ICORR Coating Inspector Opt
ICORR Coating Inspector Opt
ICORR Coating Inspector Opt
Inspector
ICorr Level 2
Pipeline Coatings
Inspector
ICorr Level 2
Part A
TABLE OF CONTENTS
PART A
1 Constituents
Coal tar enamels
Plasticised coal tar pitch from coal, distilled in coke ovens, is the main constituent to
which is added various amounts of coal oil (plasticiser), which modifies the material
for viscosity properties and temperature tolerance. Fillers are added, usually in the
form of talcum powder or slate flour, in proportions of 25% to 35%, these are classed
as inert mineral fillers.
Bitumen enamels
Bitumen (asphalt) is a heavy residue from the distillation of crude oil.
Inert mineral fillers are added, usually in the form of talcum powder or slate flour as
for coal tar. The viscosity of bitumen can be reduced by adding certain waxes and
increasing refinement. Herbicides are also added to bitumen enamels to discourage the
formation of root growth.
I Limitations
1. Overall - poor performance properties when compared to more modern systems;
90
higher CP currents required.
2. Labour intensive at least three operatives will be required for site applications
1I
For site work bulky melting pots are required.
3.
4. Coating needs reinforcement.
5. Safety hazards - (1) toxic fumes from liquid state; (2) danger of burns from hot
enamels especially during field application on welded butt joints; (3) flammablz
constituents.
6. Thermoplastic nature of coating can lead to coating damage during handling,
storage and ditching.
7. Susceptible to breakdown in UV light.
8. Susceptible to coating damage during soil stressing. '
30
Surface preparation
Factory
Surface preparation in a factory is normally carried out by dry abrasive blast cleaning
using totally enclosed centrifugal blast cleaning units. Chemical cleaning, usually
using the Footner process, is an alternative.
Typical requirements (blast cleaning)
Abrasive used - steel grit or grit and shot mix.
Profile requirements - Sa21/2, medium profile or 50-75 p.
Inspect blasted areas for surface laminations (slivers); if any exist then remove
with a grinder, check for correct contour and wall thickness then reblast the area.
Site
Full pipe lengths along
Welded joints are blast cleaned using pressure blasting equipment and dry expendable
with the welded joints may abrasive.
also be prepared and
coated on site with puTose Typical requirements (welded joints)
built equipment to allow
for a continuous operation. Remove solar protective coating and all extraneous material from the existing
coating (150 mm is typical requirement).
Degrease only if necessary.
Chamfer coating by 50 mm or 100 mm as specified, using a blow torch and
scraper.
Blast clean using dry expendable abrasive -profile requirements - Sa21/2, medium
profile or 50-75 pm.
Inspect blasted areas for surface laminations (slivers) - if any exist: remove with a
grinder, check for correct contour and wall thickness then reblast area.
Check for disbonded coating; if any exists then remove and reblast the area.
Coating application
Factory
In a pipe coating factory (mill) the enamel coating process is often done as a continual
process by using spacer collars placed between the pipes, so that in effect, one long
continuous pipe length is being coated. Some coating factories will treat each pipe
separately.
1 2.
3.
Remove dust.
Apply primer by brush.
4. When primer is dry, apply the 1st flood coat of enamel. This is poured from a
bucket and the coating is smoothed off (preventing icicles) by using a sling which
80 is pulled back and forth around the joint by two operatives.
5. Apply 2nd flood coat of enamel simultaneously with the application of a
fibreglass inner wrap overlapping the existing coating by at least 75 mm.
1 6
Apply a 3rd flood coat of enamel and apply an enamel impregnated outer wrap.
Typical thickness requirement: minimum 4 mm.
90~
Safety
When using coal tar enamels, due regard should be paid to the hazardous and irritant
fumes. Barrier creams should be applied to all areas of bare skin and ideally masks
worn. Contact with coal tar can cause warts. Medical advice should be sought at the
first suspicion. It is not advisable to use enclosures during inclement weather because
of the fumes.
Coal tar and bitumen enamels should normally be used at temperatures below their
spontaneous ignition temperature but even so, the vapour space is frequently within the
flammable range, therefore smoking or naked flames should not be allowed in the
vicinity of a tank or drum containing hot material and no source of ignition should be
put into a tank or drum which has contained this material until the tank or drum is gas
free.
1 Testing
I Tests on the primer
1. Viscosity measurement using a flow cup at a specified temperature.
40
2. Film thickness measurement.
Tests on the enamel material
1. Enamel temperature measurements.
2. Softening point (ring and ball).
50 3. Penetration.
4. Viscosity measurement using a Zahn flow cup at 230C.
I Tests on the enamel coating
1 1. Preliminary adhesion.
2. Tapping tn check for laminations.
3. Holiday detection.
X60!
4. Bond strength test.
5. Thickness of wrapping.
,, 6. Visual check for uniformity of coating contour, e.g. no icicles, ensure outer wrap
is not disbonded and bleed through has taken place and ensure no coking exists.
7. Coupons taken to ensure inner wrap is correctly positioned in enamel.
Laminations may also be evident.
Determination of filler fineness, filler content, enamel specific gravity, peel resistance,
,, sag resistance, flexibility (bend tests), low temperature disbondmentlcracking, impact
resistance and cathodic disbondment, are other tests carried out at less frequent
intervals, e.g. once a year or at the start of a project. The inner and outer wraps must
also meet specified requirements for various tests.
Repairs
Repairs to enamel coatings can be carried out by various methods depending on the
nature and size of the coating fault. Pinholes are sometimes repaired using a hot knife
whereas extensive damage would normally require full circumferential removal of the
wrapping over the affected area. The bare area may then be repaired with the same
enamel (normally incorporating reinforcement), heat shrinkable material, hot applied
1 3.
4.
Low fire risk - although loose powder particles in the air are highly flammable.
Low processing time.
5. Good film properties - especially chemical resistance.
6. Low dust pick up (-3 minutes to full cure).
7. Good edge coverage (no shrinkage therefore good on sharp corners).
8. Clean to use.
Limitations
1. Heating of components can be costly.
2. Achieving thin films, e.g. <25 pm, can be difficult to achieve if ever requested.
3. Different powders c a n ~ l dbe illixecl w i h each otlier, e.g. powders with different
colours, from different generic types or from different manufacturers.
4. Prone to chalking when exposed to UV.
5. Prone to chipping damage due to brittle nature.
6. High storage temperatures can cause sintering.
Surface preparation
Factory
Surface preparation in a factory is normally carried out by dry abrasive blast cleaning
followed by the application of a conversion coating (phosphoric acid wash and/or
The phosphoric acid wash andl chromating). Sometimes the conversion coating is omitted.
or the chromating is done to
passivute the surjface byforming It is essential to remove any oil or grease prior blast cleaning. The client's
a relutively stable strongly specification or contractor's procedures should clarify this but a typical clause would
adherent corrosion inhibiting
state 'before surface preparation commences, any oilfgrease shall be removed using
layer and to provide a sufuce tu
which coatings will readily suitable solvent'.
adhere.
Typical requirements
Abrasive used - steel grit or ,git and shot mix.
Profile requirements - Sa2%, medium profile or 50-75 pm.
No more than X hours to elapse before powder application after the conversion
coating has been applied.
Site
Welded joints are blast cleaned using pressure blasting equipment and dry expendable
abrasive. Conversion coatings are not used.
In a factory, long pipes can be manoeuvred and spun in front of blast nozzles or
centrifugal blast units as required. Once the pipes are welded together to form a string
in the field a different situation arises. The heat generated during welding often causes
a certain amount of damage to the edge of the factory coating and scorches and
disbonds the coating. These damaged areas need to be removed.
Typical requirements
Remove all extraneous matcrial and any loose or blistered coating.
Degrease the welded area and onto the existing coating either side of the joint
using a suitable solvent.
Abrasive used - dry expendable abrasive.
Profile requirements - Sa2Y2, medium profile or 50-75 pm.
Overlap blast pattern onto the existing coating by 30 mrn - only roughen the
coating.
Inspect blast cleaned areas for surface laminations (slivers) - if any exist then
remove with a grinder, check for correct contour and wall thickness then reblast
area.
Check for disbonded coating; if any exists then remove and reblast the area.
Site application
Field application of powder onto welded pipe butts is usually done as the third stage of
a continual operation carried out from one vehicle: (1) blast clean, (2) heat, (3) apply
powder.
A flat back trailer or similar carries a compressor which provides air for grit blasting
and powder application, a generator for providing power, an induction heater, a
powder application control unit, a small blast pot and the consumables needed.
In the first part of the operation the grit blasting operative prepares the butt as
previously described, he then moves to the next butt whilst the heating coil moves onto
the butt just prepared.
Heating
The coils can be built to cater The induction coil is clipped into position and the generator supplies a 110 V
for various bun joint widths. alternating current. The induction coil itself does not touch the pipe and only gets
warm from radiated heat from the pipe. The coil sets up a field which causes the metal
particles to excite, the resulting friction causes the steel to heat up. Heating time can
Powder storage
Epoxy powder is usually supplied in polyethylene lined cardboard boxes and should be
kept dry at all times but should not be left in direct sunlight or stored overnight in the
60 application container, otherwise the curing of the coating may be affected. Batches
should be used in strict rotation and faulty batches should be placed in quarantine until
written authority is gained to use or destroy.
Safety requirements
Any sources of ignition should be kept away from the area where epoxy powders are
being used. When the powder is in the air it becomes highly flammable. Masks and
goggles should also be worn.
I Factorynaboratory tests
Tests on the powder
a. Infrared scan - gives a fingerprint of the powder for comparison purposes.
b. Gel time.
c. Particle size analysis - optimum size depends on method of powder
application. Test sieves are used complying to BS 410.
d. Density.
Ruane &
T P OVNei//
*,60
Site testing
a.
b.
c.
Gel time test (rare on site).
Dry film thickness.
Holiday detection.
d. Adhesion test.
e. Cure test - DSC (sample taken and despatched to laboratory).
10' Repairs
Minor damaged areas, pinholes and areas found with low DFT are marked for repair by
using an indelible material by drawing a circle around the unacceptable area.
In factories, repairs are not normally permitted within 200 mm of the end of pipes
because heating in the field prior to joint coating would destroy the repaired areas.
Repair materials used are usually two pack solvent free compounds (epoxy or
urethane) and should be mixed and applied according to manufacturer's instructions. It
is a rare occurrence for a pipe, fitting or a welded joint to be fully stripped of an FBE
coating in order to have a powder reapplied.
I A typical repair procedure on a small unacceptable area would be:
1. Abrade the affected area using coarse grade emery, e.g. 100 grit.
OOI
1 2.
Remove dust with a clean lint free cloth.
1 3.
Repair using specified ?-pack material - using spatula or blade.
1 4. Check thickness if required and holiday detect when the coating is hard dry.
Specifications applicable to field application will usually allow small field repairs to
be carried out using materials which harden quickly, e.g. blister pack urethanes or fast
I cure epoxies supplied in two tubes.
A typical repair procedure on a large unacceptable area using more conventional
2-pack products would be:
10
1. Blast clean - to original specified requirements.
2. Remove dust.
Repair using specified material - spray, brush and/or trowel.
Check thickness and holiday detect when the coating is hard dry.
The term plastic, when used with reference to a material, is a loose term but generally
means a synthetic polymeric material that is usually pliable and can be formed into a
usable shape by moulding, extruding, heating or by using a similar process.
The term plastic can also include materials which may also be referred to as resins.
There are many types of plastic and many types of coating systems employed which
use plastics. This Unit deals with the following broad categories of plastic coatings:
1. Extruded plastic coatings - mainly polyolefins (polyethylene and polypropylene).
2. Spray applied plastics.
3. Heat shrinkable plastics.
Plastic coatings are commonly used on pipelines nowadays and can be applied in both
the factory and on site. The thickness of plastic coatings vary widely but are typically
between 1 rnm and 6 mm.
