Waterjetting 5-1

Chapter 5: Waterjetting

Objectives
When this module is complete, you will have knowledge and understanding of:
• Standards
• Equipment and systems
• Operations
• Operator technique considerations
• Special considerations
• Inspection concerns
• Inspection checklist

5.1 Introduction
Waterjetting: NACE WJ-1/SSPC-SP WJ-1, NACE WJ-2/SSPC-SP WJ-2, NACE WJ-3/SSPC-
SP WJ-3, NACE WJ-4/SSPC-SP WJ-4 describe the use of a high-energy water stream to strip
off existing coatings and remove contaminants on a substrate being prepared prior to coat-
ings application. When compared to abrasive blasting, this method has certain advantages
particularly for safety and environmental control. Respiratory protection requirements are
less stringent and waste (abrasive) disposal is not an issue because water is the medium.
The term waterjetting denotes the use of “water only,” without the addition of solid particles
such as sand or garnet in the water stream. Modern waterjetting equipment produces pres-
sures of up to 90,000 psig. However, as technology improves, equipment with higher operat-
ing pressures may be developed.
This cleaning method is particularly well suited to the marine, process and utility (power
plants) industries, where high-performance coatings require extensive surface preparation
and/or surface decontamination with minimal effect on surrounding equipment and the
environment. In the marine industry, waterjetting is widely used to remove marine growth,
depleted antifouling coatings, and surface preparation of tank/ hold interiors. Data also
proves it is effective in removing marine growth on offshore structure's jackets (submerged
sections).
It is very important to remember that while waterjetting will remove contaminants and
millscale at varying pressures, it will not create an anchor profile, which plays a critical role
in coatings adhesion. In maintenance and repair operations, waterjetting exposes the exist-
ing anchor profile (if there is one).
Waterjetting NACE WJ-1/SSPC-SP WJ-1, NACE WJ-2/SSPC-SP WJ-2, NACE WJ-3/SSPC-
SP WJ-3, NACE WJ-4/SSPC-SP WJ-4 also addresses water cleaning which is basically the
same process at lower pressures. It is important for inspectors to understand these terms and
the working pressures associated with them.
In comparing water cleaning with waterjetting, these definitions apply:

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5-2 Waterjetting

Low-Pressure Water Cleaning (LP WC): Cleaning performed at pressures below 34 MPa
(5,000 psig). This is also called “power washing” or “pressure washing.”
High-Pressure Water Cleaning (HP WC): Cleaning performed at pressures of 34 to 70 MPa
(5,000 to 10,000 psig).
High-Pressure Waterjetting (HP WJ): Waterjetting performed at pressures from 70 to 210
MPa (10,000 to 30,000 psig).
Ultrahigh-Pressure Waterjetting (UHP WJ): Waterjetting performed at pressures above
210 MPa (30,000 psig).

