
The abrasive is cleansed by Air Wash seperator
39.
What is the main disadvantage of high pressure
jetting compared to other systems. Wastage of Large
amount of water
40.
Name five method of wet blasting. High pressure
water blasting (water jetting), high pressure water plus
abrasive injection and low pressure water plus abrasive
injection, steam cleaning, Air blasting with water
injecting.
41.
What would be the typical temperature and
concentration of sulphuric acid in the pickling process.
Temperature 65c to 70c and 5% to 10% sulphuric acid.
42.
Describe the `Duplex process. Deplex system
involves the pickling process followed by a passivation
process using phosphoric or chromic acid along with a
small percentage of iron filing.
43.
What would be a maximum pressure for high
pressure water jetting. 30000 psi
44.
What are the disadvantages of wet blasting over dry
blasting? Does not provide a profile, Supply of large
amount of water, slurry and inhibitors
45.
Describe the phosphating process. Immerse the
component in a bath of phosphoric acid, 2% solution at
80c for approximately one to two minutes with iron filing
0.5%. This leaves a very thin rust inhibitive layer on the
substarte.
46.
What would be considered to be advantages of wet
blasting over dry blasting? Spark free, free from static,
operator safety
47.
Why is the phosphating or chromating of steel done?
These form a rust inhibitive layer, which passivates the
surface and increase the adhesion properties they are
extremely resistant to cathodic disbondment.
(**pasivates = reduce the chemical reactivity of a
surface by applying a coating dic)
48.
What would be an acceptable remedy for burnished
areas? Abrading with coarse emery
49.
Would burnishing be expected on areas of St2
preparation? No
50.
How many photographs of blast cleaning standards
are shown in BS 7079 pt A? 14
51.
Do the plates shown in BS 7079 Pt A relate to grit
blasting or shot blasting? Grit blasting
52.
Note:
SI 1657 states that any mineral used as an
abrasive must release 1% free silica impact.
COSHH REGS does not allow the use of stand
contaioing silica for dry blasting.
Copper salg: (random, sharp edges, amorphous)
Garnet: diamond type hardeness
Reused up to three times
Grit: (amorphous, pints and cutting edges
irregular profile)
Shot: spherical, smoother profile
Define the adhesion: The force require to separate tow
surfaces in touch
Surface profile specification(B gas): 30 - 75 microns1
Why digital gauges are ofted used(not use regurlarly)?
Batteries can produce sparks
Degree of cleanliness is mainly dependent on the time
spend on the area and the velocity of the partical
One major problem in wheellabrators is access of bolt
pockets, gussets and stiffeners etc.
20.
What is the most common cause of flash rusting on
a blasted substrate? Environmental condition
21.
What would be considered to be an ideal shot girt
mix?
A shot grit mix resulting More uniform profile.
22.
What is the purpose of mixing shot and girt? To
control the rough peaks and avoiding rust spotting
23.
Which abrasive would have the effect of work
hardening a substrate? Metallic shot
24.
Name three methods measuring or assessing a
profile. Needle gauge, Dial Micro meter using Replica
Tape and Comparators.
25.
What is the most common cause of rough peak on a
substrate?
Rust spotting
26.
In what situation would it be better to use steel grit
in preference to copper slag abrasives? Recyclable
situation
27.
If cracks or laminations are found on a substrate
after blasting what steps should be taken? Refer to
engineer to ultrasonic test.
28.
Using comparators to ISO 8503, what are the three
main profile assessments? Fine, medium and coarse
29.
What are the other two assessment when the above
three are not appropriate? Finer than fine and courser
than course
30.
What would be size of copper slag needed to give a
profile of 50 to 75 microns.
Painting Technology
10.
11.
Zinc phosphate
25. Why are extenders used in paint formulation?
Adhesion, cohesion, film strength, and
durability
26. If chromium was used as pigment, what colour
would the paint be?
Green yellow and oranges
27. Why are plasticisers added to paint?
It gives flexibility and reduces brittleness
28. Tow metals are commonly used as galvanic
pigmentation, name them. Zinc and aluminium
29. Why are driers added to oil based paint?
Instead of relying on atmospheric Oxygen
penetrating the paint layer, the oxygen is
already there, to allow even through drying
of the flim)
30. What is meant by the term `thixotropic?
Becoming fluid or less viscous when
stressed
31. If an anti oxidant was added to paint, what would
it do?
To retard the formation of a skin on the
surface of the paint
32. Give the name of two platicisers
Castor Oil Coconut Oil
1. Define viscosity
Being a fluid resistance to flow
2. What is meant by high viscosity?
Hihg fluid resistance to flow
3. Approximately, what is the viscosity of water?
One centi poise
4. Name the cgs and SI units of dynamic viscosity
Cgs = poise, SI = newton second per square
meter (N.s/m)
5. Name three different flow cups
Ford, zahn, DIN
6. When using a flow cup which unit of viscosity
would be used?
The time in second is recorded as the
viscosity
7. In ford Flow cup N 4 what does 4 related to?
4mm hole size
Gloss meter
54. How does a gloss meter work?
A light source directs a beam of light onto the
surface under test and a photo electric cell, set at
the same angle. Collects the reflected lights and
quantifies it and covers it digitally into a
percentage of the incident light.
