9%. 10. 12. Describe a) a barrier paint system, b) a sacrificial paint coating. A barrier paint system is a low permeability coating system, normally a four-coat system. Primer, tie coat, M.1.O high build and a topcoat. A sacrificial paint coating is usually zinc or aluminium based paint, which is less noble than the steel substrate that is being coated. So the less noble is coating (anode) sacrifices itself to the nobler steel substrate (cathode). Describe what a tie-coat is and give three reasons why we may require one. A tie-coat is a paint, which can tie two normally incompatible systems together, mainly used for maintenance painting. It is used in anti-fouling system. Reasons: To get proper adhesion, to avoid bleeding, to avoid solvent stripping. Describe a typical paint manufacturing process and give the two types of paint ill which could be used. Select raw materials, mill the paint, carry out any QC testing requirements, can the paint, store in the warehouse and then distribute the paint. Direct charge mill, ball mill, attriator mill Ball _mill- it grinds all the raw ingredients together. Premix mill takes all the premixed ingredients and refines this mixture to high quality paint used in large batch in run. Describe what you know of viscosity and out line one method of testing. Viscosity is the measure of fluid resistance to flow. It is used to find the amount of solvent that is added to the paint. It is tested at 20° +/- 0.5°e. Ford flow cup # 4 is used. Bring your paint temperature to 20°c, place your finger over the hole of the cup, fill with paint, level off the paint with ruler. Note the time taken i.e, how long the paint flows before the break comes in the flow of the paint when you remove the finger from the hole, Describe what do you know of density. Density is weight per unit volume. Units = gms/eubic centimetre. Can you use a banana gauge over a. An MLO coating, - No b. Analuminium substrate - No. c.A galvanized surface = ‘Yes provided itis over steel surface. Deseribe a des! ctive test for determining the dry film thickness of paint. Page | of 4313. 14, 20 PAINT INSPECTOR'S GAUGE (P.1.G): Cut a 'V' cut shaped channels over the paint film coated over an area, Place it over a microscope and measure the thickness of the paint and how many coats are there. To determine the compatibility between different coats. Give four artificial weathering devices and describe what they simulate, Salt spray test - It is used to simulate marine environment, Water soap test - It is a test for paint film permeability. Tropical box - It is used to simulate high humid environment. Cold cracking test - It is used to check the contraction at very low temperature. Temperature cycling - It is used to simulate alternate low and high temperature of a paint, spose What is the name of the instrument which measures opacity and give two examples Cryptometer - a) Pfund Cryptometer, b) Hiding power chart Describe a dolly test for adhesion. a, Clean the substrate coated with the paint. Degrease it and roughen. b. Attach dolly by regular araldite c. Leave 24 hours time at 25%. d. Afterwards cut a around dolly to isolate the substrate. ©. Apply pull of force and note down the pressure (psi). £ Note at what pressure the failure occurs. g. What types of failure occurs (cohesive / adhesive) How does the following work? a) Conventional spray set up b) Airless spray system ©) Electrostatic spray system. a) Conventional spray setup is used for relatively low pressures and thin materials, Also the cup gun does not hold big quantities of paint. So you are forever filling them up. Also the gravity and suction guns can only be used in the upright position. b) Airless spray system is a very fast system for applying paint to very large areas, roughly one square metre perminute, large spray pattern and applies thick coating in one application. ©) Electrostatic spray system requires a special spray gun, which applies charge to the paint particles. The substrate is positively carthed and the paint particles are given a negative charge at the tip as they leave the gun. So the paint particles go to the earth and wrap themselves around the normally tubular components and a even coating is obtained, very little wastage of paint. How is BS 4800 used in the construction industry? Page 2 0f 43It specifies 100 colours out of the 237 in BS 5252. It is used to identify the existing colour paint for which maintenance painting has to be done. It is useful for the manufacturer's to verify with the standard colours given in BS 4800 (100 colours) What are the essential differences between blister and osmotic blister? Expansion or contraction of the paint film against the substrate usually causes dry blisters. Osmotic blister is a blister, which contains gas, liquid, or crystal. It is caused by the entrapment of solvent, hygroscopic salts. It is usually dome shaped. What shail painting equipment comply with when being used on the Bgas site? To the paint manufacturer's recommendation. How do the following display their characteristics? Bleeding is a discolouration of a new paint applied over an old one. Bitumen and paints contain red pigments are particularly problematic. Blooming. It is where a finishing paint assumes a milky type appearance and the loss of gloss due to colour or dampened air settling on the paint before it was dry. Chalking. Paint becomes powdery or chalky. Break down of the binder due to ultraviolet light and also due to poor weather condition, Cissing, In-complete paint films due to paint over oil and grease. Grinning. Seeing the underlying surface through the finish cost, Colour contrast, lack of opacity. Flocculation. Separating out paint constituents in the tin and the refusal to be stirred back together again. Lifting. Attempting paint over, undemeath a coating, which is not fully cured. The evaporating solvent will lift up, picking up. Roopiness. Brush marks in a painted surface. Solvent stripping. Paint with a powerful solvent will lift the coating underneath due to the power of the solvent, Oxidization, The drying process between certain binders and oxygen e.g. alkyd resin, Chemical curing. The mixing of two components which produces drying in a two- pack paint Overspray. Paint which is not going to substrate. Paint, which falls over an area which, is not required to be painted. Rh, Induction period, Pot life, Flash point, elf Life, Batch No., ing out A.G.L, Rust blooming, Water borne coating, B Sa 2 1/2, Feathering, A'St3, PA 9, P 10. Dew point: The temperature at which condensation would form on a substrate. RH: The amount of water vapour in the air expressed as a percentage and calculates from the wet and dry bulb temperatures. Define the following, Dew po Page 3 of 436. Induction Period: The length of time a paint is required to stand after mixing and before application, to allow the air bulb to escape and or chemical reactions to take place and is specified by the paint manufacturer. Pot life: The length of time (following induction) that a paint remains in an applicable condition according to the manufacturer's instructions. Flash point: The lowest temperature at which a given material will flash, if a flame or spark is present. Shelf life: Maximum interval in which a material may be stored in a usable condition, Batch number: Manufacturer's data number for production date ‘Masking out: Must be carried out on items to be protected during preparation and painting, items normally masked out are control equipment, fire protection equipment, weld ends, sensing and spraying heads, name plates A.GJ: Above ground installation. Rust blooming: It is caused by moisture or humidity on new blasted steel and shows up before priming. Water borne coating: One whose solvent is water. It dries by coalescent. B Sa 2 1/2 : Rust grade B. Mixture of mill scale and rust. Prepared by very thorough blast cleaning. Feathering: Smoothing back the coating edge to allow repair. Paint to flow into and produce a smooth edges i.e. smoothing down of rough paint edges. A S13: Not possible. PA 9: B gas document properties and performance requirements refer to the ordering of paints and performance of painis systems. Any paint used on B-gas work must comply with PA 9. PA_10: It is the technical name specification for new and maintenance painting at works and site for above ground pipeline and plant installations and is arranged into three sections. Primary information, general painting information, information for specific painting applications. Give as much details as you ean for the following. SPA 1: Applies to the painting at work or site of new installation and components and maintenance paint, (CS) SPA 2: For indoor use and short term uses. SPA 3: New installation and maintenance, above 100°c, upto 340°, and above. SPA 4: Painting of damp ferrous surfaces. SPA 6: Painting of non-ferrous surfaces, Page 4 of 43PAPER 2. (B-gas) PAINTING GRADE 3. L What kind of process is corrosion? Blectro chemical process. 2. What particular problems relate to the maintaining of an effective coating system in splash zone? Rapid change in oxygen, salt spray, growth of marine life, access to the working area is difficult. Wave impact and erosion, Mechanical damage due to ship movement. 43. What factors influence the rate of corrosion? a. Variation in oxygen content on steel surface (wet and dry) b. RH percentage above 60%. ©. Higher nobility metals in contact. 4. Air borne acids, alkalis and salts. 4 What ills mill scale and why if is a particular problem when attempting to protect steel? Mill scale is an oxidized iron. Mill scale is nobler than steel so the exposed areas of stee! (anode) will sacrifice itself to protect the mill scale (cathode). 