5.2 Standards
The joint NACE/SSPC standards for abrasive blast cleaning are complete and clearly
define the surface conditions to be achieved. However, when and if specifications are being
written for surface preparation utilizing waterjetting, the 4 standards (WJ-1, WJ-2, WJ-3,
WJ-4) which replaced NACE No. 5/SSPC-SP-12 should be referenced.
Clean to Bare Substrate (WJ-1) is the waterjet cleaning equivalent to the International
Organization for Standardization (ISO)(1) 8501-12 degree of cleanliness Sa3, cleaning to
bare metal. ISO 8501-43 notes the use of various common terms for methods of waterjet
cleaning: waterjetting, water blast cleaning, hydrojetting, aquajetting, hydroblasting, aquab-
lasting, and “cleaning by directing a jet of pressurized water onto the surface to be cleaned.”
Within the hierarchy of degrees of surface cleanliness achieved by waterjet cleaning, Clean
to Bare Substrate (WJ-1) is intended to be similar to the degree of surface cleanliness of
NACE No. 1/SSPC-SP 5,4 except that stains are permitted to remain on the surface. Section
2.1.2 of the standard states, “Gray to brown-black discoloration remaining on corroded and
pitted carbon steel that cannot be removed by further cleaning is allowed.”
Very Thorough Cleaning (WJ-2) is essentially equivalent to the International Organization
for Standardization (ISO)(1) 8501-42 degree of cleanliness Wa 2.5, very thorough cleaning.
ISO 8501-4 notes the use of various common terms for methods of waterjet cleaning: water-
jetting, water blast cleaning, hydrojetting, aquajetting, hydroblasting, aquablasting, and
“cleaning by directing a jet of pressurized water onto the surface to be cleaned.”
Within the hierarchy of degrees of surface cleanliness achieved by waterjet cleaning, Very
Thorough Cleaning (WJ-2) is intended to be similar to the degree of surface cleanliness of
NACE No. 2/SSPC-SP 10,3 except that tightly adherent material, rather than only stains, is
permitted to remain on the surface.
Thorough Cleaning (WJ-3) is essentially equivalent to the International Organization for
Standardization (ISO)(1) 8501-42 degree of cleanliness Wa 2, thorough cleaning. ISO 8501-4
notes the use of various common terms for methods of waterjet cleaning: waterjetting, water
blast cleaning, hydrojetting, aquajetting, hydroblasting, aquablasting, and “cleaning by
directing a jet of pressurized water onto the surface to be cleaned.”
Within the hierarchy of degrees of surface cleanliness achieved by waterjet cleaning, Thor-
ough Cleaning (WJ-3) is intended to be similar to the degree of surface cleanliness of NACE
No. 3/SSPC-SP 6,3 except that tightly adherent material, rather than only stains, is permitted
to remain on the surface; and to the degree of surface cleanliness of NACE No. 8/SSPC-SP

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14,4 Industrial Blast Cleaning, which allows tightly adherent material to remain on the sur-
face.
Light Cleaning (WJ-4) is essentially equivalent to the International Organization for Stan-
dardization (ISO)(1) 8501-42 degree of cleanliness Wa 1, light cleaning. ISO 8501-4 notes the
use of various common terms for methods of waterjet cleaning: waterjetting, water blast
cleaning, hydrojetting, aquajetting, hydroblasting, aquablasting, and “cleaning by directing a
jet of pressurized water onto the surface to be cleaned.”
Within the hierarchy of degrees of surface cleanliness achieved by waterjet cleaning, Light
Cleaning (WJ-4) is intended to be similar to the degree of surface cleanliness of NACE No.
4/SSPC-SP 7,3 except that tightly adherent material, rather than only stains, is permitted to
remain on the surface.
An example of a specification statement is: “All surfaces to be recoated shall be cleaned in
accordance with NACE WJ-1/SSPC-SP WJ-1 Joint Standard. The method of HP WJ or UHP
WJ ultimately selected by the contractor will be based on his confidence in the capabilities of
the equipment and its components.”
If non visible contaminants are to be addressed the specifier, inspector, and contractor must
agree on the test methods to determine the amount of non visible contaminants that can be
left on the prepared substrate. Consult the manufacturer of the specified coatings to deter-
mine the coating's tolerance to the surface conditions after waterjetting, commensurate with
the in-service conditions.
The definition of visible and non visible contamination is as follows:
Non Visible contamination (NV) is the presence of organic matter, such as very thin films
of oil and grease, and inorganic and/or soluble ionic materials such as chlorides, ferrous
salts, and sulfates that remain on the substrate.
Visible surface cleanliness (VC) is the visible condition of the substrate when viewed with-
out magnification and after cleaning.
The degrees of cleanliness defined in WJ-1 through WJ-4 are defined as follows:

5.2.1 Visual Surface Preparation Definitions

WJ-1 Clean to Bare Substrate: A metal surface after Clean to Bare Substrate, when viewed
without magnification, shall have a matte (dull mottled) finish and shall be free of all visible
oil, grease, dirt, rust and other corrosion products, previous coatings, mill scale, and foreign
matter.
WJ-2 Very Thorough Cleaning: A metal surface after Very Thorough Cleaning, when
viewed without magnification, shall have a matte (dull mottled) finish and shall be free of all
visible oil, grease, dirt, rust, and other corrosion products except for randomly dispersed stains
of rust and other corrosion products, tightly adherent thin coatings, and other tightly adherent
foreign matter. The staining or tightly adherent matter shall be limited to no more than 5% of
each unit area of surface and may consist of randomly dispersed stains of rust and other corro-
sion products or previously applied coating, tightly adherent thin coatings, and other tightly
adherent foreign matter.

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WJ-3 Thorough Cleaning: A metal surface after Thorough Cleaning, when viewed without
magnification, shall have a matte (dull mottled) finish and shall be free of all visible oil, grease,
dirt, rust, and other corrosion products except for randomly dispersed stains of rust and other
corrosion products, tightly adherent thin coatings, and other tightly adherent foreign matter.
The staining or tightly adherent foreign matter shall be limited to no more than 33% of each
unit area of surface and may consist of randomly dispersed stains of rust and other corrosion
products or previously applied coating, tightly adherent thin coatings, and other tightly adher-
ent foreign matter.
WJ-4 Light Cleaning: A metal surface after Light Cleaning, when viewed without magnifica-
tion, shall be free of all visible oil, grease, dirt, dust, loose mill scale, loose rust and other corro-
sion products, and loose coating. Any residual material shall be tightly adherent to the metal
substrate and may consist of randomly dispersed stains of rust and other corrosion products or
previously applied coating, tightly adherent thin coatings, and other tightly adherent foreign
matter.
It goes on to explain that coatings, mill scale, and foreign matter are considered tightly adher-
ent if they cannot be removed when lifting with a dull putty knife.
A unit area of surface is an area approximately 5,800 mm2 [9.0 inches2] (i.e., a square 76 mm
by 76mm) [3.0 inches x 3.0 inches].
The inspector and contractor should know that surfaces prepared by LP WC, HP WC, HP
WJ, or UHP WJ do not exhibit the hue of a dry abrasive-blasted steel surface. After waterjet-
ting, the matte finish color of clean steel surface immediately turns to a golden hue unless an
inhibitor is used or environmental controls are employed. However, the use of any inhibitor
outside of the specification requirement is never encouraged. The use of any such inhibitor
without the written approval of the coatings manufacturer can result in the voiding of all
performance warranties from the manufacturer. On older steel surfaces that have areas of
coating and areas that are coating free, the matte finish color varies even though all visible
surface material has been removed. Color variations in steel can range from light gray to
dark brown/black.
Prepared steel surfaces show variations in texture, shade, color, tone, pitting, flaking, and
mill scale that should be considered during the cleaning process. Acceptable variations in
appearance that do not affect surface cleanliness include variations caused by type of steel or
other metals, original surface condition, thickness of the steel, weld metal, mill fabrication
marks, heat treating, heat-affected zones, and differences in the initial abrasive-blast clean-
ing or in the waterjet cleaning pattern.
The gray or brown-to-black discoloration seen on corroded and pitted steel after water-jet-
ting cannot be removed by further water-jetting. A brown-black discoloration of ferric oxide
may remain as a tightly adherent thin film on corroded and pitted steel and is not consid-
ered part of the percentage staining.
Additional technical considerations:

5.2.2 Flash Rust

Flash Rust is an additional technical consideration when a carbon steel substrate is sub-
jected to waterjet cleaning. Gray or brown/black discoloration remaining in the pits of