55. Which factors in paint govern the degree of gloss?
PVC degree of dispersion partical size, resin
type and solvent type
56. In a primer /mid coat what would be the expected
degree of grind?
40 um
57. In a gloss paint what would be a typical degree of
grind
20um or some instants 10 um
58. What percent reading would be expected when
measuring gloss on a glass panel?
60% and 20%
59. Using a gloss meter a reading of 25% would
signify what?
matt
60. If an aggregate size of 35 um was present in a
paint of 30 um DFT what would be a likely result
when using a gloss meter?
Lower percentage
61. Name three common tests for determining
adhesion of a paint film?
V cut test, crosscut test and dolly test
62. Which adhesion tests are quantitative?
Dolly test
63. Inter coat adhesion and primer to substrate
adhesion are two faults name the third? Cohesive
failure
64. What chemical solution is used to conduct a
cathodic disbondment test? Sodium choloride
65. Which gas evolved at the cathode causes
disbondment?
Hydrogen gas
66. What criterion is used when assessing a cathodic
disbondment test panel?
67. Name the two methods of applying Cathodic
Protection
Sacrificial anode system
Impressed current system
68. What is used to determine the potential of a
pipeline?
69. Would it be advisable to refill a pipe trench with
carbonaceous backfill?
70. Does a cathodic protection system eliminate
corrosion
No, it controls corrosion
71. Can the external surface of a tank be protected?
Cannot
72. Could a crude oil tank be fully protected
internally?
6.
A bead mill is some times called by which other
names
Sand mill, pearl mill
7.
How does a colloid mill work?
It works using stone grinding discs containing
carborundum, approximately 10 in diameter. The
top stone is stationary and the lower stone is
rotation fast at speeds up to 3600 revs per minute.
8.
Name eight items of information listed on a
materials data sheet
Description, recommended use, service
temperatures, certificates/approvals, availability,
physical constants, application details and safety
9.
What do you understand from the term
Halogenated Hydrocarbon? Toxic solvent
10. How can we determine the viscosity of a high
viscosity paint? Viscosity is fluid resistant to flow and
high viscosity is fluid high resistant to flow
11. Briefly describe the principles of CP
Cathodic protection is a secondary line of defense
against corrosion, the primary defense being the
coating. When damage to the coating occurs the
underlying steel can then be in contact with
electrolyte and corrosion can occur. But if these
areas can become cathodic i.e. receive current,
corrosion can be avoided. In order for cathodic
protection to be applied, an electrolyte must be
present. For example the external surface of a tank
cannot have cathodic protection, but internal
surfaces can if the tank is holding an electrolytic
Calculation
Destructive Test gauges
Nos Destructive gauges
21.
44.
70.
A paint data sheet provides a wealth of
information, name eight items.
11.
Which three non-ferrous substrates are painted
for anti corrosion purposed? New galvanized
surfaces
Weathered galvanized surfaces
Previously painted galvanized surfaces
Aluminium surfaces
12.
According to PA 10 in which situations would T
wash be used?
Surface preparation of sweep abrasive blast or
hand abrading eliminate the need for an T wash.
13.
How many coats of primer are specified on
surfaces at 100-149C
Tow coats
14.
Give preferential order for coating system for
surfaces 150-340C
Mask areas
Remove surface contamination
Blast cleaning (SA3 maximum profile 75 um)
Apply system
15.
Is it mandatory for a contractor to produce a test
area?
yes
16.
List four items needing masking off perior to
blasting and painting. Fire protection equipment,
weld end preparations, atmosphere sensing heads,
spray heads, vents on the control equipment, flame
traps, lubrication points and nameplates.
17.
Which aluminium substrate would not be sweep
blasted?
Thin guage aluminium
18.
Which three paint systems are specified for use
on Aluminium?
28.
What would be the specified surface preparation
and coating system for Aluminium cladding?
Sweep abrading blast and paint system G1
water born acrylic, G2 Moisture cured
urethane, G3- Alkyed or modified alkyed
29.
What would be the procedure for removal of
algae and mould?
30.
What would be the procedure for degreasing
prior to surface preparation?
31.
What would be the procedure for degreasing
after to surface preparation?
32.
When blast cleaning on an AGI what precautions
are taken?
33.
Is it permissible to prepare paint by stirring?
34.
What would be the surface preparation method
for new galvanizing? Sweep abrasive blast
35.
When would it be necessary to apply a sealer to
inorganic zinc silicate? yes
36.
How could areas of a paint breakdown be
prepared for repainting?
37.
What information should be on a paint can label
for BG?
38.
When measuring DFTs over galvanising what
allowances are made?
39.
What is the first coat applied to galvanized
substrates and why?
40.
Properties and performances of paint are
covered in which BG specification?
41.
What are the considerations when selecting a
paint system?
42.
According to PA 10 which two coats are applied
at works?
43.
Give the criterion for when and when not,
painting can take place.
44.
What should be the substrate reaction when T
wash is applied to a newly galvanized substrate?
45.
Which two materials are specified for use on
damp surfaces?
Moisture curing polyurethanes
High solids multi component epoxy paints
46.
What is the maximum time lapse from surface
preparation to coating?
47.
Which is the most common pigment used in high
temperature paints? Aluminium pigmented paints
(spa3)
48.
What would be the result of over thick
application of zinc silicate? Mud cracking (spa3)
49.
According to PA 10 is roller application
permissible?
No
The end