Materials
Plastic types
There are a large number of plastics which may be used as anti-corrosion coatings.
Some plastic materials are listed below, but not all of them are currently used to coat
pipe or fittings used on pipelines:
1. Polyolefins (alkenes) - low density polyethylene (LDPE - 0.916-0.934 g/cm3),
medium density- polyethylene
- - (MDPE - 0.935-0.940 g/cm3), high density
polyethylene (HDPE - ,07941 g/cm3) and polypropylene (PP). PP coafings are
more rigid and harder than PE coatings. There are two main groupings for
polyolefins (1) aliphahc and (5aromatiTand within each group there are many
types of material other than PE and PP.
LDPE is widely used although HDPE and PP may be chosen because they can
withstand higher service temperatures.
Carbon black is usually added to the polyolefin to protect against UV.
2. Polyvinyl chloride (PVC).
3. Thermoplastic polyester.
4. Polyamide (nylon).
5. Ethylene vinyl alcohol copolymer (EVA).
6. Huoroplastics.
The physical form of the raw materials will usually be in pellet, granular or powder
form depending on the specific requirements for application.
NOTE: For composition of
heat shrinkable plastic Adhesives
materials see page C3-4. There are three main groupings of adhesives used:
1. Mastics.
2. Copolymers - various types but usually based on the polyolefin type in the top
coat; in the form of powder for spraying and pellets for extrusion.
3. Copolymers of the grafted (interactive) type; in the form of powder for spraying
and pellets for extrusion.
The FBE is applied to the steel substrate in all cases where FBE is used with a
polyolefin coating system.
The FBE layer is usually thinner than FBE coatings used as stand alone systems.
Coating systems
There are various coating systems used which involve plastic materials, the main
systems involve polyolefins and are listed below:
Factory
1. Fused single layer PE.
2. 2-layer PE with soft adhesive (usually termed a mastic adhesive).
3. 2-layer PE with hard adhesive.
4. 3-layer PE with hard adhesive of either the normal copolymer type or the newer
grafted copolymer type. E'BE is applied as the first layer.
5. 3-layer PP with hard adhesive of either the normal copolymer type or the newer
3-layer coating systems grafted copolymer type. FBE is applied as the first layer.
combine the excellent
chemical resistance
properties of epoxy with the Site
excellent mecluznical
properties of the 1. Heat shrinkable plastics.
polyolejins. 2. Flame spray applied PP.
3. 3-layer PP with hard adhesive of the grafted copolymer type followed by the
application of a co-extruded sheet of PP. Epoxy is applied as the first layer.
4. Injection moulded PP.
Limitations
1. Polypropylene needs additives to retard oxidation.
2. Cost of heating for application (as with FBE).
3. Multi-layer processes are complicated and require careful control
Surface preparation
Factory
The surface preparation requirement on the steel will obviously be governed by the
type of initial coating. Dry abrasive blast cleaning to Sa2% is the most likely;
amplitude requirements vary but the range specified would normally fall within 40 pm
to 100 pm.
Site
As for factory application for most systems, except an expendable abrasive is likely to
be used. However, some specifications may allow heat shrinkable plastics to be
applied onto surfaces prepared to St3 in certain circumstances.
It is important to be aware that the surface preparation procedures may not be as
straight fonvard as for other coatings. Limitations on methods used to roughen the
existing coating and additional surface preparation requirements will exist especially
for multi-layer coatings.
Coating application
Factory application
'Annular extrusion' may Polyolefins are applied in factories using either side extrusion (winding) or annular
also he referred to as extrusion (sleeving) methods. Side extrusion is used on large diameter pipes and
'cross-head die extrusion' annular extrusion is used on pipes of diameters up to -500 mm.
or 'ring extrusion'.
In both cases, the raw material (in powder, granular or pellet form) is melted using
temperatures which will vary depending on the specific type of material used, the
'Side extrusion' uses 'slot screw type in the extruder and the extrusion rate (200-220C is typical). The powder
dies' and may also he
referred to as 'lateral form is only melted when it hits the pipe (like FBE).
extrusion: The granular or pellet forms of material are initially fed into a hopper and past the
heating units and as it melts it is fed towards the nozzle(s) on the extruder by a rotating
screw (or screws).
Pressure is usually applied to the coating shortly after it has been applied in order to
improve adhesion and force out any entrapped air. With side extrusion a non-sticking
pressure roller may be used, whereas with annular extrusion a vacuum system plus a
roller system may be employed.
There are a large number of coating systems involving plastics and also many
variations in the materials and application methods used within some of these systems.
Typical options are shown below for a 3-layer coating procedure; this should
demonstrate some basic principles which will also apply to other systems.
the form of the material). Thickness requirements vary but usually come u'ithic
50- 100 pm.
6. Apply the adhesive (tie-coat) by either extrusion or by powder spray (extrusion
usually gives superior properties). 300-400 pm is a typical thickness
requirement.
10
7. Apply PE or PP by extrusion. The thickness requirement is determined by the
pipe diameter and service conditions.
' 8. Cool pipe by water spray (after sufficient time has elapsed for polymerisation and
crosslinking of the epoxy first coat).
9. Inspect.
Site application
3-layer PP
The welded joints connecting pipes coated with a 3-layer PP system can be coated
using a similar system to that adopted in the factory. This system will require a
procedure similar to the following:
1. Cut back existing PP, using bevelling machine, to reveal existing FBE (25 mm or
as otherwise specified).
2. Mask off existing FBE and blast clean joint area to specified standard, e.g. Sa2%
at 50-100 pm. Remove masking and abrade existing FBE using emery cloth.
3. Heat joint area using an induction coil to the temperature specified,
e.g. 240-250C.
40~
4. Apply FEE powder when the joint is at the specified application temperature and
introduce PP adhesive (copolymer) powder during final passes to produce what is
essentially a 2-layered sintered FBEPP coating which will cross-link at the
interface. The PP adhesive must be applied within the gel time of the FBE.
Typical thickness requirements: 300 pm for the FBE and 200 pn for the PP
adhesive (tolerances will apply).
5. Apply preheated co-extruded PP sheet, which is normally the same thickness as
the existing coating, around the joint and apply hinged clamp in position around
the coating during the cool down period. The sheet should butt up to the existing
60
PP - overlap onto the existing PP is not desirable. Remove clamp when
temperature has dropped below 120C or as otherwise specified.
6. After cleaning away any adhesive material, weld the circumferential seams of the
PP sheet by using a special welding extruder gun which may be attached to a
machine which travels circumferentially around the joint. The plastic welding
filler material should be the same material brand as the PP sheet.
7. Finally, the longitudinal seam is welded with an extruder gun by using a manual
technique.
A modification to the above procedure which may be encountered is to apply the PP
layer by injection moulding in lieu of using a wrap around PP sheet.
Heat shrinkable plastics
Heat shrinkable plastic materials may be supplied in many pre-expanded forms, some
of which will fit tees, flanges and similar components. The common types
Hot melt type adhesives encountered on pipelines for use on welded joints are supplied either as short
have a higher lap shear
strength than mastic type continuous sleeves, slightly larger than the pipe diameter, or in bandage type form to
adhesives and would be wrap around the joint and overlap onto itself. Heat shrinkable tapes also exist.
preferable for certain
applicaions such ar thrust
Heat shrinkable products have an adhesive layer composed of either a pressure
boring. sensitive mastic or a thermoplastic hot melt type adhesive.
I Testing
Tests on polyolefins
a. Density.
b. Melt index.
c. Elongation at break.
d. Maximum moisture content.
e. Softening point.
f. Impact resistance.
g. Indentation resistance.
h. Electrical insulation resistance.
i. Resistance to UV energy.
j. Thermal stability.
k. Cathodic disbondment.
1. Flexibility.
m. Peel strength.
n. Thickness.
o. Holiday detection.
p. Visual inspection - blisters, general contours.
q. Weld integrity - coupons cut from seam welds on site applied systems
involving wrap around PP sheets.
I Repairs
The repair materials and procedures used would have to be approved prior to use as
applicable to any other coating system. Most standards and draft standards which
apply to polyolefin coatings do not identify specific materials or detailed procedures to
use. They do however state the obvious, that is to say that any repair material and
procedure used shall be compatible with the existing coating and satisfy service
conditions.
Repairs in the factory or on site can be effected using copolymer PE or PP which, after
surface preparation, is melted into the problem area using a special extruder gun or by
using a melt . Heat shrinkable plastics in patch or bandage form may also be used
;k 90 - especially on site.
When repairs to plastic coatings are necessary on site and on the lower integrity plastic
systems, cold applied laminated tapes may be permitted.
1 Elastomer types
EPDM
EPDM (ethylene propylene diene monomer) is an elastomer which is not widely used
nowadays due to required additions of carbon black (pigment). The addition of carbon
black improves the material's abrasion and impact resistance properties, although too
much adversely affects CP current which is conducted away from the coated structure.
EPDM is essentially a mixture of ethylene and propylene. When polymerised, ethylene
C,H,(E) gives E-E-E-E in varying numbers of ethylene molecules, hence the different
grades, e.g. LDPE, MDPE etc.. Propylene C,H, (P), when polymerised, gives P-P-P-P.
A mixture of ethylene and propylene produces a material which is rubber-like in
appearance and properties, very unlike the original materials.
Bituseal - Shell
Bituseal is a polymer bitumen and a trade narnc of a Shell product. This material is
thermoplastic and has excellent low temperature flexibility.
The softening point is much lower than conventional bitumen (85C compared to
120-130" for ccnventional materials), therefore as the limitations for usage are at the
upper end of the temperature scale, it is not recommended for use above 85C but has
excellent properties for use on land at temperatures of less than -20C.
Conventional asphalt and bitumen are brittle at ambient temperatures but bituseal can
be cold bent at temperatures in the range of -20C.
Elastomeric polyurethane
The reaction between a polyol and an isocyanate produces polyurethane. Different
reactions and formulations give materials with different properties, which vary from
elastic to rigid solids. All polyurethanes are thermoset materials and do not soften with
the application of heat.
Syntactic polyurethanes are of a similar structure to cake, with a tiny closed cell
structure and are formed in situ. The closed cell structure significantly improves the
normally poor insulation properties.
Glass microsphercs are sometimes used as $fillers to improve abrasion resistance with
this material.
O Ruane 61 T P O'Neill
Issue2 : OY10l/!J8
I Advantages and limitations
1 Advantages
1. Excellent insulation properties.
2. Thick coatings can be applied in a single layer.
3. Flexible, e.g, materials can be used on pipes to be laid by reel barge.
4. Excellent abrasion resistance.
5. Good impact resistance.
6. Good heat stability.
7. EPDM has relatively high operating temperatures, e.g. 125C.
Disadvantages
1. Crosslinking polyurethanes use toxic isocyanates.
2. Polychloroprenes require vulcanising (heat treatment).
3. Some elastomeric coating systems are not feasible for site application.
4. EPDM needs carbon black as a constituent (adverse affect for CP).
5. EPDM is difficult to stick to anything, especially itself.
Surface preparation
Factory
Dry abrasive blast cleaning to Sa2% is the most likely. Amplitude requirements vary
but the range specified would normally fall within 40-100 pm.
Site
Rarely applicable. Syntactic polyurethanes may be cast on-site but over a primed area.
Application
Application methods vary from extruded spiral layering over an anti-corrosive (FBE)
layer, to interlayering with closed cell pvc foam for extra insulation.
In most cases a primer or a bonding agent (adhesive) would be used prior to application
of the elastomeric system.
Bituseal
30
Bituseal is applied hot at approximately 190C by extrusion, usually over an
anti-corrosive primer. Brittle bitumen and coal tar enamels need temperatures in excess
of 200C but have correspondingly higher softening points of 120-130C.