5. What is the number of the Swedish standard contained within BS 7079 and list the rust and blasting grades together with their brief relevant titles? RUST GRADE, BLASTING GRADE Rust grade A - Covered in mill scale with | Sa 1 - Light blast clean. little or no rust. Rust grade B - A mixture of mill scale and | Sa2- Thorough blast clean rust Rust grade C- Mill scale, rusted with Sa2 12- Very thorough biast clean slight surface pitting Rust grade D - Heavily rusted and pitied, _| Sa 3- Blast clean and visually clean, 1 6. Name three tests for locating hygroscopic salts and mill scale on a blast cleaned surface. Potassium ferricyanide test - Soluble iron salts Silver nitrate - Soluble chlorides Copper sulphate = Mill scale Page 9 of 4310. RD What factors influence how clean and how rough the surface becomes after blast cleaning. Using the correct abrasives ensuring that si correct for the substrate. Operator's ability to ensure proper speeds, angles and distance plus speed (time) Surface profile and cleanliness. hardness, density and shape are the Regarding hand and power tool cleaning state what always concludes this process and to what standards. Wire brushing: Brushes must be made from phosphor, bronze or beryllium bronze St 2 - Thorough hand & mechanical cleaning (manual). St3- Very thorough hand & mechanical (mechanical). Used on rust grades B,C,D. What three basic ingredients make up a traditional solvent carrying paint? Binder, pigment and solvent. What are the functions of cach of these three in a solvent carrying paint? Binders: It binds the particles together and holds them in suspension. Gives the paint its finish, makes the coating adhere to the surfaces, gives flexibility. Converts toa solid dry film, resistance to water and chemicals. Pigments: Gives colour and opacity to the paint. Resistance to alkalis, acids and light. Solvent: Brushes & equipment cleaner, thins the paint, degreases if approved. forms the evaporative part of the drying process, Name five items that can be included in paint to improve its performance or suitability for a certain use. Drier or catalyst, extenders, plasticiers, thixowopie agent, anti skinning agent, stabilizer. Identify six paints by their binder name. Polyurethane, alkyd, chlorinated rubber, epoxy, emulsion, aluminium, achrolic, vinyl, silicon, cellulose and zine Name four binder / solvent combination. Epoxy = Acetone. Chlorinated rubber - ‘Xylene. Alkyd resin - White spirit, Emulsion - Water. Page 6 of 4314, 16, 7. 18. 19. Name six opaque pigments together with their respective colours. Calcium plumbate Creamy white Red iron oxide - Red Red lead - Red Zinc chromate - Yellow Zinc phosphate = - ~—— White Coal tar = Dark brown or black Describe what a laminar pigment is. The laminar pigment (M.I.O, Mica, glass flakes) particle shape tiny hands or leaves, upon drying they interweave and overlap each other to form a leave type. Surface provides a low permeability to water What is the difference between a convertible and a non-convertible coating? Convertible coating dries by chemically changing upon, afterwards it cannot be softened or damaged by its own solvent. Non-convertible coating dries by solvent evaporation only. It cannot be damaged or softened when it contacts with its own solvent. Define the term induction period. The length of the time, the two pack has to stand after mixing, before applying for allowing the air bubbles to escape and chemical reaction has to take place and is stated by the manufacturer. Define the term pot life. The length of time after induction the two-pack paint remains in an applying condition, according to the manufacturer's instructions. Define a barrier system of coating. This type of coating isolates the substrate from the environment by providing a low permeability coating system. Define the term tie-coat and give an example of its use. A coat used to apply over two incompatible coatings e.g. during maintenance painting. Page 7 of 4321, What is the difference between thermosetting and thermoplastic? Heat cured plastic, Thermosetting: They can be formed by heating and curing heat cured plastic. After setting they will not soften or degrease. Thermoplastic: They can be formed by heating and curing heat cured plastic, After setting, when they are re-heated it will become softer and become liquid and again can be reused 22, What is impressed current, What problem can arise from its incorrect setting up? Voltage from an external power source called a transformer rectifier is impressed on the circuit between the pipeline and buried earth connections known as ground beds resulting in a direct current being discharged. In discharging current to earth the ground bed materials are subject to corrosion. The impressed system can be used in all types of soil resistivites. The greater the resistivity the greater the ing voltage or no. of anodes to achieve CP cathodic disbondment will occur 23. Name two types of paint mill and give two examples of each. DIRECT CHARGE MILL. | PRE-MIX MILL COLLOID MILL Ball mill Big mill (Ballotoni) Simple roll ‘Attritor mill Sand pearl and Bead mili | Dried roll mili High speed disperser mill | Slurry mill Triple roll, 24. What is the title of BS 3900? Method of test for liquid paint. How many test sets are in BS 3900? Eight. How are the tests identified (name, number)? Title and letter from A to H. Method of test for liquid paint films (excludes chemicals) Liquid and dried films include chemical examination. Test associated with paint film formation Opacity test on paints. Mechanical test on paint films Durability test on paint film. Environmental test on paint film. Designation of intensity, quality and size of common type of defect. General principle and rating scheme. rm OO RS nom Page 8 of 43,25. 26. 30. What does a fineness of grind gauge measure? Grind gauge measures pigment grain size, how finely the pigment has been (grained) ground in the milling process. What is the flash point and by what apparatus is it determined? It is the minimum temperature at which the vapours of a liquid begin to ignite when the external source of ignition is introduced. The closed cup Abel type determines flash point. What is viscosity and what equipment is used to measure the viscosity of a free flowing paint and Thixotropie paint? Viscosity is the internal measure of fluid resistance to flow. a) Free flowing paint viscosity is determined by Ford flow cup no. b) Thixotropic paint viscosity is determined by rotating viscometer/rota thinner, krebs stormer viscometer. Set the r.p.m through the window at 200 r.p.m. to make it a free flowing paint, Paint is put in the viscometer and paint is thinned similar to the ford flow cup no.4 test, note the time taken for the paint to be broken to droplets, Time taken in seconds will give the visocity. What is density cup and give an Small black cup of 100 cc, which is made of aircraft alloy, is known as density cup. The lid in it has a hole in the top. Pour the paint inside the density cup. Close it with the lid. Wipe of the extra paint coming out of the hole from the cup. Weigh it by using the formula Density = Weight / volume. Find out the density of the liquid. Density cup is used for, a) To check the amount of solvent added to the paint. b) Whether the two-pack paint has been mixed to the correct ratio. Calculate the volume of s if the W.F.T was 186 microns and the D.F.T - 93 microns. lids of the p: VS %=D.F.T x 100 = 50% WAT. Calculate the W.F.T. microns. of a paint if the Vs Yge was 66 and D.F-T was 88 W.F.T=D.E.T x 100 = 133.3 microns Vs% Calculate the D.E.T. of paint if Vs % was 44 and W.F.T was 234 microns. DF.T=W.E.Tx Vs% = 102.96 microns 100 Page 9 of 43,32. 36. Calculate the density of paint if a 5-litre tin weighed 15 kg. Density = weight Volume: 3 gms cum Calculate the density of two pack material if part A paint wa part B catalyst was 0.5 g / eu.em (assume ratio 1:1) 5 g/cu.cm and 15405 =1g/cucm 2 Name an example of a nondestructive D.F-T. gauge and destructive D.F.T. gauge. NDT- D.FT. gauge - Blectronic gauge, banana gauge. DT- D.F-T. gauge - Paint inspectors gauge. Name four artificial weathering devices and say what they are desig simulate. Salt spray test - Tropical box test High humidity environment Water sock test ‘Test for permeability of paint system Cold crack test Test for low temperature Cracking - Temperature cycling test for flexibility of paint film varying temperature alteration(high temp &low temp) Name two drying / curing tests and state how they are operated. Drying/ curing test: Ballotini test- hardened steel balls put over the wet paint film panel Stylus test: It consists of a series of trailing needles. To find out tack dry, hard dry and fully cured, Cold leaf test: It is moved over the wet film since they are used in different tensions. What does a Cryptometer measure and give two examples of a Cryptometer. It is used to measure the opacity. Hiding power charts and P-fund Cryptometer. What determines the degree of gloss, a paint may possess. 2) The ratio between binder and pigment. The fineness of the pigment grind. b) Fineness of pigment grind. ¢) Skill of spray painter <) Method of application. e) Absorbing of the substrate for the paint. Page 10 of 4329. 40. A 2. Name three adhesion tests and describe how one of them is carried out. a) Cross cut test b) Cross hatch test ©) Dolly test. Clean, degrease and roughen the surface. Apply dolly with regular araldite end give 24-hrs time at 25°, Cut around the dolly to isolate the substrate. Apply the pull off force and find out, 1, At what pressure (psi) failure occurs. 2. What type of failure occurs. Cohesive/adhesive. State the conditions under which B-gas allows painting to take place. a) The ambient or surface temperature should be atleast 3°c and above the dew point temperature b) The relative humidity should be less than 90% c) Temperature condition for applying paint should be within the manufacturer's instruction. (maximum and minimum temperature) Name eight duties of a paint inspector 1, Inspect and report 2. He must act with integrity at all times and true to the specification 3. Learn the specification and familiarize with the plants and equipment used 4, Inspect the substrate condition (grade of paint) and select a suitable paint system as per the specification requirement. 5. Check whether dry bulb temperature, dew point & RH% i acceptable level or not. Inspect the prepared surface for its surface profile and cleanliness (grade Sa 1, $a 2,2 1/2, 3) 7. Verify whether the correct material have been obtained for the paint application. 8. Witness paint preparation (mixing) and operation at site. 9. Measure WFT, DET and check adhesion and curing, 10, Make reports - daily, weekly, monthly. within the st cight-contractor malpractic. Using unqualified personnel. Using unsafe plant and equipment Using equipment, which are in poor condition, Proceeding to further coat without inspection being carried out. . Applying coat in wrong sequence, omission of a coat ‘Apply a wrong paint. Use of date, expired products. Page 11 of 4344, 46. 8. Improper coating thickness. 9. Using more solvent. 10. Less thickness of coal 11. Improper mixing of paint. Name three methods of applying paint and compare the advantages and disadvantages of each in-terms of quality and cost effectiveness. Brush: Cheap easy method, best for applying primers. Disadvantages - slow, covers small areas and messy to handle. Roller: Cheap and easy to apply. Disadvantages - uneven coating, orange peel effect Conventional (air): Expensive (four to five times costlier than others), covers large areas, Disadvantages - overspray. What does BS 2015, glossary of paint terms refer to and give three examples? Bleeding: Penetrating and discolouring of paint coated over it. 1 2. Blistering: Dome shaped blisters formed due to contraction - dry blisters. 