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waterjet cleaned carbon steel is not the same as flash rust. Metals other than carbon steel can
manifest discoloration as well. Degrees of flash rust may be qualitatively described as fol-
lows:
No Flash Rust - A carbon steel surface that, when viewed (Slide) without magnification,
exhibits no visible flash rust.
Light (L) flash rusted surface: A carbon steel surface that, when viewed without magnifica-
tion, exhibits small quantities of a rust layer through which the carbon steel substrate may be
observed. The rust or discoloration may be evenly distributed or present in patches, but it is
tightly adherent and not easily removed by lightly wiping with a cloth.
Moderate (M) flash rusted surface: A carbon steel surface that, when viewed without mag-
nification, exhibits a layer of rust that obscures the original carbon steel surface. The rust
layer may be evenly distributed or present in patches, but it is reasonably well adherent and
leaves light marks on a cloth that is lightly wiped over the surface.
Heavy (H) flash rusted surface: A carbon steel surface that, when viewed without magnifi-
cation, exhibits a layer of heavy rust that hides original carbon steel surface completely. The
rust may be evenly distributed or present in patches, but it is loosely adherent, easily comes
off, and leaves significant marks on a cloth that is lightly wiped over the surface.
Appendix B of WJ-1 provides additional information on methods of assessing the degree of
flash rust.

5.2.3 Description of Non Visible Surface Cleanliness Definitions

None of the standards (WJ-1 through WJ-4) specifies the amount of non visible contami-
nants (soluble salts) that are allowed to be left on the surface. This is left up to the specifier.
Inspectors are required to know the recommended test procedures for extracting and ana-
lyzing soluble ferrous salts, chlorides, nitrates, and sulfate contaminants of surfaces to be
cleaned and/or coated. Later chapters teach and demonstrate test methods to determine the
presence of and how to quantify existing soluble ferrous salts and chlorides. Keep in mind
that while these procedures are generally the same, different manufacturers have slightly dif-
ferent guidelines for performing these tests. If the coatings specification does not require
testing, the inspector should not request the contractor to do so or do so on his or her own
accord and then use the results as a benchmark for surface preparation acceptance.
The coating inspector should obtain, read, and understand all requirements of the standard
before inspecting surface preparation done by waterjetting. If testing procedures are not
clearly outlined in the coatings specification, all parties involved should discuss it and reach
agreement before the project begins (i.e., pre-job conference). This is critical to avoid con-
flicts and unnecessary delays when the project gets started.
Waterjetting (WJ) is the use of water discharged from a nozzle at pressures of 70 MPa
(10,000 psig) or greater to prepare a surface for coating or inspection. Waterjetting uses a
pressurized stream of water with a velocity that is greater than 340 m/s (1,100 ft/s) when
exiting the orifice. As stated earlier, waterjetting does not produce an anchor pattern or pro-
file of a magn tude currently recognized by the coatings industry. Rather, it exposes the orig-
inal abrasive blasted surface profile if one exists.

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5-6 Waterjetting

Water cleaning (WC) is the use of pressurized water (<10,000 psig) discharged from a nozzle
to remove unwanted matter from a surface.
Standard waterjetting is using water of sufficient purity and quality that it does not impose
additional contaminants on the surface being cleaned and does not contain sediments or
other impurities that are destructive to the proper functioning of waterjetting equipment.

5.3 Waterjetting Equipment and Systems

This section introduces basic waterjetting systems and the basic equipment required to suc-
cessfully accomplish the work.

Figure 5.1 Typical UHP Pump

A commercial waterjet unit can be skid, trailer, or truck-mounted and usually consists of
pumps, hoses, a prime mover (diesel, electric, etc.), along with various tools such as guns,
nozzles, lances, etc.

Figure 5.2 Trailor Mounted UHP Pump Unit

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Waterjetting 5-7

The high-pressure hose, hose connections, and all other equipment, including the nozzle
control valve, lance, and nozzle, should have minimum burst strength of 2½ times the capa-
bility of its maximum-rated operating strength.