Unlike the conventional bitumen enamels, the elastomeric bituseal does not have an
inner layer of reinforcement. A typical thickness range is 4-6 mm with usually an
impregnated outer wrap for abrasion resistance.
Thickness
50
Magnetic or electromagnetic induction.
Cure
BitusealIEPDM - hardness (shore, barcol, needle penetration).
Neoprene - hardness (shore), cure (rheometer).
60 Polyurethane - hardness.
Adhesion
Peel adhesion (on pipe ends).
Disbondment
Ultrasonic methods.
Tapping (sounding).
Pinholes
High voltage holiday detection.
Constituents
Epoxies
Base resin in one container with m i n e or amide reagents supplied separately, either in
tubes or cans.
Urethanes
Urethane, or urethane and pitch, supplied in drums or cans with modified isocyanate or
di-isocyanate curing agent in another can or drum. Sometimes provided in blister
packs for small repair jobs.
Disadvantages
Epoxies
1. Short pot life.
2. Very poor adhesion to plastics.
Urethanes
1. Short pot life.
2. Very poor adhesion to plastics.
3. Toxic components.
4. Some types are very moisture sensitive.
30 Site
Welded joints are blast cleaned using pressure blasting equipment and dry expendable
abrasive.
Typical requirements (welded joints)
Remove any solar protective coating and all extraneous material from the existing
coating (150 rnm is typical requirement).
Degrease only if necessary.
If existing pipe coating is thick, e.g. if coated with an enamel, chamfer coating by
50 mm or 100 mm as specified, using a blow torch and scraper.
Blast clean using dry expendable abrasive. Profile requirements: Sa21/2, medium
profile or 50-75 pm.
Inspect blasted areas for surface laminations (slivers); if any exist then remove
with a grinder, check for correct contour and wall thickness then reblast the area.
Check for disbonded coating, if any exists then remove and reblast area.
60
-
Coating application
Factory
Urethane MCL's are sometimes used for coating pipeline fittings and special
fabrications for subsequent delivery to site. Because urethanes (two pack) are
isocyanate cured, application by spray can only be carried out in closely controlled
conditions.
When using moisture sensitive material, the maximum RH% requirement during
application and for part of the cure period may be as low as 70%. The minimum
airlsteel temperature requirement during application may be 10C in some instances. It
is therefore a common requirement that heaters and dehumidifiers have to be used.
Multi-component spray grade urethanes are usually applied using a twin component
hot airless spray system. These use twin airless pumps, skid mounted and specially set
to dispense pre-set amounts of base and activator. The components are heated, usually
by coils around the container, and the pre-set flow rate measures out the correct ratio of
base and activator into a mixing chamber. The mixing chamber is usually tube shaped
and contains a series of baffles through which the two components pass and so the
mixing is accomplished. There is also a solvent feed line entering the chamber.
Because the chemical reaction rate increases as the temperature rises, the pot life is
considerably shortened, in some cases to a few minutes. Spray lines are usually kept to
a limited length. Tip blockages or hold ups of any kind are critical because the material
Site
MCL's are likely to be brush andlor trowel applied on site. The material will be
20
supplied in cans in any situation other than for minor damage and pinhole repair where
epoxy or urethane are likely to be supplied in tubes or blister packs respectively.
Becanse of the short pot !ife consideratio:: and the requirement that b ~ t hco=pone::t~
be thoroughly mixed in the correct ratio, mechanical mixing is desirable when
components are supplied in cans.
For urethanes, ambient conditions may be more stringent than for epoxies.
Application should be in accordance with the manufacturer's instructions and for
urethane, will usually require application in two layers, the second layer being applied
at right angles to the first after a specified time lapse.
1 Safety
When using MCL's, especially urethanes, it is advisable to wear protective clothing
with a positive air supply face mast for urethanes (isocyanates).
If welding of coated components is required, a suitable uncoated margin should be left,
e.g. 150 mm. Heat should not be used to remove urethanes because various cyanide
gases will be released. Removal of faulty coatings should be by prolonged blasting
only.
I Factoryflaboratory tests
Tests on the unmixed components
a. Total non-volatile content.
b. Viscosity.
c. Specific gravity.
d. Mixing ratio.
e. Pot life.
f. Flash point.
g. Stability
Tests on the detached film
a. Micro-sectioning - for homogeneity.
b. Tensile strength - for maximum strength and strength at break.
c. Elongation.
d. Dielectric strength - quoted in kVImm.
e. Water permeability.
f. Water absorption - after three months immersion at 20C.
I Tests on the attached cured coating
a. Cissing and pinholing.
b. Blistering and appearance test.
Site testing
30
a. Dry film thickness.
b. Holiday detection.
c. Adhesion test.
d. Hardnesslcure test.
Repairs
Repairs to MCL coatings are usually made using the same material as the original
coating or, especially on site, by using a fast drying product with the same base material
and from the same manufacturer.
A typical repair procedure on a small unacceptable area would be:
1. Abrade the affected area using coarse grade emery, e.g. 100 grit.
2. Remove dust with a clean lint free cloth.
3. Repair using specified 2-pack material - using spatula or blade.
,, 4. Check thickness if required and holiday detect when coating is hard.
Specifications applicable to field application will usually allow small field repairs to be
carried out using materials which harden quickly, e.g. blister pack urethanes or fast cure
epoxies supplied in two tubes.
A typical repair procedure on a large unacceptable area using more conventional
70 2-pack products would be:
1. Blast clean - to original specified requirements.
2. Remove dust.
3. Repair using specified material - brush and/or trowel.
,, 4. Check thickness and holiday detect when coating is hard dry.
Several types of wrapping tape are used in the pipeline industry, the main categories
are as follows:
1. Hot applied tapes.
2. Cold applied laminate tapes.
3. Grease based tapes.
4. Self adhesive overwrap tapes.
5. Heat shrinkable tapes - see Unit C3.
Whenever tapes are used on risers and similar, care should be taken to ensure
spiralling and terminations create a water shed, otherwise disbonding may occur.
When spiralling a tape around a pipe the following should be observed:
a. Correct tensioning of the tape
b. Correct overlap distance onto itself - typically 55% of tape width (referred to
as double wrap)or 25 mm for thicker tapes.
c. Correct overlap distance onto existing coatings - 75 mm minimum is typical.
d. The tape should face downwards at the start and finish.
Specifications do not normally specify DFT requirements when tapes are used because
the thickness of the tape and the overlap requirement will be known.
Constituents
A synthetic fibre bandage, e.g. woven nylon, coated with plasticised coal tar or
bitumen. The coal tar or bitumen is sometimes applied to one side of the bandage
only. In this instance the coated side is placed against the pipe.
Surface preparation
90
Factory
Not normally applied in factories.
Safety requirements
Generally as required for site application of enamels.
Testing
I Tests on the primer
1. Viscosity measurement using a flow cup at a specified temperature.
2. Visual check for coverage.
80 3. Measure D m of primer if requested.
Tests on the final wrapping
I 1
2.
Tapping to check for laminations.
Holiday detection.
,, 3. Bond strength test.
4. Visual check for uniformity of coating contour and ensure no coking exists.
Constituents
Cold applied laminate tapes are made up from a polyethylene (PE) or polyvinyl
chloride (PVC) carrier tape with a coating of self adhesive, anti-corrosive bituminous
compound or self adhesive synthetic rubber compound.
Over width silicone coated or wax coated interleaving paper exists in each tape roll to
make it easier to unroll the tape during application and it also reduces the amount of
dirt contaminating the edges of the rolls.
Surface preparation
Factory
Not commonly applied in factories - if done, blast cleaning or chemical cleaning may
be encountered..
Site
Welded joints are blast cleaned using pressure blasting equipment and dry expendable
abrasive.
Application
Factory
When CALT is applied at a factory as the primary anti-corrosion system, machine
application with a static roller rig is likely to be the method used. The pipe lengths are
rotated and geared to the rig which carries the spool of tape, correctly tensioned, to
wrap neatly and evenly along the pipe.
A primer as specified by the tape manufacturer would be used before tape application.
The primer usually has to be in a dry state before the tape can be applied.
Site
Although line travel machines do exist for CALT, application is more likely to be
manual.
A primer as specified by the tape manufacturer would be used before tape application.
The primer usually has to be in a dry state before the tape can be applied.
The tape is then applied in a spiral fashion, usually with a 55% overlap, maintaining a
uniform tension. Under tension can result in unsightly creases and wrinkles, which if
left, will lead to early failure (or their existence will increase the CP current used).
Over tension shows up as discoloration of the (normally black) tape. The tape
stretches and narrows and shows up light bluelgrey in the area of the stress.
Safety requirements
There are no significant hazards associated with CALT
Testing
Tests on the primer
1. Viscosity measurement using a flow cup at a specified temperature.
2. Film thickness measurement.
Tests on the final wrapping
1. Holiday detection.
2. Bond strengthladhesion test.
3. Visual check for uniformity of coating contour.
Repairs
Repairs to CALT wrappings, e.g. after adhesion tests, can be carried out by
overwrapping with CALT. Patch type repairs are not advisable; full circumferential
wraps are normally specified.
Surface preparation
Factory
Not normally applicable.
Site
Blast cleaning would not normally be specified when grease based tapes are used. In
most instances, as long as loose and flaky materials are removed, that will suffice.
Wire brushing to St2 or St3 is commonly specified. All traces of moisture should be
removed.
Application
Factory
Not applicable.
Site
Grease based primers are normally recommended but not always specified.
The tape is applied in a spiral fashion usually with a 55% overlap. Grease based can
also be applied doubled or twisted to fill in sharp contours because of its mouldability
and may sometimes be used in place of more conventional filler materials, i.e. mastics
and putties.
Safety requirements
There are no significant hazards associated with grease based tapes.
Testing
The are no testing requirements other than visual examination for contour. Holiday
detection and DFT measurements are not practical propositions unless the grease based
tape is overwrapped. Even if overwrapped these tests are not always carried out
because it will be very unlikely that any specification deviation will be found. Holiday
Repairs
Repairs to grease based tapes are easily applied by using the same product. Patch type
10 repairs are not advisable; full circumferential wraps are normally specified.
Constituents
A strong pressure sensitive adhesive is bonded to a tough carrier tape of PE or PVC.
This medium is not designed as a corrosion protection system but to add mechanical
strength to other mediums and to stop migration of constituents in grease based tapes
and mastics and fillers.
60
3. Not tolerant of uneven surfaces.
Surface preparation
Factory
Not normally applicable.
, Site
Blast cleaning would not normally be specified when grease based tapes are used. In
most instances, as long as loose and flaky materials are removed, that will suffice.
Wire brushing to St2 or St3 is commonly specified. All traces of moisture should be
removed.
80 Application
Factory
Not normally applicable but could be applied mechanically or manually as overwraps
for other mediums.
Site
90
Primers are sometimes recommended but not always specified.
The overwrap tape is applied in a spiral fashion usually with a 55% or 25 mm overlap.
It may be specified that the direction of spiralling must be made in the opposite
direction of the spiralling on the existing tape wrapping.
If welded joints or repairs are being made with either grease based tape or cold
laminate tape, the overwrap tape must be firstly adhered to the existing coating before
overwrapping the joint wrap and beyond onto the existing pipe coating on the other
side of the joint. Overlap requirements on either side of the joint wrap is typically a
minimum of 50 mm, 75 mm or 100 rnm depending on the specification.
Safety requirements
There are no significant hazards associated with self adhesive overwrapping tapes.
Testing
Tests on the primer
1. Viscosity measurement using a flow cup at a specified temperature.
2. Visual check for coverage - DFT not normally measured.
Tests on the final wrapping
1. Holiday detection.
2. Bond strengWadhesion test (in rare circumstances).
3. Visual check for uniformity of coating contour.
Repairs
Repairs to overwrap tapes are easily applied by using the same product assuming the
underlying coating material is not significantly affected. Patch type repairs are not
advisable; full circumferential wraps are normally specified.