3. Osmotic blisters: It is formed due to entrapped liquid, gas and salts 4, Chalking: Pigment becomes chalky or powdery when it comes under chlorides, sulphides, 5. Flocoulation: Separating out of certain elements 6. Grinning: Seeing the underneath surface through the finish coat. 7. Holidays: Poorly or missed coating. 8. Pinholing: Holes down through the paint caused due to escape of gases. What is BS 4800 and how is if used in the construction industry? It is arranged of 100 standard colours taken from the 237 colours contained in BS 5252 and used in the construction industry. Jt can be used to identify existing colours when maintenance painting and is a method by which all manufacturers can make exacily the same colour. How does B-gas define the following. Long term protection: Upto 10 years. Short term protection: Upto 2-3 years. Medium term protection: Upto 5 years, New galvanizing: A substrate coated with zine galvanized surface where this cohesive oxide layer has not formed glossy and shinning appearance-less than three months old. Weathered galvanizing; Wire brushed with stiff brushes, more than 3 months old. ‘A galvanized surface where the cohesive oxide layers has formed dull and lacking in sheen. Page 12 of 43,47. 48. 49, 53. What is the procedure fo preparation commences? moving oil and grease from a surface before Because of oil & grease paint will not spread properly. White spirit should not be used. Use only approved solvent with safety precaution to be followed. For applying solvent use disposable swab. Do not use cotton rags. After solvent cleaning use a detergent pressure washing followed by clean water, rinsing and then drying it. What is the procedure for removing oil and grease from a surface, found after preparation has taken place? Use approved solvent and afier degreasing, do pressure washing with 2% detergent followed by clean water rinsing and drying it off. Reblast and clean it, What is the procedure for removing Algae and mould growth work? ‘om pipe Apply antifungicidal bi-oxidant over the algae and mould growth and give minimum twenty-four hours time. Leave it free for this period. After this time elapse use stiff wire brushes to scrub off, pressure wash with a detergent followed by clean water rinsing, Under what conditions must paint be stored? In ad dry, lockable, well ventilated building away from gas areas, flames, heat sparks and rays of the sun and follow any special storage condition. 2 How do we check for What is T-wash? What is it used for? What colour is ‘eet reaction when using it? neo It is an etch primer. When applied first it provides a key for new galvanized steel. Blue in colour Turns black upon drying. *I-wash should not be used in aluminium, Use PVB* What vo coat paints are applied at works? High solid solvent based epoxy primer to 75 microns 4.f.t Epoxy m.i.o. Mid coat to 75 microns d.fit. What distance must be left at areas to be welded when pain Seventy-five mm. (Pb mas Page 13 of 4356. 60. 61 How much must new paint overlap on old repairs? Hundred mm. What is the maximum allowed time for priming to take place following the preparation and by what method is primer applied” ‘Maximum four hours follow completion of blasting. Except Spa 4 where priming is immediate. By brushing or spray as appropriate. What do B-gas class as hot duty services? ‘One which reaches a temperature of above 99%c, when (it is working) in use. What must all pneumatically and electrically operated power tool equipment's should be done before use? Properly earthed What type of sheeting may and may not be used for protection against spillage and spotting? Sheeting must be non-flammable. Flammable sheets like tarpaulins should not be used. (Fire hazard) ‘What must not be used to clean out kettles or dispose of rubbish? Fite or flames. Give the rules for mixing of paints regarding sizes. Upto five litres may be mixed by hand. Above five litres must be mechanically mixed. What are osmotic blisters and what ean eause them? Osmotic blisters are blisters, which contain liquid, gas or crystals (chlorides). Ma causes are solvent entrapment, water entrapment, hygroscopic salts left on the blast cleaned surface. re N: three and describe how you might Some metals are dif prepare them. 1. Aluminium sheeting extrusions: Infactory - Degrease in acid bath. Onsite - Etch ‘and degrease with emery cloth and white spirit. Etch primer, zinc chromate (no lead paints) Page 14 of 4363. od. 66. 2. Galvanized iron (steel dipped in molten zinc): Infactory - Degrease in acid or alkali bath (t-wash). Onsite - Allow to weather for several months or degrease with zinc chromate, calcium plumbate or etch primer. Copper, brass and bronze: Infactory - Degrease in solvent bath. Onsite - Use emery cloth and white spirit (do not weather or dry abrade). Etch primer. Where does a pipeline leave the ground and what problems would you find and how might you treat this? Sketch: Mechanical damage from back filling, Rapid change in oxygen in soil, steel interface due to alternate wetting or drying conditions. Soil may be chemically reactive. Acid attack. Will produce conosion, - a) apply extra coating b) apply masking (polyethylene) c) better drainage to avoid standing water d) top mustle well seeded. whe What additional information would you record when maintenauce painting a pipeline without removing the previous coats? 1. It needs to be established whether the existing system contains any toxic coatings as this will dictate the method of preparation used. 2. Are the existing coatings compatible to the new system interms of adhesion possibility of solvent stripping, possibility of bleeding. Get the information from the paint manufacturer. 3, Further information required. Nature and extent of surface contamination, extent of break down, extent of corrosion, where adhesion problems, solvent striping or bleeding might occur. A tie coat would be employed to prevent these particular problems arising e.g. inservice environmental condition. Name five paints and state their drying or curing method. i. Emulsion - Coalescence - Evaporates without chemical action but it also gets dries like a non-convertible but acts like a convertible coating, 2, Alkyd - Solvent evaporation followed by oxidation. 3. Chlorinate rubber - Solvent evaporation only. Non-convertible coating 4, Two pack epoxy - Solvent evaporation followed by chemical reaction. 5, Fusion bonded epoxy - Heat cured - Thermosetting, convertible coating, Name a black pigment in common use apar( from coal tar. Carbon blocks, Page 15 of 4367. 68. 0. 70. What is a holiday detector and a pinhole detector? What does it detect, and how does it work? It is an electrical device applied to detect holidays, pinhole, voids ete., Coil spring typ 1. Preset the voltage. 2. Pass this holiday equipment through it (job). 3. Where there is a holiday present, it produces a spark, visual warning audio signal peep will be heard, 4, Speed of running the coil is 1ft - 2fv/sec. It need not be used on above ground conditions. It can also be used inside tanks, offshore structure, and platforms, on underground pipelines 100% holiday test is required. Brush shape, horseshoe type, coil spring type, wet spring type are the various types of holiday and pinhole detectors. If you worked on a contract where frequent stoppages occurred for poor weather, what additional information would you record? 1. Time of starting and stopping of work. 2. Wastage of materials should be noted down. 3. Extra reasons for weather. 4, Progress of the work before the work is stopped. 5. Record of damages to partly dried coating on to prepared areas (blasted). If a pipeline was in direct contact with acoustic cladding what paint system might be applied if we wished to maintain it every three years or not at all? Cladding - No maintenance required, Acoustic cladding does not have any anti corrosion property. Acoustic cladding reduces the noise level by 10 - 20 dB. Thermal cladding is carried out to with stand the temperatures in between -10°e to +1000°e. What is important about selecting a paint system suitable for a certain environment? Each and every paint has its own characteristics. Select a paint system that should with stand the environmental conditions and comply with the specification requirement. Marine conditions, high humid condition, too low temperature conditions, What information do B-gas require {0 be on a paint tin and what By document deals with the properties and performance of paints. The document PA 9 properties and performance of pant, 1. Manufacturers name, 2, Transeo identification number. 3. Description of the product, Page 16 of 43,nN. 74. 4. Colour code (specified by Transco) 5. Any special storage requirement. 6. The expiry date. 7. Application grade (brush/spray) 8. Batch identification code. 9, Identification of parts, mixing ratio by volume (paint catalyst) 10. Any marking required by current legislation. What is unusital about the preparation of surfaces which are dealt by SPA 4? After blasting remove grit contamination with clean water Describe what you know of HASWA and COSHH? HASWA - Health and safety at work act 1974. It deals with duties of employer and employee with regard to health and safety. Employee should report accident, spillage. It is a statutory requirement. COSHH - Control of substances hazardous to health 1988 one advantage of using fesfex tape and plastic disposable W.E-T combs. It can be kept as a permanent record. State the principles of being able to use a banana gauge for taking D.F.T. readings. When using the banana gauge on ferrous metal (substrate) coated with non-ferrous coatings, then the D.F.T can be measured with banana gauge. It works on the principle of magnetism. Briefly describe the various paint application methods and its limitations. Brush application: Brush painting is said to achieve superior wetting and is the only acceptable way to apply some anti corrosive primers. Brush marks leads to areas of low film build. Use of brush is slow, and time consuming, Rubbing action of a brush can be and additional aid to good adhesion. A brush of suitable size for the work in band should always be selected, as a small brush on a large area makes it difficult to apply an even coating and slows down the rate of working, whilst using a large brush on a narrow area makes accurate working impossible. Rollers: Quality of roller application depends partly on the covering or sleeve of the roller and partly on how conscientious the applicator is. It is not suited for