Figure 5.3 Typical Shoulder Gun w/Nozzle

High-pressure hoses are fitted with a safety device known as a whip-lock or whip check.
This is a short length of cable or wire looped over each end of two hoses connected by a cou-
pling. The whip-lock or whip check prevents the ends of the hoses from whipping around if
the coupling breaks.
The section of hose next to the gun is fitted with a hose shroud, which usually is a short
length of heavy-duty hose placed over the high-pressure hose to provide instantaneous pro-
tection if the hose bursts. A hose shroud also can be used over other hose connections. The
shroud, however, does not form a permanent barrier to the flow of water from a damaged
hose or broken connection.

5.3.1 Equipment Types

Waterjetting equipment types generally fall into one of two basic categories:
• Manual
• Robotic

5.3.1.1 Manual Waterjetting

The majority of waterjetting falls under the manual category and is the topic of most of this
chapter. A human operator using a handheld wand performs the surface cleaning effort.

5.3.1.2 Robotic Waterjetting

Technology is quickly improving and a new kind of equipment recently developed is a
robotic waterjetting unit. It is a cleaning vehicle that attaches itself, using vacuum, cables, or
magnets to a vertical, horizontal or overhead surface. It is controlled by a single operator.

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5-8 Waterjetting

Figure 5.4 Robotic Waterjetting Unit

A unique features is that it collects in excess of 95% of the water, removed coatings and rust
(waste generated). The coatings and water are transported to a filtration bag, where the
waste is contained for future disposal. The water drains out at a clarity level generally accept-
able for treated sewers. However, check with area authorities before disposing untreated
waste in the sewage system.
A standard 40,000-psi direct-drive pump powers the unit. A vacuum system process that
provides suction, attaches the HydroCat® to the work surface where it conveys removed
coatings and water to the filtration bag mentioned earlier.
This unit is used on vertical surfaces such as ship hulls and tanks on horizontal surfaces such
as flat decks and on overhead surfaces such as the bottom of ship hulls. It also works well
over weld seams, doubler plates, lap joints and riveted seams, and moves easily in and
around keel blocks and other common obstructions. For straight-line work, it uses an “auto-
path” control feature.

5.3.2 How it Works

The tools can be hand held or mounted on a robot. Water is propelled through a single jet, a
fan-jet, or multiple rotating jets. The jets are rotated by small air, electric, or hydraulic
motors. Slightly inclined orifices in a multiple-orifice nozzle can also cause jets to rotate.

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Waterjetting 5-9

Orifices or tips come in a variety of forms and

sizes. Round jets are most commonly used. A reli-
able round jet can produce 35,000 psig (240 MPa).
Tips can be designed to produce multiple jets of
water that rotate automatically to achieve higher
removal rates. The round jets are cutters, and fan
jets are scrapers and/or pushers. The interchange-
able nozzle tips produce the desired streams. A
typical water flow rate is 4 to 53 L/min (1 to 14
gal/min).
The equipment sends a concentrated stream of
water through the hose and nozzle at pressures of
70 to 414 MPa (10,000 to 60,000 psig). With cur-
rent technology, however, the most practical pres-
sures are 70 to 240 MPa (10,000 to 35,000 psig).
Use lower pressures if appropriate. Generally,
using UHP with reduced water volume produces
less thrust and less operator fatigue.
Figure 5.5 Different Guns/Tips/Hoses
Results from the use of HP WJ and UHP WJ are
not necessarily similar. For example, surface oil and grease may not be removed by HP WJ at
70 MPa (10,000 psig), but will be removed completely by UHP WJ at 210 MPa (30,000 psig).
At working pressures of 28 MPa (4,000 psig) or higher, the waterjetting team consists of:
• The nozzle operator
• The pump operator
• Additional operators or workers
The nozzle operator controls the operation while waterjetting is taking place by holding the
gun and lance or delivery hose and controlling the motion and direction of the waterjets.
The pump operator monitors and controls the pressurizing pump during the jetting opera-
tion, and watches the nozzle operator at all times to be able to react if any difficulty arises, or
if the operator begins to show signs of fatigue. The pump operator also monitors the work-
ing area and its surroundings in case anyone tries to enter the area or if a potentially hazard-
ous condition occurs.
In either circumstance, or as necessary, the pump operator may reduce the pressure in the
supply hose until a situation is under control. The operator should use caution when rapidly
reducing the system pressure; otherwise the nozzle operator may lose footing.
Depending upon the size and scope of the project, other operators or workers may be
required to assist in handling a jetting gun if it is fitted with more than one jetting extension
or if the hose must be fed to the work piece.
If the pump is located at some distance and out of sight of the nozzle operator, a team mem-
ber may be required to monitor the jetting operation and to communicate with the nozzle
operator and pump operator.