30
Application
The following text shows a typical application procedure:
1. After surface preparation, apply primer by brush, overlapping onto the factory
applied coating, to attain a total dry film thickness of approximately 25 pm.
2. As soon as the primer has dried, e.g. after 1 hour at 20C, apply one coat of the
specified mastic, laid on evenly by brush, to give an appropriate dry thickness
specified by the manufacturer overlapping on to the existing factory applied
coating by a minimum of 75 mrn.
3. Allow to dry for at least 4 hours at 20C before applying a second coat of the
specified mastic, by brush, to a minimum dry film thickness specified by the
manufacturer.
4. Before the coated components can be handled or buried, a specified time must
elapse which can be anything from 24 hours to 7 days depending on the product
type and ambient conditions.
1 Surface preparation
Surface preparation is normally carried out by dry abrasive blast cleaning to Sa2%
medium grade. Slivers, laps etc. to be removed by grinding. Dust removal to class 0
in accordance with I S 0 8502-3.
Use high pressure water to remove contaminants such as salt and dirt. Any organic
contaminant such as grease or oil to be removed by using detergent or an approved
organic solvent.
The remaining salt level and methods for measurement should be agreed between
contracting parties.
Other standard specifications may specify chemical cleaning (pickling) as the
preparation method, especially on small diameter pipes where blasting will be
impractical.
I Coating application
Temperature shall be at least 3C above the dew point temperature - heat pipe if
necessary. Other ambient requirements would be as specified by the coating
manufacturer.
Paint will be spray applied.
An accelerated curing procedure may be used by heating the pipe up to a maximum of
100C.
10' Testing
Tests on the wet paint
a. Viscosity.
b. Density.
c. Solid content (by weight).
d. Solid content (by volume).
e. Drying time (to handle).
f. Pot-life.
g. Pinholes (porosity) - using glass plates.
h. Ash content.
i. Fineness of grind.
j. Sieve retention.
k. Flash point.
Repairs
Significant defects are repaired using the same procedure as used with the original
coating, except that pinholes and small damaged areas may be wire brushed instead of
blast cleaned. In both cases lightly abrade onto existing coating by at least 10 mm.
Damaged internal coatings are not often repaired when found on site.
Softening point
This is a test conducted on raw materials for thermoplastic systems, e.g. enamels and
polyolefins.
Ring and ball apparatus is used to determine the temperature at which two steel balls
pass through prepared discs of the test material by virtue of the material softening
sufficiently to allow displacement.
' Elongation
This test is mainly on plastics, e.g. tapes, polyethylene cladding and polypropylene,
but also used on detached films of FBE and fibreglass reinforcements.
The test is done to determine how far a material will stretch before it breaks,
sometimes called elongation at break, and is expressed as a percentage.
A bar bell shaped sample is used which is clamped at both ends. A pulling force is
applied at a specified rate (expressed in mm per minute). Two lines are scribed on the
narrow section of the bar bell and the distance between them measured before and after
the test.
A minimum elongation would normally have to be achieved, e.g. at least 350% for a
material such as polyethylene.
Tensile strength
Fibreglass reinforcements detached epoxy coatings and most plastic coatings are
subjected to a tensile strength test.
40
The test is similar to the elongation test except that the maximum load the sample
withstands before failure is recorded. Applicable units: ~lmrn'or MPa.
Adhesion
30 See also Unit P7N.
Various forms of adhesion tests exist for different types of material and situations.
Qualitative and quantitative type tests may be specified according to procedural
requirements. Adhesion tests which may be encountered on pipeline coating systems
include:
a. Vee cut tests.
b. X cut tests.
c. Bond tests.
d. Primary bond tests - enamels (factory).
e. Dolly test.
f. Hydraulic adhesion test.
g. Peel creep (usually identified as a separate type of test).
Only selected tests are briefly described below.
Vee cut test
This is a quick and easy qualitative test for thinner coatings, e.g. primers, MCL's and
FBE.
X cut test
A test more likely to be used on B E .
This test is not the same as the X-cut tape test.
This is a test with the same principle as the vee cut test but uses an X instead of a V.
A metal bar or similar is used to provide a fulcrum and an attempt is made to peel the
coating off by using the point of a utility knife at the intersection. The intersection is
then assessed for damage and rated against a standard set of diagrams in the applicable
specification.
Bond test
A qualitative test usually done on enamels on coated pipes, similar principle to the vee
80 cut but uses a rectangular test area, e.g. 30 rnrn wide 100 mm long.
Peel creep
Used largely on polyolefins and other plastic coatings.
A method of measuring the average force required to peel off a coating from a
substrate at a constant rate of pull.
A strip typically 20 mm wide is cut circumferentially into the pipe coating, e.g. 100
mm long or as otherwise specified. The end of the strip is lifted and placed in the jaws
of the pull off mechanism. A rate of pull is specified, e.g. 10 mm per minute, and the
lo
Holiday detection
See Unit P7R.
Ideally, pipeline coating inspectors should be issued with relevant procedures and
work instructions to enable them to carry out inspection and associated activities in
accordance with the client's or organisation's requirements. The procedures should
leave the inspector in no doubt as to what is to be done. Unfortunately, this
documentation rarely exists!
1 2.
3.
Ensure the contractor's supervisor is aware of your duties and authority.
Ensure you have correct applicable specification(s) and data sheets. Also ensure
you at least have access to relevant referenced normative documents.
1 9.
Ensure that all concerned are clear about the reasons for any rejections.
10. Where remedial work has been necessary, re-inspect for conformance to the
specification.
I Coatinglwrapping material
I 1.
2.
Check the specified requirements.
Check that the materials delivered to the work place correspond to the
20
requirements of the specification and data sheets. The specification may require
certain information to be displayed on each material container or package.
3. Check that any primer or liquid material is the correct type for the application
method being used, i.e. brush grade or spray grade.
Check the material storage conditions against manufacturer's recommendations.
30
Note: Any warranty on the material is likely to depend upon proper handling
and storage.
5. Especially when dealing with materials having a short shelf-life, determine
whether the material is being withdrawn from the store in proper rotation,
i.e. usually on ajirst in, jirst out basis.
40
6. Ensure material is not being used beyond its shelf life.
7. Monitor material usage to determine whether there is sufficient material in
storage for the completion of the job (or part job). (This is not always a
responsibility of the inspector).
8. Check that liquid coating materials are being mixed and stirred correctly. Any
permitted addition of thinners must be monitored to ensure correct type and
amount. For two pack coating materials:
a. check that the materials are mixed strictly in accordance with the paint
manufacturer's data sheets, e.g. add Part B to Part A in the correct ratio;
b. confirm that any induction time is strictly adhered to;
c. confirm that mixed material is not used after its pot life.
9. Conduct that all necessary sampling procedures and tests; or c o n f m that such
tests have been carried out prior to the commencement of work. Record batch
numbers of materials tested.
I Coatinglwrapping application
10' 1. Check the specified requirements.
2. Check that the surface to which the coatinglwrapping is being applied is free
from contamination, i.e. oillgrease, dust, spent abrasive, corrosion products etc..
Any areas suspected as being defective, e.g. cracked, laminated or mechanically
damaged, should immediately be reported to the supervisor or client.
Note: Do not allow surface laminations, cracks and similar to be dressed without
the permission of the supervisorlclient (not usually the remit of a
coatinglwrapping inspector).
3. Ensure that the ambient conditions allow coatinglwrapping to take place. The
following may have to be assessed/measured:
a. Air temperature.
b. Steel temperature.
c. Relative humidity
d. Dew point temperature.
e. Moisture on the substrate.
1 5.
Check that the correct application method is being used.
1 6.
Check that correct application temperatures are being used (where applicable).
1 7.
8.
Identify areas being coatedwrapped.
Carry out inspection of coatedwrapped surfaces as required by specification. For
example:
a. Check that primers and coatingslwrappings used on field joints or repairs
overlap onto the existing coating by the correct distance.
b. Check that tapes are applied on risers from the bottom upwards.
c. Check that tapes are being applied in spiral fashion with 55% overlap or as
otherwise specified.
d. Check that coatingslwrappings possess uniform contours after application.
e. Measure the dry film thickness (d.f.t.) where required.
f. Carry out holiday detection.
g. Carry out adhesionlbond tests.
9. Take any test samples required.
401 10. Ensure that any areas of defective coating are identified for remedial work.
I 11. Ensure that all concerned are clear about the reasons for any rejections.
12. Re-inspect any remedial work carried out to ensure that it conforms to the
specified requirements.
13. Record the results of the inspection. The areas inspected must be identified in the
50
report ensuring that it is clear what has been accepted and what has been rejected.
The reasons for any rejections should be clearly identified.
Miscellaneous
1. Check that the handling, transport and storage of coatedwrapped pipes and
fittings is carried out in a manner approved by specification which does not cause
60
damage to the coating.
2. When required, attend appropriate meetings, such as periodic on-site meetings or
those meetings called to provide solutions to a particular problem that has arisen.
You may also be in a position where you need to arrange a meeting to resolve
problems that have arisen.
70 3. Ensure that you effectively organise your time so that you are available for
inspections when required. Do not give the contractor an excuse to say, "we were
waiting for the inspector to carry out inspection".
4. Check the work area housekeeping. For example, equipment and consumables
should be cared for (correctly handled, stored and maintained) and the site or
80
shop should be tidy (free from empty containers, worn brushes, spent abrasive
etc..).
5. On completion of the worklcontract, ensure that all records (specifications,
procedures, work instruction, permits, concessions, plans, report sheets etc..) are
collated and filed in the appropriate location. This is only required when it is
your designated responsibility.
6. Do not seek confrontation. Try and avoid arguments. Never be condescending,
patronising or arrogant. Remember the main duty of an inspector is to inspect
against specified requirements and report findings. If the specification is not
clear on a particular requirement, seek advice from the supervisor or client. Do
not accept or reject work based on your opinion alone. Be objective at all times.
4011 1.
2.
3.
The applicable specification(s).
Procedures and related work instructions.
Quality plans.
( 4. Method statements.
1 5.
6.
Concessions (waiver or variation orders).
Daily inspection report forms.
I 7. A daily log (this may be stand-alone document or one in addition to a daily
inspection report).
8. Lists of remedial action.
9. Progress reports.
10. Minutes of meetings.
11. Correspondence.
12. Calibration certificates.
70 13. Copies of work permits.
14. Site instructions.
15. Mechanical completion certificates (hold-point release forms or inspection
request forms).
16. Audit reports
a. Internal.
b. External.
17. Non-conformance reports.
18. Certificates of conformity.
0 Ruane 8: T P O'Neill
Issue 1 : 28/04/97
Pipes and fittings must be handled, transported and stored in accordance with specified
requirements. The following text offers some typical requirements.
Handling
The two main considerations for handling pipe correctly are (1) personnel safety and
(2) prevention of damage to the pipe or coating.
Where practicable, pipes should be lifted using a spreader beam with suitable slings
(nylon type), as this is the safest method. Where a spreader beam is not practicable,
two leg chain slings (brothers) could be used, these should be fitted with properly
designed profiled hooks fitted with guide ropes, and the inner edge of the hooks should
be coated in nylon or soft alloy. The use of vacuum lifts and magnetic devices may be
permitted.
Chains must not be slung around pipes even if padded.
When handling large bends or tees, a nylon sling should be passed through the bore.
II Transport
When chains or straps, pipe cradles, batten carriers, or stanchions are being used
during transport, they must be padded, e.g. with at least 12 mm of rubber at contact
points.
Pipes may be stacked in pyramid or parallel fashion when transporting. Stacking in
parallel fashion will require the use of padded pipe cradles or battens between the pipe
layers.