anti-corrosive and anti-fouling paints. Dip-coatings Paint must have a fast drying time. The paint in the dipping tank must be stirred continuously as the viscosity of the paint is important. Rapid withdrawal from the dip tank can cause too thin a coating, Page 17 of 43Powder Coating - Fluid bed & Electrostatic Technique. A fluid bed is one in which a mass of broken up solid is kept in a state of agitation by mechanical or other means. Fluid beds for coating purposes consist of finely powdered pigmented resinous solids through which air is blown to keep the particles in motion. Electrostatic Spray: Paint is sprayed from a pressure feed tank through a fluid hose to the gun in the usual way. At the same time paint is given a -ve electrical charge. As the lecttically charged paint leaves the gun, it atomizes and each particle is attracted to any earthen object, in its path i.e. the article being sprayed, Conventional spraying This involves using a compressed air to both atomize the paint and to convey it to the substrate. In high pressure, the painting is stored in a pressured container from which large quantities can be delivered quickly. Airless spraving: Paint supplied by a hydraulic pump is forced at high pressure through a narrow orifice in a tungsten carbide nozzle, The pressure is such that the paint is atomized and carried to the substrate by its own momentum, Page 18 of 43PAINTING — ERS (ENGINEERING RESEARCH SCHOOL) What is the Swedish standard of surface preparation and how does it differ from BS 4232? SIS — 05 - 5900 is the Swedish standard of surface preparation. It is a pictorial representation. State the Swedish grade of blast cleaning and compare them to BS 4232, Sa3 SIS — 05 — 3900 BS 4230, = White Metal. First Quality Sa2 al ‘Sa2 Vs — Near White Metal (Very thorough | Second Quality blasting) — Thorough Blasting Third Qualit bt Blastin; NA Identify three abrasives used in blast cleaning and disadvantages. state their uso, advantages Chilled iron grit, crushed slag, ceramic grits Chilled iron grit: Excellent all purpose abrasive, due to its relatively high density which gives high particle energy, maintains sharp cutting edges on the grit. Can be reused.Causes rogue peaks if directed at a particular place for a quiet long time, Crushed slag: From a metallurgical process it is cheap / expendable abrasive. Quiet effective grit for one use only. No reclamation due to their rapid break down to dust. No reuse. E.g. copper slag, aluminium. Ceramic grits: Expensive grit, Retains their sharp cutting edges. Can be used on hard base materials. Used at lower pressure on thin metal and on stainless steel, non-ferrous materials as they are inert and do not stain or discolours, What do surface profile and amplitude mean? The shape of a cross ~ sectional blast finish is known as surface profile. The size of profile as measured from the peaks to the troughs is known as the amplitude or peak to trough height. Page 0 of 379. 1. A 12. 13. What is the maximum amplitude on BGC painting contract? 75 microns. (Max) 30 microns (min) Can sand be used as an abr: cleaning operation? No. How are the Swedish standards of wire brushing defined? St2 ~ Wire brushing by manual means, thorough scrapping and wire brushing. S(3 - Very thorough scrapping and wire brushing by machine brushing. Describe the two blasting techniques that use water. Slurry blasting and wet blasting. What is a micron and how many are there in one thou? Micron is a measurement of film thickness, One thou = 1/1000 of an inch, 25.4 microns = one thou, 40 thou =] mm. How thick are imperial and metric values of a plastic backing of testex Imperial = 50 microns Metric = 0.2 mil What disadvantages is associated with wire brushing? Care must be taken to avoid over brushing a particular area causing “Burnishing” a condition with polished surface that has an adverse effect on coating adhesion. Very laborious and expensive What associ: Jason’s hammer? Where could if be used, what restrictions are ced with its use? Needle gun is Jason’s hammer. Needle guns are used for cleaning difficult surfaces such as rivet heads and welds. They leave sharp edge craters and rogue peaks, and they have a tendency to push impurities into the surface ion. Explain the footner process and sequence of ope: Phosphating ~ footner or duplex process: this technique involves a final treatment in a one to two percent phosphoric acid solution held at 80% for one to two minutes, This leaves a thin a rust inhibitive phosphate coating on the steel surface to which the coating shall be preferably applied while itis still warm, possibly after a final wash. Page | of 3714, 15. 16. i. 18. 19, How does the flame cleaning process work and what precautions are necessary if itis used for BGC? Cleaning of the surface by passing a high velocity oxyacetylene flame over the surface to be cleaned. The process removes much of the mill scale and rust, but leaves a dust on the surface, which has to be removed by wire brushing. What is mill scale and is if more or less noble than steel? Millscale is an oxide of iron produced when the steel is manufactured. It is a result of hot steel coming into contact with air and forming oxides composed of three layers, FeO, FepO« and Fe,O3, Mill scale is noble than steel, What is a rogue peak? What problem can it cause? Rogue peaks are peaks, which stand out above the required profile. They lead to spot or flash rusting. Ifa surface is designated Bsa 2 4, what does it mean? Rust grade B, blast clean to Sa 2/4. Describe the two methods of measuring the amplitude Surface profile needle gauge: Relies on the needle touching the bottom of the troughs on the surface profile. Take 20 readings and calculate the average of amplitude Testex tape: 1. Zero the micrometer ensuring flat contact point and clean tip of it 2. Remove the paper backing from the testex tape and stick the testex tape fo the surface to be measured. 3. Rub the testex into the troughs using a blunt instrument, until the peaks can be seen butting up to the transparent plastic. 4, Remove the testex tape from the surface and measure the overall thickness with dial micrometer. 5. Deduct 50 microns for the plastic backing from the reading to obtain amplitude Give five essential requirements for abi ive blasting at site, Removes surface contamination, It gives a surface profile Economical and efficient way Better results than other cleaning. Relatively safe. pape Page 2 of 3720. 2. 22. 24, 26. 21. Describe the action and purpose of dead man’s handle. Deadman’s handle is used for direct operator control, to stop the flow of abrasive vwhen the operator lets go of the nozzle. Where should air pressure for blasting be determined and how is it done? ‘The pressure at the nozzle may be measured using the hypodermic needle gauge. This is placed through the hose near to the nozzle with the hole in the needle facing the nozzle at 45°. Identify two blasting nozzles by shape. State advantage of each, Straight bore nozzle concentrates most of the abrasive in the central arca of the blast pattern, fringe arca of lower blasting size. For small or repair areas and softer metals. Venturi shaped nozzle produces a large blast pattern with the whole area receiving relatively equal amount of abrasive. Gives an even blast pattem area over a relatively large area Des be a test for detecting mill scale on a blast clean surface, An acidic solution of copper solution when applied to a blast clean surface will react by tuning to bright colour on clean sheet but will tun to black colour if mill scale is present. Which BGC code of practice relates to blast cleaning at site? BS 7079. What isa polymer and where do they occur? Polymer produced by the growth of suitable stable molecules called monomers. Monomers, they occur in synthetic resin, polyurethane, What is polymerization and how it is brought about’? Polymers produced by the growth of suitable stable molecules called monomers. ‘The process by which these monomers are joined together is called cross-linking and the result as in the hardening of drying oil type of paint What are convertible and non-convertible coatings Convertible coatings are those that undergo a chemical change dl process that cannot be reversed e.g, alkyd epoxy. ing the drying Page 3 of 3728. 29, 30, Non-convertible coatings are those, which after they have dried may be restored to the original liquid form by the application of solvent. E.g. Nitro cellulose and chlorinated rubber, thermoplastic resins What are the basic components of paint? Paint consists of binders or resins in which pigment or colouring matter is suspended. Usually the binder is diluted by the addition of a solvent. What are the characteristics of M.1.O and its advantages? M.L.O -Micaceous iron oxide: It decreases the permeability of the film. Protects the substrate from the environment. Interferes with the corrosion reactions (inhibitors). ‘What is the function of binder and pigment content? Binder consists of oil or resins or blend of oils and resins. It's essential is the film formation, the ability to change from liquid film which flows to a more or less hard plastic film. Pigment is used for colour or to modify the physical properties of binder resins. To provide rust inhibiting properties. To protect the film from the effects of ultraviolet light and weather. To add body. Name eight binders. 1, Natural drying oils = Linseed oil, tung oil 2. Oleo resinous oils ~ — Alkyds, resins 3. Convertible binder = Vinyl, nitro cellulose, chlorinated rubber 4. Non-convertible binder. - Epoxy, urethane, polyester. What is the fun ion of solvent and its main properties? Solvents are volatile organic liquids used in paints to reduce the viscosity or consistency of the material and to facilitate the application of a uniform coating, Name five solvents and their associate binders. Water ~ Water based paints, emulsions M.LB.K - Vinyl MEK ~ Epoxies. Acetone ~ Epoxy Turpentine / white spirit - Alkyds Toluene / xylene ~ Chlorinated rubber. AWvAUN= Explain T.L.V, M.AC, P.P.M. T.L.V - Threshold limit value Page 4 of 3739. 