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5.4 Waterjetting Operations

Waterjetting is effective for removing:
• Surface oil and grease
• Rust
• Concrete (shot-crete) spatter
• Existing coatings
Waterjetting also effectively removes copious amounts of water-soluble contaminants.
Waterjetting removes what cannot otherwise be removed by abrasive blasting alone, espe-
cially in the bottom of pits, cracks, crevices, and craters in corroded metallic substrates such
as steel.
An underwater waterjetting unit generally is used to clean the build up of barnacles or other
micro-organisms off ship hulls or off-shore platform legs. Take care not to use too much
pressure to ensure the antifouling coating is not damaged and ensure the safety of the opera-
tor.

Figure 5.6 Underwater Waterjetting

Figure 5.7 Waterjetting Steel Substrate Figure 5.8 Waterjetting Tank

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5.5 Operator Technique Considerations

The type of matter that needs to be removed from the surface determines the equipment to
use (HP WJ or UHP WJ), the angle at which to hold the nozzle, and the distance to hold it
from the surface. Although the waterjet nozzle distance from the surface varies from 0.6 to 1
m (2 to 3 ft), typically hold the nozzle 5 to 25 cm (2 to 10 in) from the surface. In some
instances with UHP WJ, the nozzle is held only 6 to 13 mm (0.25 to 0.5 in) from the surface.
Hold the nozzle 5 cm (2 in) from the surface when removing heavy rust scale or old coat-
ings, i.e., virtually perpendicular (90°) to the surface. For best results when removing mas-
tics, hold the nozzle at 45° to the surface.
One element of operator fatigue, mentioned
earlier, is the back thrust from the high-pres-
sure water. Ensure operators do not have to
withstand a back thrust of more than one-
third of their body weight for an extended
period of time. For example, an operator
working with a jet flowing at 70 MPa (10,000
psig) and 38 Lpm (10 gpm) experiences a
back-thrust force of 23 kg (52 lbs). The opera-
tor should weigh at least 70 kg (156 lbs) to
operate the nozzle at this pressure. Newer
units operate with less back thrust than some Figure 5.9 Proper Operator Position
of the earlier units.
To minimize operator fatigue and to ensure a safe operation, make sure the nozzle operators
periodically alternate positions with another operator, depending upon the equipment and
pressures used.

5.5.1 Nozzles/Tips
As stated earlier, orifices or tips produce waterjets. Round jets are the most commonly used,
but other shapes are available. A reliable round jet can produce waterjets at 240 MPa (35,000
psig). Tips are available that emit multiple jets of water that rotate to achieve higher removal
rates.
The round jets are cutters, and fan jets are scrapers and/or pushers. The interchangeable
nozzle tips are what produce the desired streams. A typical water flow rate is 4 to 53 L/min
(1 to 14 gal/min).