I Ditching
10
I Ditching is the lowering in of a pipe, or string of pipes, into a trench.
Side booms are normally used for ditching, the number of which depends on size,
weight and number of pipes to bc ditchcd. It is good practice to have the booms (jibs)
lined with rubber, e.g. car tyres, to prevent damage to the pipe coating if the pipe
comes into contact with the boom.
If the trench is excavated in rock, a well rammed bed of approved sandlgravel mixture
,, would be applied to the base of the ditch to a depth required by specification, e.g. at
least 150 rnm deep.
The base of the ditch must be evenly bedded and the inspector must make sure there
are no stones, welding electrodes etc. present in the ditch which could cause damage to
coating or interfere with cathodic protection.
When thermoplastic coatings have been used, e . g coal tar enamel, lowering-in should
,, not take place if the ambient temperature is high, e.g. above 27C or as otherwise
specified.
When the pipes are lifted from the skids prior to lowering-in the coating must be
checked by holiday detection to ensure freedom from skid damage. It is normal to
ensure earth has been achieved by testing the bare bevel ends of the pipe string.
I Backfilling
I The important considerations when backfilling are as follows:
a. The pipe and pipe coating must not be damaged.
b. Foreign material which may cause damage to the coating or interfere with
cathodic protection must not be placed in the trench.
c. The backfill should be well compacted, otherwise the pipeline may not be
adequately protected by the CP system or a much higher current may be
required to achieve adequate protection.
d. Environmental considerations may apply - ideally the excavated material
should be returned in layers which correspond to how it was originally. When
the excavated material contains rocklstones, it will not be permissible to return
this material in the layers around the immediate viscinity of the pipe.
Backfill material, consisting of either the excavated material or imported fill, is placed
into the trench in layers of a specified depth, e.g. 300 mm each layer. Each layer must
f 70 be well compacted with hand rammers or mechanical vibrators prior to the deposition
of the next layer.
Stone free layers are deposited until the backfill material is a specified distance above
the pipe, e.g. at least 300 mm. The remaining excavated material is then returned to
the trench in layers and compacted as above.
The minimum depth of cover between the top of the pipe and the surface of the normal
ground will be specified.
Water courses, road crossings, railway crossings and similar require special
considerations.
Note: To protect the coating against stones and soil stressing, a plastic grid mesh is
sometimes wrapped around the pipe prior to backfill.
Part B
TABLE OF CONTENTS
PART B
CORROSION ..........................................................................
GKAPHlTISATION ........................................,........ ...................
BASIC CHEMISTRY ...................................................................
SURFACE PREPARATION ............................................................
Dry abrasive blasting .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . ..... . . .. . . ..... . . . . . . . . . . . . . . . . . . . .
Wet blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. ... . .. . . . . . . . . . , .. . . . . . . . . . . . . . . . . . .. .
Hand and power tool cleaning . . . . . . .. . . . . . . . ... . . . . . .. . . . . . . . . .. . . . . . .. . . . .. . . . . . . . . . . . . . .
Flame cleaning . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . .. , . . . . .. . .. . . . . . . . . . . . . . . . . . . .
Chemical cleaning . . . . . .. . . . . . . . . .. .. . . . . . .. . . . . . . .. . . .. . . .. .. . . .. . .. .. . . . . . ... . . . .. . . .. ..
TESTS T O DETECT SURFACE CONTAMINATION ...................................
FLASHPOINT ...............................................................,..........
VISCOSITY ............................................................................
DENSITY ............... ............................................ ...................
WET FILM THICKNESS (WFT) ........................................................
DRY FILM THICKNESS (DFT) .........................................................
ADHESION .............................................................................
CATHODIC DISBONDMENT TEST ....................................................
HOLIDAY DETECTION ................................................................
WEATHER CONDITIONS ......................................... ................
HEALTH & SAFETY ...................................................................
COSHH Regulations 1994 . . . . . . . . . . . . . . . . . . . ... . . .. . .. . . . . .. . . . . . . . . . .. . .. . . . . . . .. . . . . . . . .
Occupational Exposure Limits (EH40) . . . . .. . . .. . . . .. . .. .. . . . . . .. . . . . . ... . . . . . .. .. . . . . .. . ..
Volatile organic compounds . . . . . . . . . . .. . . . . . . . . . . .. . . . . . .. . . . . . .. . . ... .. . . . . .. . . . . . . . .. . . .
Health & Safety data sheets . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . .. . . . . .. . . . . . . . . ... . .. . ... . . . .
FLAWS ON T H E SUBSTRATE
CATHODIC PROTECTION (INTRODUCTION) ........................................
QUALITY ASSURANCE ................................................................
NORMATIVE DOCUMENTS ...........................................................
Ruane &
T P 0'Neil/
reaction and at least one cathodic reaction. The corrosion of steel takes plrrt a e,,t
1 anode.
G n o d i c reaction is expressed as follows:
-
ore is converted to iron, the chemical balance is changed and the iron becomes active,
i.e. it corrodes on contact with the natural environment and tries to revert back to its
natural inert state. The natural environment usuallv contains moisture (which ~ r o v i d e s
An electrolyte is a substance
which, when in solution
the electrolyte) giving the following simultaneous reactions:
(usually water or in its fused Anodic reaction:
(moltett)state), will conduct u
current and be broken down Fe + Fe* + 2e-
by it. i.e. iron gives fcrrous (iron) ions and electrons
I Cathodic reaction:
A positive ion may be 2H20 + 02 + 4e- + 40H-
called a cation whereus a
negative ion m y be called i.e. water + oxygen + electrons give hydroxide ions.
an anion. These rennr can The products of these reactions take part in further reactions with thc immediate
cause confusion because
cathodes are thought of us environment leading to the formation of corrosion products, the most familiar being
being negative and anodes rust:
positive! 61
Fe* + 20H- + Fe(OH)2
I i.e. ferrous ions plus hydroxide ions gives iron hydroxide.
SkO Corrosion reactions can be accelerated by the existence of certain criteria including:
1. variations in oxygen content on the material's surface;
2. chlorides and sulphates;
Mill scale is an oxide of
iron produced when the 3. other metals or metal compounds of higher nobilip (more electro-positive) in
steel is rrmufactured; it is contact with the steel, e.g. mill scale;
a result of the hot steel 8,
coming into conract with 4. acids or alkalis;
air and forming an oxide
composed of three layers: 5. certain types of bacteria near the material's surface. 6 . I nCw6* L*
FeO nearest the steel,
Fe,O, then Fe,O, on the The following list shows some metals/metal compounds in their order of nobility in sea
outside. Mill scale has a water at ambient temperature. The relative positions of the metals/metal compounds in
total thickness bemeen the list can change with a change in electrolyte type or temperature; this list is known as
approximately 25 pm and
-
the galvanic series. The galvanic series may show the potential of each metaumetal
compound measured in volts against a specified type of reference electrode. If absolute
potential values of metal elements only are shown, which are independent of the
electrolyte used, the list becomes known as the electrochemical series.
I
Silver
' The electrochemical series Nickel
is nroduced under
standard conditions and is
Copper
-
useful for theoretical 10 Mill scale
assessnlents or in
laboraror-)i siriratiurrs. Mild steel 5g& &v
Alum~nium
Zinc
Magnesium IGNOBLE (ELECTRO-NEGATIVE)
Example: If steel was in intimate contact with zinc or attached to zinc via a wire in an
electrolyte, e.g. soil or water, the zinc would corrode first because steel is more noble
than zinc.
In this example the zinc becomes the anode and the steel the cathode, i.e. the steel is
30 being cathodically protected and the zinc is acting as a sacrificial anode.
Carbon and graphite are inert in many corrosive environments, their tensile strengths
are very low, e.g. 500 to 3000 psi, impact resistance is nil and abrasion resistance is
poor. Resistance to alkali's and most acids is good but oxidising acids such as nitric
acid (HNO,), sulphuric acid (H2S04)and chromic acid (H,CrO,) attack it. They also
have a low resistance to reaction with halides and halogens (fluorine, chlorine, bromine
and iodine).
Graphitisation is the process where the iron component is removed from the metal
leaving a network of carbon particles - a de-alloying process.
The residual carbon retains the shape of the original object and, unless the weak
structure is fractured.
,, The mechanism of this corrosion process is believed to be based on cathodic
depolarization caused by removal of hydrogen from the surface, thereby reducing iron
sulphate (FeSO,"'') to iron sulphide (FeS), which is itself corrosive.
This leads to bacterial attack from sulphur reducing bacteria (SRB) called
Desulphovibrio Vulgaris, sometimes referred to as metal eating microbes (MEM) of
which there are two types - aerobic and anearobic.
30
Graphitisation most commonly occurs in salt waters, acidic mine waters, dilute acids
and those soils containing sulphates and SRB. It is possible to mimic these conditions
and cause graphitisation in a laboratory by immersing in diluted H2S04.
Graphitisation usually progresses directly into the surface in a uniform manner, leaving
a porous matrix of the remaining alloying element carbon. There is no outward
40
appearance of damage but affected material loses mass and becomes porous and brittle.
The porous residues may retain appreciable tensile strength and also have moderate
resistance to erosion, e.g. a completely graphitised pipe may continue to hold water
until fractured by impact.
It is essential that all graphitisation is removed because the exterior of a structure or
pipe containing graphitisation becomes very noble in any galvanic coupling, therefore
50 any other metal in contact or in close proximity will have its corrosion rate accelerated.
Anti-graphitisation measures include efficient barrier coatings and for new systems the
addition of several percent of nickel during the manufacturing process.
Atoms
The smallest part of an element that can have the elements properties. All matter is
composed of atoms which are tiny particles, so small that 100 million placed
end-to-end would measure 1 cm. An atom as a whole is electrically neutral.
Molecule
When atoms are bonded together in a fixed whole number ratio, they are known as
molecules.
A molecule is defined as the smallest particle of an element or compound. Examples of
molecules are:
0 2 co2 H20 HCI
Oxygen Carbon dioxide Water Hydrogen chloride
Element
An element is said to be a pure substance which cannot be broken down into anything
simpler by chemical means.
There are 110 elements known to man. Below is a table of the elements most
commonly encountered in paint technology and corrosion technology.
16 S Sulphur AC
17 C1 Chlorine
26 Fe Iron
r 30 I ~n I Zinc I
Ruane &
T P OINei//
Compound
A pure substance which is made up of two or more elements chemically bonded
together is called a compound.
The chemical bonds by which the elements are joined together may be either ionic or
10 covalent.
Examples of compounds are:
CH.4 H20 NaCl
Methane Water Sodium Chloride
20 Ions
When a compound such as sodium chloride is dissolved in water it dissociates into
ions, i.e.:
NaCl+ Na+ + C1-
An ion is a positively or negatively charged particle. Positively charged ions are called
30 cations, e.g. Na+, and negatively charged ions are called anions, e.g. C1-.
Groups of atoms can also possess a charge, e.g. hydroxide OH-, sulphate SO4 and
these are known as radicals.
Chemical bonding
Atoms are held together in molecules and large chemical structures, such as a cross
linked epoxy, by chemical bonds.
There are various kinds of bonds such as co-ordinate, covalent, double, hydrogen,
ionic, trip Le.
These bonds are the forces that exist between the atoms and are produced by electrons.
Electrons are either shared between atoms, or atoms gain or lose electrons forming
ions.
The sharing of electrons is called covalent bonding and this occurs when similar atoms
bond together.
Losing or gaining electrons occurs when different types of atoms bond together, e.g. a
metal such as sodium Na+ and a non-metal such as chlorine CI-. This form of bonding
is known as ionic.
Covalent bonding
,, Covalent bonds are formed by two similar atoms coming together and sharing their
electrons, e.g. hydrogen, which only has one electron.
The two hydrogen atoms form a molecule of hydrogen (Hz) by the two electrons
coming together to form a bond.