40. AL M.A.C — Maximum allowable concentration P.P.M — Parts per million How is toxicity of a solvent measured? ‘Tri ~Tector can measure toxicity. Define the three types of drying mechanism. Evaporation: This involves the evaporation of a solvent from the vehicle, leaving behind a film of solid material Chemical reaction: Polymerization — molecular growth by cross-linkage of the res Oxidation: This involves the conversion of the constituents of the vehicle to the solid state by chemical changes involving mainly oxidation by reaction with atmospheric oxygen. How do chlorinated rubber, epoxy and alkyd paint dries? By chemical reaction and solvent evaporation, What is meant by pot life and how does it differ from the induction period? Pot life is the time limit within which the mixed components can be used e.g. five minutes at 20°c. Induction period is the time of mix to the application time. 2s? What are plasticiers and what are they used for, give Plesticiers are usually liquids and must have a minimum tendency to volatize so that they will remain in the film. E.g. camphor, castor oil, chlorinated waxes. What are dryers and why they might be added to oil based paints? Drying agent (Siccative) is added to an oxidative paint to speed up the drying process. Siccative increases the capacity of the binder to absorb oxygen What is the formula for density? Density = Mass / Volume. (Units ~ gms / cubic centimetre) What is cathodic disbondment and under what conditions does it o¢cur? If the impressed current is greater than the corrosion current then the cathodic disbonding may result. This effect happens when excessive CP current is sufficiently strong to begin to generate gases at the metal surface by a process of electrolysis of moisture on the surface. The gas generated pushes the coating from the surface’ and causes adhesion failure beneath the edges of the coating, Page 5 of 3743. 44, Explain relative humidity and dew point. Relative humidity is defined as the amount of moisture (water vapour) in air compared with the meximum possible in air. It is expressed as a percentage. Dew point is defined as the temperature at which condensation occurs. Name five methods of paint applic: 1 2. 3. 4, 5, 6. Brush application Roller application Dip coating (electrostatic technique) Electrostatic spray application Conventional spray application Airless spray application ate the advantages of airless spray over conventional spray Airless spray applies most types of paint much faster than any other manually operated method of paint application. As the paint is not under pressure the pump can operate from the manufacturer’s can, Because no air is used, there is no over spray. A uniform thick coat is produced, reducing the number of coats required A very wet coat is applied, ensuring good adhesion and flow out ‘Most paints can be sprayed with very litle thinning No thinnages on the spray pattern means no overlapping in each stroke with wide form patiern. This makes airless spray much faster than conventional spray. Because of the even spray pattern and cleanage, cutting at angles can be achieved, ‘The single hose connection to the gun makes it easier to handle. Page 6 of 37L 4 6 1. PAINT What is paint? Paint is a film-form in fluid that is spread in thin coats to decorate and or protect a surface, What does paint contain? Paint consists of binders, resins, pigments and extenders. What are the important properties of paint? Provides adhesion to the surface being painted. Colour retention and stability. Gloss Permeability Mechanical properties ~ Hardness, resistance to abrasion or expansion and contraction due to temperature changes. yeeye What influences the mechanical properties of 2 paint film? ‘Nature of substrate and a coating with ideal characteristics. ‘What isa binder and what does it do? Binder consists of oils or resins or a blend of oils and resins. Its essential function is film formation. The ability to change from a liquid film that flows to more or less hard plastic film, What are modern Manufactured from synthetic or resins, What is cross-linking, ‘explain better in epoxy coating specification’? Polymer is produced by the growth of suitable stable molecules called monomers. The process by which these monomers are joined together is called cross-linking and the result is as in the hardening of the drying oil type of paint. lame the four groups of binders. 1. Natural drying oils - Linseed oil, tug oil 2. Oleo resinous oils - Alkyd 3. Convertible - Vinyl, nitro cellulose 4, Non-convertible - Epoxies, urethane, polyester Page 7 of 3710. i. 1. 16, 17. What are pigments? Pigments are small particles that are soluble in the paint solvents that may be used for colour or to modify the physical properties of binder resins. Name the ovo groups of pigments Organic pigment ~ Indian yellow. In organic pigment - Titanium di oxide. Why is pigment added to paint? To provide colour, hide the surface, protect the film from UV light and weather, decrease the permeability of film, rust-inhibiting properties add body. What is M.J.0. and what are its advantages? MLO, ~ Micaccous iron oxide decreases the permeability of film. Protects from UV light and from the environment. What are extenders? Extenders are added to paints to add thickness e.g. chalks, china clay, and tale. What are anti skinning agents and what do they do? A drying agent is added to an oxidative paint to speed up the drying process. E.g. compounds of lead, cobalt. Name the two groups of paints. 1. Non —convertible coatings, e.g. nitrocellulose, thermo plastic resin 2. Convertible coatings, e.g. alkyds, epoxy resin. Name three ways a paint system can dry, Explain each method. 1, Evaporation of solvent from the vehicle leaving behind a film of solid material 2. Oxidation involves conversion of the constituents of the vehicle to the solid state by chemical changes involving mainly oxidation by reaction with atmospheric oxygen. 3. Chemical reaction — polymerization. Molecular growth by cross-linkage. Exp ble and non-convertible coatings. conv Convertible coatings undergo a chemical change during the process that cannot be reversed. Page 8 of 3718, 20, 22. 24. 26. ‘Non-convertible coatings are those that can be restored to their original liquid form after they have dried. Name two heavy-duty coatings and what are their disadvantages? Coal tar, asphaltic bitumen. Applied at elevated temperatures 260°c, fumes — fire hazardous, ‘What are plastic coatings and how are they applied? Use of plastics for corrosion resistant coating. 1. Dipping the preheated object into either a liquid plastic or a powder of plastic particles. 2. Spraying powder particles on to the heated object or through flame onto the object. 3. By extrusion, What is the disadvantage of plastic coatings? Poor bonding to the substrate. Stresses induced by the heating / cooling cycle. What are self adhesive tapes? PVC or polyethylene backing with a rubber base adhesive wrapping tapes: What is polyethylene coating? Sintering a powder directly to the pipe, in much the same way as an epoxy powder Hot extrusion on to an adhesive or mastic. Why is concrete coating used? Itacts as ballast and ensures that the pipeline will have negative buoyancy even when empty, What is antifouling? To prevent growth of marine organisms. What are powder coatings? Use of thermo plastic powders. What are the requirements for priming paints? To secure good wetting of the substrate and provide adhesion to the substrate for the entire system. To control corrosion of steels (by inhibition), Page 9 0f 3727. What are solvents? Solvents are volatile organic liquids used in paints to reduce viscosity or consistency of the material and to facilitate the application of uniform coating. 28. What are the important features of solvents? Rate of evaporation if too slow leads to runs or sags, if too fast it leads to dry spray and poor film. Flash point — Fire hazard, Toxicity ~ Health hazard, 29. What is the M.A.C of common solvents give values? M.A.C- Maximum allowable content limiting value for the exposure. Xylene - 200. ppm Toluene - 200 ppm Benzene = 100. ppm Acetone = 1000 ppm MIEK = 100 ppm Carbon tetrachloride - 10 ppm 30. What are the Positive features Negative features 1. Excellent exterior durability | 1. Poor chemical and solvent Resistance. Alkyd 2. Good flexibility, recoatability | 2. Fair water resistance. 3. Excellent adhesion to moist | 3. Poor heat resistance. surface and easier to apply. 1. Fast dryin, I, Limited heat resistance. Chlorinated [2. Good chemical and water | 2. Poor solvent resistant. rubber. resistant, 3._Good exterior durability. 3, Blast cleaned surface required 1. Excellent chemical and solvent | 1. Poor gloss, to exterior exposure. resistant, Epoxy 2, Excellent adhesion 2, Difficult to overcoat 3. Good high build capabilities, | 3. Mistakes possible in mixing and and good long term application. performance, Page 10 of 3731. 32. Name four types of solvents. 1, Hydro carbons —Turpentine, benzene, white spray 2. Aleohol ~ Methyl, Ethyl, isopropyt 3. Ketones ~Methyl, ethyl-ketone (MEK) 4. Esters — Methyl acetate, amyl acetate. What are plasticicrs? Plasticisers are usually liquid and must have a minimum tendency to volatize so that they will remain in the film e.g. camphor. List solvents and associated paints. Water - Water based paints Toluene/ Xylene - Chlorinated rubber Acetone - Epoxies MIBK - Vinyl MEK - Epoxies In paint manufacture explain pre mixing. Binder, solvent and dilutants are pumped in correct quantities through a centrally controlled pipe system into measuring and mixing vats, where measure quantities of pigment and possible extenders are added. What is dispersion? The raw materials mixed into a batch are dispersed by means of a dissolver, consisting of a shaft with a rotating seriated disc. Paint grinding? Name types of mill and explain. Pearl or sand mill: The paint is pumped into the sand filled mill from below in a vertical mill or from one end in a horizontal mill. The paint is pumped under pressure through a number of rotating discs, which creates strong abrasion effects, and can cause very fine dispersion in the short time of its travel through the mill. Paint collected at the top of the mill at a rate upto 1000 litres. Roller mill: This unit consists of adjustable steel rollers, rotating against each other so that the paint is subjected to pressure and shear forces, which decrease the conglomerate size. The paint is removed from the final roller in the row by a scraper blade or knife Ball mill: This consists of a rotating drum, part filled with steet or porcelain balls of about 2~3 cms. Dia. The mill is filled with the paint until the balls ate covered ancl the drum is set in motion, the pigment conglomerates are ground down due to the abrasion between the balls. The rotation speed is slow, generally less than one revolution per second and the pigment size is controlled by the period of time the mill is operated. Page 11 of 3737. 