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Figure 5.10 Tips/Nozzles Figure 5.11 Fan Nozzle/Tip

5.5.2 Efficiency of Operation

Based on studies in the early 1980s, the following illustrates the overall efficiency of the HP
WJ and UHP WJ.
At pressures lower than 70 MPa (10,000 psig), loose rust, debris, and material in depres-
sions and pits are removed, but the black iron oxide Fe3O4 (magnetite) remains. A matte
finish is not achieved.
At pressures of 70 MPa (10,000 psig), a uniform matte finish is obtained that quickly turns
to a golden hue unless an inhibitor is added or dehumidification is used. The black oxide is
removed but at a rate too slow to be considered practical.
At pressures of 140 MPa (20,000 psig), a uniform matte finish is obtained that quickly
turns to a golden hue unless an inhibitor is added or dehumidification is used. Black oxide,
paint, elastomeric coatings, enamel, red oxide, and polypropylene sheet lining are removed.
Chemical contaminants will be removed, but with varying degrees of effectiveness.
At pressures of 234 to 248 MPa (34,000 to 36,000 psig), a uniform matte finish is obtained
that quickly turns to a golden hue unless an inhibitor is added or dehumidification is used.
Surface materials, including most mill scale, are removed.
Generally, more time is required in localized jetting to remove extremely well-bonded mill
scale.

5.5.3 Stand-off Distance

The distance the tip is held from the surface varies depending upon the substrate condition.
When removing mill scale and rust scale the tip should be held 5 cm (2 in) from the surface.
When removing other contaminants such as dirt, oil, grease, and light rust the tip may be
held further from the surface. The operator soon learns what the stand off distance should
be once he/she starts the waterjetting process.

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5.5.4 Safety
Safety systems include hose shrouds to protect from
high-pressure hose bursts and “deadman” controls
to prevent the waterjetting system from being acci-
dentally activated.
Before beginning work, the waterjet team should
ensure that:
• The work area is properly barricaded with
appropriate warning signs.
Figure 5.12 Typical Braided Hose
• Electrical equipment is properly covered and
protected from the water.
• Electrical connections do not sit in water.
• All fittings and hoses are in good condition (not worn or damaged) and have the
proper pressure rating for the working pressure to be used.
• Nozzles are open and free of obstructions.
• The complete system is flushed clean and air removed from the system before install-
ing the nozzle.
• The dump system and all control systems are operational.
• All relevant moving equipment, such as conveyors, mixers, etc., are mechanically or
electrically disabled, with appropriate lock-out provisions including the determination
of confined space entry requirements.
As a practical matter all personnel involved with the waterjetting, washing, and cleaning
operation should obtain, study, and be familiar with, all regulations and safety procedures
that apply.
The waterjetting unit shall have a pressure-control relief valve (deadman valve), which
immediately interrupts the flow of water when the operator releases the trigger (this is simi-
lar to the deadman valve on a typical abrasive blasting hose). The operator may use a
shrouded foot valve to control the flow of water to gun.

Figure 5.13 Foot Guard for Gun Trigger

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5-14 Waterjetting

Safety considerations require that only a well trained

operator use the waterjetting equipment. Take the fol-
lowing precautions as well:
• Ensure the platform is stabilized when using
swings, scaffolds, boson chairs, and similar rig-
gings.
• Have an attendant present to monitor safety and
functional conditions while the waterjetting unit
is in operation.
• Ensure the operator wears the proper PPE when
operating the equipment. This should include:
— Head protection with full-face shield, and
eye protection, such as goggles
— Body protection, such as waterproof or
chemically resistant (if required) body suit
— Hand protection such as plastic-coated Figure 5.14 Improper PPE (notice
gloves, rubber gloves, or metal-mesh rein- no gloves)
forced gloves
— Foot protection such as steel-toed boots and metatarsal guards
— A respirator as required, including full-face shield with supplied air
Specialized safety equipment is available for UHP waterjetting operations. One manufac-
turer produces a system called TurtleSkin®, which uses specialized materials to protect work-
ers from the high water pressures of waterjetting.