Hydrogen molecule
20
Ionic bonds
These chemical bonds occur because of the electrostatic attractive forces between
negatively and positively charged ions, i.e. between anions and cations.
Ionic bonds are found in compounds of certain non-metals, e.g. Na+Cl- and also in
compounds involving radicals, for example:
Chemical formulae
A chemical formula is a way of representing a substance or compound by using the
symbols of the elements present in the formula.
50
There are two commonly used forms of chemical formulae: (1) molecular and
(2) structural.
The molecular formula of a substance shows the number and types of atoms in the
molecule but it does not show how the atoms are arranged, for example:
C3H,0 Acetone
A structural formula is one that shows the bonds between atoms and the position of
60 the atoms with respect to each other, for example:
'=
I O Acetone
To summarise, it will be seen that the formula for acetone can be written in any of the
80 following ways, all of which are correct:
y 3
C3H,O C=0 CH, CO CH,
I
CH3
30
-
remaining on the substrate after cleaning although it may also relate to the resultant
surface texture, e.g. the surface profile on a substrate after abrasive blast cleaning.
abrasive particles onto the substrates surface at speeds of up to approximately 720 km/h
(450 m.p.h.). The operation removes rust, scale, dirt and any other extraneous material
from the substrate and also leaves an irregular profile which provides an ideal key for
coating adhesion. Dry abrasive blasting is often the best method of surface preparation
for long term protection coating systems.
50
Abrasives
The degree of surface roughness and rate of cleaning is partially governed by the
characteristics of the abrasive used; these being:
Size
Hardness
60
Density
Shape
1 Effect of abrasives
Grit is angular in profile with sharp cutting edges; it shatters mill scale and undercuts
any surface contaminant resulting in a clean surface with an irregular profile. The
amplitude tends to be quite erratic with a large occurrence of rogue peaks, especially
Both metallic shot and
when blasting in one area for too long. Many materials both metallic and non-metallic
metallic grit particles tend are used to manufacture grits.
to ricochet and so the Shot is spherical, it shatters mill scale, but does not have sharp cutting edges to cut into
blasting area needs to be
totally enclosed for a surface, however, the visual appearance of a shot blasted finish is similar to a grit
efficient recovery and blasted finish although there is less roughness to the touch. Shot blasting work hardens
cleansing. a steel surface to a greater degree than grit, which has the effect of reducing the chance
of any stress corrosion cracking which could otherwise occur in the future. Shot also
reduces the occurrence of rogue peaks but may press impurities into the surface.
Shot is usually made from cast steel although a natural mineral called staurolite is also
available in shot (spherical) form.
It is common practice to mix metallic shot and grit to obtain a blast finish close to the
ideal (a typical mix being 70-80% shot and 20-30% grit).
1 Abrasive analysis
The use of large particle sizes does not increase blasting efficiency or economy. The
large particles tend to bounce and ricochet along the blast hose loosing speed and hence
impact energy. Also large particles cannot always clean out the corrosion pits within
the substrate or clean out the pits of the profile cut by abrasive which has already
impacted.
The most efficient medium contains a controlled mix of large and small particles
known as a working mix.
Because non-metallic abrasives are normally expendable, the working mix should be as
required on supply.
Metallic abrasives, being recyclable, gradually reduce in size cycle by cycle until the
particles are small enough to be drawn out by the air cleansing system. It therefore
SURFACE PROFILE
The size of the profile as measured from the peaks to the troughs is known as the
amplitude or peak to trough height, and is primarily governed by the size of abrasive
used, although other factors are important, e.g. angle of impingement, hardness of
Blast finishes should not be surface and other characteristics of the abrasive itself. Maximum amplitudes or
touched with bare hand.^
amplitude ranges would normally be quoted in specifications, a typical amplitude range
otherwise contamination will
result. for liquid paints would be in the region of 30-75 pm.
The amplitude of a blasted surface may be measured by a number of methods,
including the use of a surface profile needle gauge, surface replica tape, e.g. Testex
tape, or a surfnce comparator.
Surface profile needle gauge
This relies on a needle reaching the bottom of the troughs on the surface profile.
Because there are so many troughs of different depth, it is normal, and necessary, to
take ten or twenty readings and calculate the average amplitude. Before taking any
A11 accurate measuring
readings it is necessary to zero the gauge on a flat piece of glass.
equipment, e.g. dial
micrometers, should be
issued with calibration
certificates or certificates of
cotgfonnance to give
msurarzce that the readings
obtained are going to be
correct within a stated
murgin of error.
( 2.
Remove paper backing and stick Testex tape to the surface to be measured.
3. Rub the Testex paste 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
the dial micrometer.
5. Deduct 50 pn (2 thou") from the reading to obtain the amplitude. The plastic
(Mylar) to which the soft compound is attached is 50 pn thick.
Surface comparator
3 The roughness of the surface to be assessed is compared to the different areas on the
It is important to note that comparator by visual examination and if necessary by scraping with a finger nail, small
needle gauges, surfoce wooden stick or similar - never with the fleshy part of the finger as this will
replica tape and surface
contaminate the blast.
comparators only gives
the degree of roughness A profile grading can be given when the area under assessment is rougher than the
and not the degree of smoothest of two adjacent areas on the comparator but not as rough as the rougher of
cleanliness. 41
the two areas. The profile is then graded according to the following:
Fine profile: Equal to or rougher than area I but not as rough as area 2.
Medium ~ r o f i l e :Equal to or rougher than area 2 but not as rough as area 3.
BS 7079 :Part A1 is the
same as I S 0 8501-1 and
SS 0 5 59 00.
I
Coarse
-
Equal to or rougher than area 3 but not as rough as area 4.
If the profile is fine;than area 1 it is termed finer than fine.
If the profile is coarser than area 4 it is termed coarser than coarse.
Blasting grades
The grade of a blast finish relates to the amount of surface contaminant remaining after
blasting. The grade of blast finish is primarily governed by blasting time and the
velocity of the abrasive particles.
BS 7079 : P a r t A 1
BS 7079 - Preparation of steel substrates before application of paints and related
products. Part A1 of this standard is pictorial and shows rust grades prior to blasting
and the degree of surface cleanliness after blasting.
70
The surface under examination is visually compared with high quality photographs in
the standard both before and after blasting. The preparation is then given a coding,
e.g. C Sa2% which can be interpreted using the following extract from the standard:
80
I Rust grades:
B
-
A - Steel surface Iar~elyc o v w with adherent mill scale but little, if any, rust.
- Steel surface which has begun to rust and from which the m ~ l scale
to flake.
l has begun
C - Steel surface on which the mill scale has rusted away or from which it can be
scraped, but with slight pitting visible under normal vision.
D- Steel surface on which the mill scale has rusted away and on which general
pitting is visible under normal vision.
01 Preparation grades - blast cleaning.
Prior to blast cleaning, any heavy layers of rust shall be removed by chipping.
Visible oil, grease and dirt shall also be removed.
After blast cleaning, the surface shall be cleaned from loose dust and debris.
Sa2 -
Light blast cleaning. When viewed without magnification, the surface
shall be free from visible oil, grease and dirt, and from poorly adhering mill
scale, rust, paint coatings and foreign matter.
Thorough blast cleaning. When viewed without magnification, the
surface shall be free from visible oil, grease and dirt, and from most of the
mill scale, rust, paint coatings and foreign matter. Any residual
contamination shall be firmly adhering.
Sa2% - Very thorough blast cleaning. When viewed without magnification, the
I
LSa3
surface shall be free from visible oil, grease and dirt, and from mill scale,
rust, paint coatings and foreign matter. Any remaining traces of
contamination shall show only as slight stains in the form of spots or stripes.
- Blast cleaning to visually clean steel. When viewed without
magnification, the surface shall be free from visible oil, grease and dirt, and
shall be free from mill scale, rust, paint coatings and foreign matter. It shall
have a uniform metallic colour.
SSPC BS 7071
(SS 05 59 00)
1 NACE 1
White metal (SP5) Sa3 Grade 1
Near white metal (SP 10) Sa2% Grade 2
Commercial finish (SP6) Sa2 Grade 3
Light blast and brush, off (SP7) I Sa 1 I Grade 4
SSPC = Steel Structures Painting Council
NACE = National Association of Corrosion Enmneers
I Equipment
( Centrifugal blast units
Blasting in factories is often carried out using rotating wheels which throw the abrasive
at the component. These units, known as centrifugal blast wheels, are usually fixed
installations and are commonly used for large production runs, e.g. on pipes in pipe
mills and large steel plates in shipyards.
I The main advantages of this system compared to air blasting systems are as follows:
a. lower cleaning time,
b. lower abrasive consumption,
c. lower energy consumption,
d. less labour used,
e. more consistent and uniform blast finishes,
f. more environment friendly,
g. safer to implement - closed system.
80 The abrasive is fed into the centre of the wheels and to the inner edges of the attached
blades by means of an impeller. The abrasive is then accelerated to the end of the
blades and onto the component by centrifugal force at speeds typically between
250-350 kmfh (160-220 m.p.h.).
For cost reasons the abrasive used would normally be reusable. The abrasive is
recycled up to approximately twenty times providing it is free from grease or oil
90
contamination. An air-wash separator removes any dust contaminants from recycled
abrasive before it is fed back into the wheels.
Ruane &
T P O 'Neil/
I Air blasting
Pressure blasting, which is a type of air blasting system, would normally be used on
site work. Vacuum blast and suction blast equipment also come under the category of
air blasting but are not as widely used due to lower efficiency.
Pressure blasting equipment basically consists of:
a cnrnprewnr, providing an air supply of approximately 0.7 MPa (100 p.s.i.),
a pressurised pot containing the abrasive,
l~quidseparators, i.e. moisture filters (knock-out pots),
a carbon impregnated hose,
a Venturi shaped blasting nozzle,
a dead rnurzs handle for direct operator control.
The velocity of abrasive particles leaving a blasting nozzle is primarily governed by the
pressure at the nozzle; the higher the pressure the higher the velocity and therefore the
higher the rate of cleaning.
There is a point at which an increase in pressure does not increase the velocity
substantially, this is at approximately 0.7 MPa (100 p.s.i.) depending on the abrasive
used. Limiting pressures to 0.7 MPa (100 p.s.i.) is also advantageous for safety
reasons.
It is important to keep the pressure at the nozzle as close to 0.7 MPa (100 p.s.i.) as
possible because for every 1% loss in pressure there is approximately a I%% loss in
efficiency. The pressure at the nozzle may be measured using a hypodermic needle
gauge, this is placed through the hose near the nozzle, with the hole in the needle
facing the nozzle.
I Blasting nozzles
Blasting nozzles are available in a variety of materials and orifice sizes. Sometimes the
,, nozzles are lined with relatively abrasive resistant materials, e.g. tungsten carbide, for a
longer working life.
Two types of nozzle which exist are the straight bore nozzle and the Venturi shaped
noule. Straight bore nozzles are rarely used for blasting large surface areas because
they are not as efficient as Venturi shaped nozzles. The velocity of abrasive leaving a
straight bore nozzle at 0.7 MPa (100 p.s.i.) is approximately 350 k m h (220 m.p.h.),
60 whereas the velocity for a Venturi shaped nozzle under similar conditions would be
approximately 720 km/h (450 m.p.h.).
Venturi shaped nozzles also produce a larger blast pattern with the whole area
receiving a relatively equal amount of abrasive, whereas, a straight bore nozzle
concentrates most of the abrasive in the central area of the blast pattern, resulting in a
fringe area of lower blasting efficiency.
Wet blasting
Wet blasting methods are good for removing soluble salts such as chlorides from
surfaces and are good for the removal of toxic coatings, e.g. red lead paint films,
because they do not create dust.