38. Explain final bateh mi After grinding, the paint is pumped to final batching where more binder and or thinner are added while stirring in order to obtain the correct delivery viscosity. Tinting colour adjustment and quality control adjustments may be performed, prior to loading the materials into the delivery containers. “Draw the different sketches for various mills. Page 12 of 373. QUALITY CONTROL TESTING — PAINT What is specific gravity? Specific gravity is called relative density. Ratio of density of material and the density of water (comparison) SG = Density of x Density of water. It is a ratio, No units. How is testing for specific gravity carried out? Name the equipment. Equipment name: Weight per gallon cup. Weigh the cup and lid empty. Fill the cup with the paint. Allow the paint to stand for two minutes. Excess paint removed Clean external surface of the cup. Weigh the cup lid + paint 6-1 = Specific gravity BOWEN What is the typical specific gravity of paint? 1 to 1.75 What is viscosity. Viscosity is the internal resistance to flow possessed by a liquid. How is viseosity calculated? By Ford Flow Cup No.4 Warm the cup. Cover the hole at the bottom of the cup with finger and Gill the paint. Remove excess paint. Start the stopwatch while simultaneously removing the finger from the hole. Observe the time taken for the flow of paint to start to break into droplets. Time taken in seconds is the viscosity value. SYeena What is the calewlation for volume of solids? Volume of solids = D.E.T_x 100% WRT Page 3 of 3710. ML What is used to find wet film thickness (W.F.T) how is it used? Wet comb gauge: It is pushed firmly into the wet paint so that the outer most teeth makes contact with the substrate, Held at right angles to the surface. Gauge is removed and the teeth are examined, W.F.T. lies between the last tooth i.e. coated and the first tooth that is uncoated, Midpoint between this is W.F-T. fat is used to find dry filin thickness (1)-F.T) how is it used? Banana gauge ~ magnetic pull of gauge: 1. Calibrate the instrument on steel surface profile, which matches with the profile of the painted surface being measured. 2. Using shim of known thickness, calibrate the instrument in the range expected measured thickness will lie What are the thickness of the shims used and identify by its colour? 25 microns = — purple Sl microns ~ dark blue 127 microns - brown 254 microns — white 508 microns. - yellow How is thickness measured on M.L.O and why? Metallic painting by W.F.T. By knowing the W.F.T. and conversion using the formula WET. = 100x DFT Vs % xplain the cross cut fest method. Pressure sensitive tape, sharp knife, and rubber eraser. No. of cuts shall be six or eleven. Surface is clean and dry. 40-mm long space, cut 1mm apart if carrying leuts, two mm apart for six cuts. Cut through the film in steady motion. Repeat the process in the opposite plane to give 1 mm or 2 mm. Inspect the cut to establish that the surface has been penetrated. Place the tape over the grid and smooth it by finger, then rub with eraser. Remove the tape after 90 seconds. After making several cuts examine the cutting edge and discard if jagged or if tearing of the paint film. What are acceptable results of eross cut tap SB: The edges of the cuts are completely smooth, none of the squares of the lattice is detached. Page 14 of 3713. 16. 4B: Smail flakes of the coating are detached at intersections less than five percent of the area is affected. 3B: Small flakes of the coating are detached along the edges and at intersections of couts. The area affected is five to fifteen percent of the lattice. 2B: The coating has flaked along the edges and on parts of the squares. ‘The area affected is fifteen to thirty five percent of the lattice. 1B: The coating has flaked along the edges of the cuts in large ribbons and whole squares have detached. Area affected is thirty five to sixty percent of the lattice. OB: Flaking and detachment worse than grade TB. Explain the X cut test. Pressure sensitive tape, sharp knife, rubber eraser are the materials required to carry out the test. Surface should be clean and dry. Make two cuts in the coating each approximately 40 mm that intersects near the middle with an angle of 30°, Inspect the cut to establish that the surface has been penetrated. Using a piece of tape 75-mm, place the centre of the tape at the intersection of the cuts, smooth the tape by finger and then rub firmly with eraser. Brush the area lightly with soft brush, remove the tape after approximate 90 seconds by taking one end and rapidly. Examine the cutting edge of too! for signs wear and replace when needed, Inspect the cut area and rate the adhesion, What are the acceptable results of X - eut tests? SA: No peeling or removal 4A: Trace peeling or removal along incisions. 3A: Jagged, removed along most of incisions upto 1.6 mm on either side. 2A: Jagged, removed along most of incisions upto 3.2 mm on either side 1A; Removal from most of the area of X under the tape, 0A: Removal beyond the area of X Explain pull of test A dolly made of aluminium alloy is stuck on to the coating system under evaluation using araldite adhesive. Afier the adhesive has cured, the dolly is removed by direct pull-of using a special tool and the force required is measured, Explain flash point and how this is obtained? Flash point of a material is the lowest temperature at which the vapours given of will ignite when a flame or spark is passed over it. Flash point is obtained by the use of Abel cup. Fill the test cup with the paint and place it in the water bath, which is heated to the required temperature. Light the ignition device when the paint has reached the required temperature. Carry out flame test, Raise the temperature by 0.5% and repeat ignition, in steps of 0.5% raise until the flash point is reached. Read the thermometer reading of the temperature accurately. Page 15 of 377. 18. 19 20. 21 What is relative humidity? It is the amount of water vapour in the air expressed as a percentage and it is obtained by a calculation made from the dry bulb and dew point temperatures. What are acceptable application conditions for blasting and painting? Paint should be applied only to the surfaces that are thoroughly dry and under such conditions of humidity and temperature, as it will promote evaporation, rather than condensation. Other factors to be aware are strong hard sunlight, strong winds which could cause too rapid evaporation of solvents and the paint film being impregnated with dirt ete., Bgas Specification 1. The air or metal temperature is atleast 3°e above the dew point temperature. 2. The relative humidity is less than 90%. 3. The temperatures for the applications are within the manufacturer recommendations. What is dew point? Dew point is the temperature at which condensation of water vapour in the air would form on the surface. What equipment is used to find humidity and dew point? Explain its use. Using whirling hygrometer, 1. Cheek the fabric of the wet bulb is clean, wet and secure at both the ends. container should be full of ctean water. 2. Whiel the hygrometer at about three revolutions per second for one minute. 3. Read both the thermometers, noting the wet bulb first 4. Whirl again for another minute. Read temperature again. Repeat until constant temperature reading are obtained 5. Records wet and dry bulb temperature. 6. Calculate relative humidity, dew point using chart How is surface profile measured? Model 123 - surface profile gauge is a quick, direct reading and easy to use instrument. The gauge is first set to zero by leveling the foot and the pointer on a flat surface. When the foot is subsequently pressed against a blasted profile, the foot will rest upon the peaks and the pointer will penetrate the valleys. The dial will show reading. Take ten such readings and take the average of it What is BS 7079? Preparation of steel substrates before application of paints and related products Page 16 of 3724, 26. What is the maximum time between blasting and painting? Four hours. What specification is used to define this time? BS 5493, Name the four international standards for blast cleaning. 1, SSPC - Steel Structures Painting Council. 2. NACE - National Association Of Corrosion Engineers 3. SIS - 05-5900 - Swedish standard - pictorial surface preparation standard for painting steel structures. 4. BS 7079 - British Standard Specification. List blast cleaned surface i.¢. give comparison of blasting grades fo the above standards. PC 7079, BS 4232 NACE 900 depreciated White metal (SPS) First quality [Grader | Near white metal Second quality Grade 2 (ploy) - — Commercial finish | Sa2 Third quality Grade 3 (SP6) - _ Light blast and brush | Sa i N7A off (SP7, 27. Explain the test for soluble iron. 28. Test paper - soaking of filter paper in a freshly prepared 5% solution of potassium ferricyanide in water and allowing the paper to dry When pressed against a wet steel surface it will show a blue colour whenever soluble iron salts has been dissolved by water Explain test for soluble sulphates. Filter paper soaked in a barium chloride dehydrates 6% wet solution and dried. The dry paper is then pressed against the test surface backed by a second paper soaked! in saturated potassium permanganate, contamination is absorbed and held in the barium sulphate lattice, imparting a pink colour to those parts of the paper which contacted sulphates Page 17 of 3729. 30. 33, Explain the soluble chlorides. Filter paper wetted with silver nitrate 2% wet solution and then pressed against the steel surface for about twenty seconds. It is then peeled off and thoroughly washed in chloride free water, Immersion photographic developer can detect any silver chloride formed remains in the paper. Chloride sites shows brown - black areas. ‘Explaiii test for mill scale. An acidic solution of copper solution when applied to a blast cleaned surface will react by tuming to a bright copper solution on clean steel, but will tum to a black colour if mill scale is present. Explain the test for oil contamination. Shinning on ultraviolet light source on the surface causing the oil to fluorescence. Pouring solvent across the surface, the solvent should form a continuous flow and not break into droplets. Explain the test for dust. Use of strip of clear cello-tape 25-mm wide strip. Press the tape onto the surface lightly rub over the tape with finger, then snatch the tape off. Any loose dust will stick to the tape and will show up clearly when the tape is put onto white paper Explain care of blasted surface. Surface prepared for coating should not be allowed to deteriorate or the contaminated in anyway between grit blasting and spraying. Blasted surfaces should never be handled or touched unless hands are protected with clean gloves. Page 18 of 376 9, 4, SURFACE PREPARATION What is used to detect pinholes in paint? DC Voltage - wet sponge (low voltage) test by holiday detector. What is tacking? Coating has partially set only; surface is not wet but has a sticky feel, like tape, due to excessive thinner, insufficient drying time, low temperature. What problems result from poor mixing of paint? Poor opacity, slow drying, poor gloss What type of stirrer is used when mixing by hand? Properly made stirrer should be used which is long enough to reach the bottom of the container and with a broad, chisel like edge and a comfortable handle. What percentage of thinner is normally required? Ten percent. What is the result of over thinning? Thin coating will result in poor durability and a lower resistance to corrosion. What is induetion period? In multi pack paints, itis the time of the mix to the application time. What is pot life? ‘The pot life is the time limit within which the mixed component can be used. five minutes at 20°. What condition shows when paint is stored for long periods or in poor ar On aging paint may tend to thicken or go out of condition, Paint tends to settle during storage and after prolonged period. Page 19 of 3710. ik 12. a 16. 