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Figure 5.15 TurtleSkin

Water Armor

As previously stated, injuries caused by waterjetting or water-cleaning equipment can be

life-threatening. It is a good practice to require every operator to carry a medical alert card
to present to medical personnel prior to any treatment. The card should have information to
this effect:
“This person has been waterjetting at pressures up to 414 MPa (60,000 psig) and/or a waterjet
velocity up to 870 m/s (2,850 ft/s). People injured by direct contact with high- or ultrahigh-
pressure water typically experience unusual infections with microaerophilic organisms. There
may be gram-negative pathogens, such as those found in sewage. Before administering treat-
ment, the attending physician should immediately contact a local poison control center for
appropriate information.”

5.6 Special Considerations

Some of the advantages of waterjetting over dry abrasive blasting are:
• Less dangerous for crew
• Better air quality for workers
• Respiratory requirements may be less stringent.
• No dust contamination or clean-up
• Less damaging to the environment
• Relatively cost efficient
• Requires less clean up after surface preparation

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5-16 Waterjetting

Some of the disadvantages of waterjetting over dry abrasive blasting are:

• The surface must have a prior anchor pattern or profile (waterjetting leaves no profile)
• Equipment is very expensive to purchase
• Dangers of a breached UHP hose
• Danger of water injection into the skin or serious cuts
• Collection and disposal of the contaminated water (especially in ports when working
on ship decks or hulls)
• Lack of proficient operators (however as waterjetting becomes more prevalent this
issue subsides).

5.7 Inspection Concerns

Coating inspectors monitor the waterjetting operations and evaluate surface cleanliness in
accordance with the descriptions set forth in the joint standards.
In addition to inspection and testing, the inspector may also be required to:
• Monitor clean-up of the waterjetting area
• Ensure that the water run-off from jetting operations is collected, treated, and/or dis-
posed of according to applicable regulations
• Document carefully (with photographs, if necessary) each phase of the waterjetting
operation

5.8 Inspection Checklist

The following is a general checklist that inspectors may find helpful during a waterjetting
project:
• Attend the pre-job meeting to ask questions, clarify issues, and contribute to the
understanding of the specification, tools, and the methods of operation to be used.
• Read and understand the specification.
• Become familiar with the work schedule.
• Maintain all required forms of documentation, including the weekly report.
• Get a broad understanding of equipment to be used.
• Confirm that the equipment is properly sized for the job.
• Check and verify operator qualifications if required in the specification.
• Know the surface preparation requirements for the job and become familiar with the
standards.
• Inspect and document the processes on the daily report.
• Ensure the job site is cleaned up on a daily basis, or as required by the contractual doc-
uments.
• Follow all safety requirements and encourage others to do the same.
• Immediately document and report all non-conformance with safety or quality.

CIP | Level 2 ©NACE International

Waterjetting 5-17

As with all standards the inspector who will be working on a Waterjetting project should
become familiar and knowledgeable with all aspects of the Waterjetting standards (WJ-1
through WJ-4).
Key Terms Definitions
Non Visible Contamination (NV): The presence of organic matter, soluble ion materials,
and/or sulfates that remain on the substrate after cleaning that cannot be seen with the
naked eye.
Visible Surface Cleanliness (VC): The visible condition of the substrate, when viewed with-
out magnification, after cleaning.
Waterjetting: The use of standard jetting water discharged from a nozzle at pressures of 70
MPa (10,000 psig) or greater, to prepare a surface for coating or inspection.

Study Guide

1. Is the WJ-1 (Visual cleanliness) comparable to any abrasive blast cleaning standard?
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2. A general description of robotic waterjetting includes:

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3. A typical waterjetting team consists of:

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4. Waterjetting is effective for removing:

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©NACE International CIP | Level 2

5-18 Waterjetting

5. Describe two of the considerations with regards to “back thrust:”

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6. To ensure a safe work place before beginning the job, the waterjet team should ensure
that:
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7. Waterjetting advantages include:

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8. Disadvantages of waterjetting include:

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CIP | Level 2 ©NACE International