However, all wet blasting methods have similar disadvantages over dry abrasive
blasting, including:
a. the availability and drainage of water;
b. the production and disposal of sludge (particularly with abrasive injection);
c. the extra cost of supplying and mixing a corrosion inhibitor (assuming the
specification allows the use of an inhibitor);
d. the problems associated with drying large surface areas or the higher cost of
water miscible primers compared to conventional primers.
Reciprocating needles
1
1/ Compressed aif
I NEEDLE GUN
After needle gunning the amplitude of the surface profile may be checked by the same
methods used for abrasive blast cleaning if the contour of the substrate allows.
I Flame cleaning
The application of an oxyacetylene flame to the steel surface to be cleaned is an
efficient method of removing rust, mill scale and other contamination. The
effectiveness of the process is due to a combination of factors:
Differential expansion - The mill scale on contact with the intense heat expands at a
faster rate than the steel to which it is attached and flakes off.
-
Dehydration Rust is a combination of iron oxide and moisture. As the moisture is
rapidly driven off the rust is dehydrated and converted to a dry powder which can be
removed by wire brushing.
Heat penetration - The heat from the flame penetrates all the surface irregularities and
removes all traces of moisture, oil, grease, etc..
The flame cleaning of any form of fastener, e.g. rivets or bolts, should be avoided as a
loss of mechanical strength may be caused.
Flame cleaning often requires three operatives who work in a team as follows:
No.1- flame cleans the surface, this gives a light grey appearance on the surface
when finished.
No.2 - wire brushes the surface to remove all the dry powder.
No.3 - primes the surface; it is often necessary to apply the paint while the metal is
still warm, around 40C (which is about the maximum to which the hand can
be comfortably applied).
The warmth of the plate lowers the paint viscosity enabling it to flow more easily into
irregularities and also ensures that condensation will not form on the surface.
BS 7079 : Part A1 shows minimum flame cleaning standards according to rust grades,
i.e. A F1, B F1, C F1 and D F1.
60
Chemical cieaning
Pickling and phosphating
Pickling is a chemical cleaning process which is widely used in a factory environment
for preparing items such as pipes and steel plates.
The process usually involves immersing the steel in a bath of hot acid such as sulphuric
acid (H,SO,) which has been inhibited to reduce attack by the acid on the steel. The
acid dissolves a thin oxide layer at the interface with the steel causing the rust or mill
scale to be removed.
Other acids, e.g. phosphoric acid and chromic acid, are used to passivate the substrate
to retard corrosion reactions and also to promote adhesion. The acids react with the
steel to form a thin layer on the surface which passivates the surface and provides
corrosion resistance.
Procedure (H B Footner's duplex process):
1. Degrease: Removes surface contaminants such as grease and oil by the use of a
suitable solvent, e.g. xylene, usually applied by cloth.
2. Pickle: Total immersion in a tank of acid, e.g. 5 1 0 % sulphuric acid at 65-70C
to remove mill scale, rust etc., the time taken=iable and depends upon the
type and degree of contamination. An inhibitor is also present in this tank.
Emulsion cleaners
Emulsion cleaning uses oil emulsifying agents (soaps) which form a suspension of oil
droplets within a liquid. It is usual to follow emulsion cleaning with water or steam
cleaning to remove the soap and emulsified oil or grease.
Alkali cleaners
Economic and efficient in use and therefore popular but operator safety is a serious
consideration. Vegetable oils are saponified and mineral oils are emulsified. This
category is designed to preferentially wet the substrate, thus displacing any
contaminants.
-
40
test may also be referred
to U S the potarsium Potassium ferricyanide test
hexacyanoferrate (111)test.
1. Spray a fine mist of distilled water onto a small area of the blast cleaned surface
using a scent-spray type of bottle.
2. Wait a moment for any water droplets to evaporate then apply a potassium
ferricyanide test paper by pressing down for 2 to 5 seconds.
3. Remove the test paper and check to see if any salts have been drawn by capillary
action. They show as prussian blue spots.
Merckoquant Test
,, This test is also known as the Eisen test and is a colormetric quantitative test claimed to
be 85% accurate down to 30 mg/m2.
Small test pads on plastic strips are soaked in a solution of 2,2' bipyridine which reacts
with Fe++to produce a red colour. A colour change through white to dark red is shown
on the test kit container with corresponding values in parts per million (ppm).
70
Procedure
It is generally accepted that by using the areas and quantities mentioned below, a direct
conversion to mg/m2 can be obtained.
I 1.
2.
Tape off an area of 150 rnm x 150 mm using masking tape or similar.
Soak a swab of cotton wool in a pre-measured 22.5 ml of distilled water and swab
80 the masked off area, replacing the cotton wool into the distilled water.
3. Dry off the area using a fresh piece of cotton wool, removing as much moisture as
possible and place this second swab into the distilled water.
4. Stir the water containing the cotton wool swabs well and immerse the test strip
into the solution, after approximately ten seconds, shake to remove the excess
water and monitor the resulting colour change with the master chart.
There is a laboratory test
to determine the quantity
of chlorides on a cleaned Bresle sample patch
surface to BS 7079 :Part This is a mercury (11) nitrate (mercuric nitrate) titration test claimed to be 95% accurate
8 2 which also invloves
mercury (11) nitrate.
down to 10 mg/m2. (Reference I S 0 8502 : Part 6).
Mill scale
Mill scale is cathodic with respect to steel. This means that if any traces of mill scale
are present on the surface after preparation they can accelerate the corrosion of the
underlying steel and disbond, leading to the eventual failure of any coating system
applied.
To test for the presence of any mill scale particles left behind after blast cleaning to
BS 7079 grade Sa3 the copper sulphate test may be used.
Procedure
A fine mist of slightly acidic copper sulphate solution is sprayed onto a localised area
of approximately 100 mm in diameter. The steel turns a bright copper colour and any
mill scale particles show as black spots.
Dust
The presence of dust may be determined by applying transparent pressure-sensitive
adhesive tape to the test surface and then removing. The tape is examined using a
magnifying glass and an assessment of the degree of dust contamination is made.
Standards do exist which standardize the test conditions and the way in which the
results are assessed. For example, the pressure applied to the tape and its degree of
stickiness will partly govern the results. (Reference BS 7079 : Part B3).
Oil or grease
Simple visual assessment may reveal the presence of oil, dr grease, however, a cotton
wool swab wiped over the surface may reveal oil or grease which was not directly
visible when on the surface. The use of an ultraviolet lamp may also detect oil or
grease by causing it to fluoresce, but a dark environment is required for this method.
Another method is to drip several drops, using an eye type dropper, of a solvent such as
xylene onto the suspect area. After a few moments remove some of the solvent with the
dropper and drip the solvent onto a tissue or filter paper. When the solvent has
evaporated any oil or grease removed by the solvent will show up on the paper as a
brown ring.
Ruane &
T P O'Nei!
Flashpoints give an indication of fire risk and are defined as, 'the lowest temperature at
which solvent vapour from the product under test in a closed cup gives rise to an
airlvapour mixture capable of being ignited by an external source of ignition'.
Flashpoint determination of paints or solvents may be carried out in accordance with
BS3900 part A9 using a closed cup of the Abel type.
Procedure:
1. Fix the Abel cup containing the substance for assessment into a water bath.
2. Apply a heat source to the water bath and monitor the temperature of the
substance in the Abel cup.
F a n orange f i m e is
-
3. Activate the source of ignition every YiC rise in temperature.
observed, the temperature is '
roo high and overhearing has 4. The flashpoint temperature is identified when a blue flame flashes over the
occurred The material substance being assessed.
under resr should be cooled
or reploced and the resr
restarted.
1
-
ROTATION VISCOMETER ROTOR ENDS
A simple method for measuring the viscosity of free flowing paints is by using aflow
% 6o
cup; again there are may types including the /SO, Ford and Zahnflow cups.
Density is weight per unit volume and is therefore found by the following formula:
weight
Density = -
volume
10
The unit used for measuring the density of paint is usually grams per cubic centimetre
(g/cm3).
1 cm3 of water = 1 millilitre = 1 gram
1000 cm3 of water = 1 litre = 1 kilogram
20
mater. -
The density of a paint will be hi her than that of water; the density of a solvent will be
hp
lower than that o m e r ; the ensity of a curing agent may be higher or =than that
DENSITY CUP
Relative density
Relative density or specific gravity is the density of any substance compared to the
10 density of water:
density of x
Specific gravity (SG) =
density of water
O'
Because the density of water is lg/cm3the figure obtained from the SG formula will be
the same as that obtained from the density formula, the difference is that the answer for
the SG formula will have no units, i.e. it is a dimensionless &
atr.
"
Example formulae
1. What is the density of a paint if 5 litres weighs 7.35 kg?
weight
a. Density = -
volume
40
7.35 kg
b. Density = -
5 litres
60
2. A two pack paint is mixed at a ratio of seven parts base to two parts curing agent;
the densities are 1.59 g/cm3 and 0.78 g/cm3 respectively. What is the density of
paint after mixing?
90
Substrate
'Scale
ECCENTRIC WHEEL
w.f.t. = ,
,
volume
Adhesion failures more often occur between the uncoated substrate and the primer due
to inadequate wetting of the substrate which may be as a result of insufficient surface
1 preparation, insufficient dust removal after surface preparation or contamination
All paints within a system should have compatibility between coats and with the
substrate. It is advisable to obtain all the components for a paint system from one
'0 manufacturer otherwise it may not be possible to guarantee the system; when
compatibility is lacking it is often the adhesion which suffers.
\ /
eslve failure
(between
paint films)
'i-
Substrate
Adhesive
(between failure
primer
and substrate)
80
1 X-cut tape test
A sharp knife or similar is used to make an X shaped cut with the smaller angle
between 30" and 45". The cuts must be made down to the substrate in a single action
and are made approximately 40 mm in length. A piece of specified pressure sensitive
tape approximately 75 mm long and 25 mm wide is placed over the cut and pressed
down in the central area first using a finger. An eraser on the end of a pencil is then
used to firmly rub the tape so full adhesion is achieved. Within 1 to 2 minutes the tape
is pulled off rapidly at an angle as close to 180" as possible. The X-cut area is then
examined and the adhesion is rated using a scale from 5A = no peeling or removal
through to OA = removal beyond the area of the X .
Dolly test
A more technical adhesion test, the pull-ofladhesion test or dolly test, may show:
adhesive failure between primer and substrate (most likely);
adhesive failure between paint films;
cohesive failure within an individual paint film.
Load indio
Dolly puller
Paint film
Substrate
1 I.
2.
Clean and degrease the surface to be tested and the dolly contact surface.
Roughen both surfaces with finelmedium grade emery cloth.
Altert~ativeadhesives ctrz 50
possible, see test procedure 3. Mix regular araldite and stick dolly to the surface, leave for 24 hours at 25OC.
sheefs.
4. Cut paint around the dolly down to the substrate using special cutter.
5. Attach pull-off instrument and apply pull-off force.
6. Take reading from position of cursor when dolly detaches itself. Values will be
60 typically obtained in either MPa, N/mm2 or p.s.i..
A minimum pull-off value for the paint type used should ideally be specified in the
specification(s) for the work being carried out. In the absence of such criteria, a
minimum pull-off value should be obtained from the paint manufacturer who should
also state categorically whether or not all values less than the minimum pull-off value
are deemed a failure.
Plastic ring
I 'It is not permissible to apply paints when the following conditions apply:
During rain, snow, or high winds.
10 When the air or metal temperature is not at least 3OC above the dew point
temperature.
When the air or metal temperature is below 5C.
When the relative humidity is above go%.'
y&
The dew point is the temperature at which water v w n the atmosphere would form
condensation Therefore, if the temperature dropped to the dew point temperature the
-t would rise to 100% and condensation would be formed on any
objects at, or below, that temperature.
Repeat the operation until consecutive readings of each bulb temperature agree to
within 0.2"C.