17, 18. What is drying time? Drying time is the period when, 1. Solvent is evaporating from the film 2. Curing by oxidation or when chemical reaction is taking place. ‘What is drying time affected by? a. Temperature b. Paint film thickness. c. Ventilation (concentration of solvents immediately above the surface) What do manufacturers data sheets quote for drying time? ‘Touch dry: When the film is no longer tacky, Hard dry: When the film is sufficiently hard to permit measurement of D.F.T Full cure: When maximum chemical resistance has been built up within the coating, What data would you require from manufacturer prior (o paint application? Paint manufacturers should quote the temperature at which the drying times are applicable e.g, 20°e. What improvement to a paint surface would blast cleaning have over other methods? Better surface preparation improves the performance of any coating, What is the fundamental principle of blast cleaning? It is the removal of rust, millscale, or other surface contaminant by projecting a highly concentrated stream of relatively small abrasive particles at high velocity against the surface to be cleaned What type of abrasives can be used? Chilled iron grit, crushed slag's, ceramic grits ‘The degree of surf ce roughness is related to what? The degree of surface roughness and the rate of cleaning depend primarily on the characteristics of the abrasive grit used. What al rasives are commonly used? Crushed wall nut shells, glass and crushed s Page 20 of 3720. Why is sand and flint not o be used for blast cleaning? Due to health hazard - formation of silicosis. Name types of surface cleaning other than blasting. Water blasting Manual cleaning Flame cleaning Needle gunning Weathering Acid pickling Degreasing. yavayee Page 21 of 37METHODS OF PAINT APPLICATION 1. What points have to be considered when brush painting? Paint application has a significant effect on the life of a paint system. By employing skilled painters, applying paints. under properly. controlled-conditions, and only suitable ambient conditions outside What method of paint application is performed for primer and why? Brush painting is said to have achieved superior wetting and is the only acceptable way to apply some anti corrosive primers. Brush marks leads to areas of low film build. Rubbing action of a brush can be an additional aid to get good adhesion. 3. What are the advanta; s and dis-advantages of roller application? ADVANTAGES. DISADVANTAGES 1. Mobility and low equipment cost. 1. Not suited for imegular surfaces, 2. Cleaner than spray gun. 2. Thin uneven coats with misses / pinholes. 3. Faster than brush. 3. Poor penetration, not suited for all types of paints. 4 When is dip coating used? Objects coated by dipping are usually part of a conveyor belt system in which stowing is also involved in order to prevent more drips. 5. Name methods of powder coating. 1. Fluid bed, electrostatic technique. 2. Electrostatic spray. Explain electrostatic spray with advantages and disadvantages. ADVANTAGES [DISADVANTAGES, T-'No over spray. T. Not suitable for water thinned paints or _ — heavily pigmented metallic coating, —_| 2, Very clean to use. 2, Equipment is costly and not easily maneuvered, Great saving in paint Page 22 of 371, Airmotors 2. Electrically driven hydraulic pump. What types of spray pumps are used? Explain conventional spraying with advantages and disadvantages. This involves using compressed air to both atomized paint and to convey it to the substrate. ADVANTAGES, DISADVANTAGES. 1. Highly quality finish, 1. Paint fog and loss of material. 2. Even film thickness. 3. Easy adjustment, 2. High equipment cost. 3. Not always suited for outdoor work. 4, Applies water borne silicates. 4. Unsuitable for high build and high viscosity paints, 9. o Explain airless spraying with advan Poor penetration, risk of over spray ages and disadvantages. ADVANTAGES, DISADVANTAGES 1. Very high work rate. 1. High equipment cost. 2. Good automation paint fog, little or no 2. Depends on power source. 3. Pole gun for awkward places 3. Less mobile than brush / rolier. 4. Only really suitable method for the application of high builds. 4. Risk of dry spray. 3. Good penetrafor. 5, Adjustments only by changing the nozzle. 10. What are fluid tips and what do they Readily changeable part of the gun and 1. Controls the width of the spray patt control? are fitted by the retaining nut. em by varying the angle of the tip. 2. Controls the quantity of paint passing through, 11. Why isa reversible head used? To save removing, cleaning and replacing the tip each time to clear the blockage by small particles of dust. 12, What type of fluid fine hoses are used Specially designed high pressure, solver with wire mesh, fitted with thread conn: gun allowing free movement. (For rem J and why? nt resistant, small bore hoses, reinforced ection, swivel fitted between hose and the ote location application) Page 23 of 37Explain the advantages of airless spray over conventional spray. 1 een ave Airless spray applies most types of paint much faster than any other manually operated method of paint applied. As the paint is not under pressure, the pump can operate from the manufacturer's can. No air is used. No over spray. A.uniform thick coat is produced, reducing the number of coats. A very wet coat is applied erisuring good adhesion anid flow out ‘Most paints can be sprayed with very little thinning. Faster than conventional spray. Even spray pattern, clean edge, cutting at angles can be achieved. Single hose, easier to handle. Page 24 of 376. INSPECTION, STANDARDS AND SPECIFICATI: What major factor determines the success of a coating? Environment in which it is placed. ‘Temperature, the coating has to.endure.. Direct impact, mechanical damage, wear or erosion. Chemicals. Service conditions. Why are environmental tests carried out during a project? a. Extremes of weather can be detrimental to the coating process. b. Moisture on the surface prevents film formation or reduces the quality of coating adhesion. c. High temperature may cause rapid evaporation of solvents or create a layer of coating at the substrate interface, which has not been able to flow. d. Low temperature may reduce solvent evaporation rate or interfere with the cure cycle of the coating, plain how environmental testing is carried on a. Measure the ambient temperature (air) and substrate temperature. b. Relative humidity and dew point by the use of whirling hygrometer. ©. Surface temperature - magnetic dial type. When shall coating be not appli a. During rain, snow or high wind, . When the air or metal temperature is down to within 3% of the dew point temperature. c. When the air or metal temperature is below 5°. (according to the paint manufacture). a. When the relative humidity RIT is above 90%, e. Substrate is wet Explain how wet film thickness gauges are used? The wet film gauge should be placed in the coating film at a angle 90° to the Surface. Teeth are examined after immersion in the wet coatings on their surface Measures less than the W.F.T., while those with no coating measures more than W.F-T. Mid of the values shall be taken. Pron 26 af 479 10. What is BS 7079? Preparation of steel substrates before application of paints and related products. What is rust grade D? Heavily corroded and pitted steel. What is the wri ten equivalent of Sa 2 1/2? Second quality to BS 4232, How is surface temperature measured”? By magnetic surface temperature gauge. How accurate are magnetic D.F.T. gauges? 110%. What are the advantages of electronic D.F-T. gauge’? Electronic gauges can be very good when they are properly calibrated. Accuracy is very precise, Capable of storing many measurements, making statistical analysis and printing the results on a computer pointer. What voltage is used for a wet sponge holiday detector? Operating at voltages below 100 volts. (normally at 67.5 volts) What standard describes the se of holiday detector? NACE standard RP - 01 - 88. What is testex? How is it used and what are their lim ns? Testex tape Press - 0 - film is a replica tape composed of an incompressible Mylar backing of known thickness (2 mils) coated with a compressible film. Peel off one piece of tape, remove the backing tape and stick the tape on the blast cleaned surface. Rub the top surface of the tape (ie. on the middle of the sticky section) with a blunt tool such as eraser head of a pencil, until the tape has picked up an impression of the blast-cleaned surface. Set the dial tape micrometer to the zero mark, Put the tape into the jaws of the dial tape micrometer. Be sure i is placed on the tape window only. Measure the reading, subtract two mils from the reading. It gives the surface profile. If anchor profile is less than 0.8 mils or greater than 4.5 mils testex tape will not give a worthwhile measurement. Pave 26 of 3715. 16. 17, 18, a When are high voltage holiday detectors are used and at what voltage? Holidays in virtually any thickness, 1000 volts - 20,000 volts. What is BS 4800? Schedules of paint colours for building purposes. What is 5493? Code of practice for protective coating of iron and steel structures. What is BS 3900? Method of test for paints, What is BS 57507, 1SO 9000 series - Quality system. What is an inspector's prime concern? Monitoring quality on a coating project Why are verbal communieations important? Need to communicate effectively. Take an objective view of interpersonal skills. Why are written communications important? Writer is aware who will read the document, what is needed, to pass on the required information, describe the activities ete., As an inspector would you he expected fo supervise? No. Asan inspector what do you consider as your main respons To ensure compliance to the specification, To assess the quality of the work. To ensure safe working methods are adopted. To report the deficiency/any deviation from the set standards. To prepare inspection reports To ensure adherence to good work practices. meaege Page 27 of 3726. 30. Do you consider a good relationship with the client to be important? ‘Yes, Good working relationship helps to resolve problems, to arrive at an amicable solution. What factors determine the level of inspection? ‘Type of protection treatment, requirements of the coating, its end use, cost of inspection, quality of supervision to be expected of the coating-applicator. ‘What would you a painting specification contain? It should outline a procedure. How many measurements are to be taken, time interval when it is to be done? Which instrument to use. ‘What would be the inspection authority and responsibility? Guideline for completion and submission of inspection reports. paege What would a pre job conference provide? a. Contribute an understanding of the inspection criteria, which are specified, the tools and methods that will be used. b. Ensure that every class of the specification is understood. Highlight potential problems 4. To record the purpose of the meeting. What safety ehecks would an inspector carry out prior to blast cleaning? Work permit obtained ‘Areas are cordoned of (restriction to entry). Earthing is done. Display of caution boards An observer to watch the operation. Use of PPE, overall, bridging apparatus, shoes and ear defenders. Air inlet without any contamination Equipments are checked for their performance. Unauthorized entry restricted. meaege ree What checks would an inspector Check the masking of sensitive areas of site, electronic components, plates etc., Ensure existing coaters are protected from over spray. Check contaminant screens. Ensure that the hazard warning signs are in place. Check the equipment. Check the environment conditions. Page 28 of 37What surface preparation cheeks do you consider to be most important? &. Visually examine the substrate prior to blast cleaning or power tool cleaning to ensure there is no inherent defects or detrimental contamination such as mud, oil, or construction debris, Check blast-cleaning air to ensure itis free of oil and water, Check that the oil and water traps are functioning and empty of water. Observe the surface preparation looking for unusual surface conditions/colouration, Visually check the abrasive being used. Measure anchor profile atleast once for each hour of blast cleaning, Surface cleanliness - does it meet the standard, Surface profile pattern. Unblasted areas, Make scotch tape test to ensure dust has been removed. me ees Se see Page 29 of 376. 10. HEALTH AND SAFETY. What documents state health and safety at work? Health and safety work act 1974 (HASWA). What year was the health and safety act passed? 1974. What is an inspector's first duty to access? Access the risk. How long would records of personal exposed be kept? Thirty years. What is E. PA? Environmental protection act. What is V. XE? Volatile organic compounds. What is the V.O.C. regulation on the maximum level of pounds per gallon? 4.5 pounds per gallon. How would structures coated by lead based paints be blast cleaned? Blast cleaning in an enclosed environment Name some heavy metals used in coating and painti Red lead, zine chromate, chrome lead Is personal protection equipment important (PPE)? Yes. Itis a must for safe working. Page 30 of 37ri 2. 14. 18. 19. 20. What types of filters are used for breathing apparatus? Charcoal filters. How would you remove or reduce r a. Ceasing to use the process, which uses the hazardous material, or by substituting an alternate material. Provide sufficient ventilation inthe area to reduce the hazard to non-hazard. Enclose the area completely. Restrict access to the area, Provide protective clothing, breathing equipment, ppe. sao What type of protective clothing is required? Long sleeve cover-all, full leather protective suiting for the blast-cleaning operator What is toxicity? Risk of explosion in an enclosed environment What is L.R.L? Lower exposure level. What is P.P.M? Parts per million, What is used for gas testing - list equipment, a. Explosive meter. b. Dragger meter. c. Tria tector. 4. Oxygen meter. When must a paint contractor register with the E.P.A When applying more than twenty tons of paint of five tons of solvent. Painting contractors are monitored to ensure what? Hydrocarbons solvent emission rates are less than 50 mg of carbon per cubie metre coatings, 250 mg per litre of solvent. What is a work permit and why it is required? Work documentation system that must be followed before work is performed in a hazardous environment. Requirements for entry to confined spaces. Restriction on acess, equipment and working method. Page 31 of 376. CATHODIC PROTECTIO! What is corrosion? Corrosion is an electrochemical process. Corrosion the surface due to interaction with the environment. the decay or deterioration of What factors can prevent corrosion? a, Material selection. b. Protective coating. ©. Cathodic protection. Name seven types of corrasion. a. Surface corrosion. b. Pitting corrosion. ¢. Stress corrosion cracking 4d, Fretting corrosion. e. Crevice corrosion. f. Corrosion in acid or alkaline environment, g. Bacterial corrosion. What factors influence corrosion? a, Temperature. b, Humidity. c. Surface condition of the metal. d. Time, e. Effect of stress. £. Atmospheric pollution How will coating help to prevent corrosion? a, Prevents or restricts contact between the environment and the substrate. b. Releases substances (inhibitors) which repel attack by the environment. c. Produces an electric current, which protects the substrate. What is cathodic protection? Cathodic protection is the process of reducing or eliminating corrosion by altering the flow of electric current in such a way that anodes become cathode. Page 32 of 377, Name two types of cathodic protection system. a. Sacrificial anode system. b. Impressed current system. List metals in the noble order. a. Gold. b. Silver er Copper d>Hydrogen - e. Lead £ Nickel g. Iron h, Zine i, Aluminium j. Magnesium List anodes normally used for a. Pipelines in the ground — - Magnesium. b. Pipelines under the sea. - Zinc. c. Fixed sea structures - Zinc or Aluminium, 1. Explain stray current effeets Other metal structures near to the ground bed may cause CP current to flow in an unpredictable fashion. Interfering structures to be connected to electric resistor 11. Explain cathodic dishonding. If the impressed current is greater than the corrosion current they are strong enough to generate gases at the metal surface by electrolysis of moisture on the surface. The gas generated pushes the coating from the surface and causes adhesion failure beneath the edge of the coating. 12. What information can be gathered using survey techuiqu Measurement of soil resistivity Measurement of corrosion potential Pearson survey (for location of holidays in coating) Interference survey. aeoe 13. What is mill scale? Is if more noble than steel? Mill scale is a thin black, flaky layer of oxidized iron formed on the steel during its manufacture. Mill scale is more noble than steel. Page 33 of 3714, 16. 18. WW, 20. What is calorising? Calorising is a method of impregnating aluminium powder on to and into a metal surface at high temperature (700 to 800°c) producing a surface with excellent corrosion resistant. What is stainless steel? Itis an alloy of irowand chromium. What is corten? Itis a low-grade stainless steel What is Monel? tis an alloy of 70% nickel, 25% copper and iron, magnesium and silicon, Where is cupro-nickel used? Where erosion and corrosion might occur Explain an impressed current CP system. Voltage ftom an external power source called transformer rectifier is impressed on the circuit between the pipeline and buried earth connections known as ground bed resulting in a direct current being discharged. In discharging current to carth the ground bed material is subjected to corrosion. The impressed current system can be used in all types of soil resistivities, the greater the resistivity, the greater the driving voltage or number of anodes to achieve CP. Why corresion is particularly severe in industrial and marine environments? Variation in oxygen content on the steel surface (wet / dry) RH % (above 60% is critical) Presence of impurities in air (acids, alkali, salt etc.) Higher nobility suetals in contact with the steel (e.g. mill seale) ‘Temperature (ambient and substrate temperature) ene se Page 34 of 37PAPER 1. (B-gas) PAINTING GRADE 3,2. Deseribe why and how corrosion occurs. Corrosion is an electrochemical process called electrolysis, which results from an anodic reaction and atleast one cathodic reaction & metal iron reduction. Whenever a material.which is having free +ve ions is immersed in an electrolyte have -ve ions or free electrons, metal is reduced to its oxide by chemical bonding process. This is called corrosion of metals. Deseribe what is meant by bimetallic corrosion. Bimetallic corrosion occurs when two different metals are attached close together. Th less noble of the two metals will act as an anode to the nobler one, the cathode and will sacrifice itself. Deserihe the following. a. The galvanic series: is that metals carry an order of nobility to corrode. This nobility is found by testing in seawater. Gold and silver corrode less quickly than copper mill scale, steel, aluminium and zine. So we can use the galvanic series to bring about cathodic protection to steel b. Mill scale: is a black flaky layer of oxidized iron found on steel during its manufacture, c. Rust grades to SIS 05-5900: There are four grades. Grade A - Covered with mill scale, with little or no rust. Grade B - A mixture of mill scale and rust Grade C - No mill scale, surface is slightly rusted. Grade D - Heavily rusted and pitted Blast cleaning grades to SIS 05-5900: There are four standards. Sa | - Light blast clean. Sa 2 - Thorough blast clean. Sa2 1/2 - Very thorough blast clean. Sa 3 - Blast cleaning to visually clean steel. i Deseribe the difference between water blasting and pressure washing. Water blasting is carried out at very high psi and with added abrasives to remove the most contaminations - can cut a profile in steel. Also very good in removing toxic coatings. It is excellent at cleaning tube bundles, Pressure washing is @ low pressure water system mainly used for cleaning painted surfaces, it can also be used with a detergent for removal of salts, chlorides, and contamination from substrates. Very usefull tool in the maintenance paint field. Page 35 of 37