If it is 100% relative humidity the wet bulb will be the same temperature as the dry
bulb, because no evaporation can occur, i.e. the air is saturated. If the wet and dry bulb
temperatures are the same, the current temperature is the dew point.
The relative humidity and dew point cannot be read directly from the apparatus,
hygrometric tables or special slide rules must be used. Hygrometric tables are more
accurate in the 90% RH region and above.
Metal temperature
The metal temperature may be measured with a magnetic temperature gauge,
sometimes known as a limpet gauge, or electrical contact thermometer.
( COSHH Regulations 1994
1
I
Scope
Thc Control of Substances Hazardous to Health (COSHH) Regulations 1994
(SI No. 3246) define a substance hazardous to health as:
a. a substance listed in part 1 of the approved list as dangerous for supply within
the meaning of Chemicals (Hazard Information and Packaging) Regulations
1993 and for which an indication of danger specified for the substance in
Part V of that list is very toxic, toxic, harmful, corrosive or irritant.
b. one which has a maximum exposure limit (MEL) in Schedule 1 of COSHH or if
the H & S Commission has approved an occupational exposure standard
(OES).
c. a biological agent.
d. dust in air - when substantial.
e. a substance comparable with the above.
The COSHH regulations are not applicable to the control of lead, asbestos,
radioactivity, explosive or flammable properties of materials, high or low temperatures,
high pressures, medical treatment or below ground work (mining). Other Regulations
deal with these areas.
40
Responsibilities
The exposure of an employee to substances hazardous to health is under the control of
the employer. A training organisation is responsible for exposure by trainees.
Employers must prevent exposure to substances hazardous to health, or control
exposure when total prevention is not reasonably practicable. Personal protective
equipment, e.g. masks, are a second choice for control.
Prior to work commencing, employers must always carry out a risk assessment for all
substances hazardous to health to which employees may be exposed.
Employees have a duty to report any problems in exposure control procedures or any
defects found in protective equipment.
6O Employers must keep records of examinations/monitoring tests carried out. These are
kept for 5 years; 40 years for identifiable employees.
-
2. Occupational exposure standard (OES): 'the standard approved by the Health &
Safety Commision for that substance in relation to the specified reference period
when calculated by a method approved by the Health & Safety Commision.'
When a MEL is specified, exposures must be kept as low as is reasonably practicable,
but always below the specified value.
Long term exposure limits are An OES should not be exceeded, but, an exposure over the limit is acceptable
averaged over an 8 hour providing that the reason for exceeding the OES has been identified and measures are
reference period. Short relm
exposure limits are taken over
taken to reduce the exposure below the OES as soon as is reasonably practicable.
u I5 minute reference period. Examples of solvents with their corresponding long term exposure limits (OES's
unless otherwise specified) can be seen in the following table:
- - -
of VOC by 1998. COSHH Regulations also require paint manufacturers to screen all
raw material used in the manufacture of their product and eliminate, where possible, all
materials which may be dangerous to manufacturing operatives and to applicators.
The alternatives to standard paints containing organic solvents ate solvent free paints
(100% VS), high volume solid paints, i.e. over 65% VS, water borne paints and powder
coatings.
Most paint manufacturers have chosen their particular product path, some have opted
for acrylics and vinyls, some for new formulations of water borne epoxies and some for
100% VS. Each of the systems have their advantages and disadvantages, e.g. 100% VS
urethanes have no VOC's; they are mainly fast curing; highly resistant to chemical
attack; chalking and natural erosion is virtually nil but the activator chemicals are
extremely toxic.
High volume solid paints still contain VOC's and therefore in the future their use is
likely to be restricted.
Water borne coatings are environmentally friendly and biodegradable, therefore extra
costs are not incurred in disposing of containers and sludges etc. but application areas
are significantly reduced because of the slow evaporation rate of the solvent water.
Water borne epoxies have been in use for some time now, but when used in high
humidity environments their successful application and attainment of intended
properties is difficult to achieve.
Powder coatings can be applied as thin as 25 pm electrostatically with a utilisation
yield of 98%. The disadvantage is that costly heat is required for the reaction. The
Waferborne epoxies are component needs to be heated to a minimum of 70C (over 200C in some cases) to
offen referred fo as new melt the powder in order to form a film and for the reaction to take place. Powders can
generation or third
generation epoxies.
be formulated to melt at much lower temperatures but this would create manufacturing
problems and storage stability problems.
There are many faults which may exist on the surface of the material to be coated. The
potential consequences of coating over these faults are ( I ) premature failure of the
Tenm such as defects, I coating system and (2) failure of the component.
flaws, discontinuities or
The painting inspector is normally expected to evaluate whether sharp contours such as
imper;fectionr may be used
to describe faults on rhe edges are acceptable to paint, however, it is rarely ever a painting inspector's duty to
substrate. 10 determine what remedial action, if any, needs to be applied to inherent material defects
such as laminations or cracks.
It is important for the painting inspector to be aware that flaws in the material may still
exist after inspection and acceptance by other QC personnel. Flaws may also have
been induced by secondary processing, e.g. grinding, or may have been induced in
service, e.g. fatigue cracking.
7n
Substrate faults may only reveal themselves to visual inspection after surface
preparation, it is at this stage the inspector should be vigilant.
I There are three common causes for cracking during the heat treatment process:
a. during reheating - cracking due to thermal shock;
b. during quenching - cracking due to rapid contraction;
70 c. after a hardening process - when the component is not tempered soon enough.
Grinding cracks
Grinding cracks usually occur in groups at right angles to the direction of grinding or as
a network of cracks when rotary grinding wheels are used. They are commonly caused
by using the incorrect grade of grinding wheel, by applying too much force or by loss
of grinding fluid (if used) and only occur in materials which can be hardened.
Hydrogen cracking
Hydrogen cracking may not only occur during welding but may occur in service or due
to secondary processing. A sufficient quantity of hydrogen has to be available to enter
the material or the inherent hydrogen content has to be high enough. The material must
also have a grain structure which is susceptible to cracking.
Hydrogen cracking may be in the form of a fine network or may exist as a linear or
wandering line. Hydrogen can also form blisters on the surface.
The following list shows common sources of hydrogen which may lead to hydrogen
cracks:
a. Chemicals used during etching - etching cracks.
b. Chemicals used during the plating process - plating cracks.
c. Acids used during pickling -pickling cracks.
d. Hydrogen contained within chemicals being transported via pipework or
contained within vessels, e.g. sour gas.
Fatigue cracks
Fatigue cracking is a service failure which occurs under cyclic stress conditions. It
normally occurs at a change in section, e.g. groove, radius, step, weld toe etc., therefore
design and workmanship are important to minimise failure by fatigue.
I Them are two main sources of stress cycles:
a. Mechanical stress cycles - caused by vibration or movement.
b. Thermal stress cycles - repeated heating and cooling creates repeated
expansion and contraction.
All metals are susceptible to fatigue failure. Since design and workmanship play a
major part, ferrous based materials have an endurance limit applied to one grade of
steel in a specific heat treated condition operating within specific parameters, below
this limit fatigue is unlikely to occur. Other metals will all have the potential to fail by
fatigue given the required conditions.
Fatigue failures start at a specific point and propagate with each stress cycle at a rate
that depends on the applied stress. Fatigue failure is easily identified by beach
markings on the fractured face. Final failure can be any other mode of fracture,
e.g. brittle or ductile failure.
1 2.
Electrolyte resistivity is high.
1 3.
4.
The anodes are too close to the structure.
Non-uniform coating quality.
QA standards
BS EN I S 0 9000 series - Quality systems.
BS 4778 - Quality vocabulary.
[EN 28402; I S 0 84021
BS EN 3001 1 - Guidelinesfor auditing quality systems.
Normative document: Document that provides rules, guidelines or characteristics for
activities or their results.
Note: The term normative document is a generic term that covers such documents as
10 standards, technical specifications, codes of practice and regulations.
[IS0 GUIDE 2 & BS EN 4.50201.
NON-DESTRUCTIVE
TEST GAUGES
Memurhg the cl.f.1. clireclly with a n u n - c l t ~ u c i vla31 gaugt! iu UIU lrlusl wicluly uu~cl
method; there are a variety of gauges available with various scale ranges:
magnetic film thickness gauge
$ electromagnetic gauge
eddy current
ultrasonic gauge
I Scale wheel\
Ferromagnetic substrate /
MAGNETIC FILM THICKNESS G A U G E
Calibration procedure:
1. Choose a magnetically insulating shim of known thickness, close to the thickness of
the paint you expect to find, i.e., do not choose a 25pm shim to calibrate if you
expect the coating thickness to be considerably greater as this will reduce the
accuracy.
2. Place the shim on the same substrate material type and profile as that on which the
paint is to be measured, i.e., if the paint is on a blasted surface, calibrate the gauge
on an uncoated blasted surface and visa versa.
3. Place the magnet onto the shim and press f m l y on the instrument, wind the scale
wheel anti-clockwise (away tom yourself) until the magnet is definitely attached to
the shimlsubstrate.
4. Gradually wind the wheel slowly clockwise until the magnet detaches itself. Repeat
to confirm the reading (the reading is taken opposite the fixed cursor). If the
reading is not accurate to the shim the scale itself must be moved by adjusting the
calibration bar to move the scale the appropriate amount.
The instrument is now calibrated and may be used to measure the d.f.t. of any non-
magnetic paint films to within a claimed accuracy of *5% in some cases.
100
Pull-off gauge
This type of gauge may only be used for measuring the thickness of non-ferromagnetic
10 coatings applied over ferromagnetic substrates. They are not very accurate compared
to the other non-destructive test gauges.
;k DESTRUCTIVE
TEST GAUGES
Destructive test gauges cut into the paint film and should therefore only be used where
necessary due to the cost of repairing the damaged coating.
80 They are sometimes used on paint films containing M.I.O. pigment; M.I.O. is
ferromagnetic and therefore non-destructive test gauges, which rely on a non-magnetic
coating, cannot be used.
&
,- The paint inspection gauge (PIG) is one such type of destructive test gauge. A small
vee shaped channel is cut lnto the coating at a f ~ e angle
d governed by a cutter built
into the gauge. The width of the channel is then measured on a graticule scale by
90
means of a microscope which is again built into the instrument.
Other destructive thickness gauges are the Saberg thickness drill or Erichsen thickness
#
drill which work on a similar principle to the paint inspection gauge.
7
CALCULATION
20 The daft. may be assessed indirectly by measuring the w.f.t. of the paint, and providing
the volume solids (v.s.%) content of the paint is known, calculating the d.f.t. as follows:
Example:
30 What would be the d.f.t. if 15 litres of paint with a volume solids content of 44% is
used to cover an area 12 m x 7 m?
To find d.f.t:
44
c. d.f.t. = -x ?
wJt. is not given directly in 50 100
the question, therefore must
be found by calculation. To find w.f.t.:
I d. weft. =
volume
-area
15 litres
e. w.f.t. =
12m x 7m
Convert all existing units
to common units i.e. cm.
15000
f. w.f.t. =
1200 x 700
70
Convert to pm
g. w.f.t. = 0.017858cm x 10,000
(10,000pm = 1 em).
h. w.f.t. = 178.58pm
f
Solven tless 'Solvent' thinned
-I- 'emulsion' types
I'
Non-drying
I
Drying
*.
waxes
I I
I I
fish oils, etc. Convertible Non-Convertible
petroleum
jelly
Air Heat Chemically
drying convertible cured
I
Oleoresinous r
(linseed and/or a phenolics two-pack paints
tung oil with epoxy e.g. epoxy
synth~ticresin) poyuret hanes po1yure:hanes
Alkyds acrylics tarlepoxy I heated
Epoxy esters (stoving) tarlurethaze air drying (plastisols)
zinc silicates
- I
organosols
rubber, vinyls I