GENERAL MECHANICAL EXAMINATION

1. What is NACE MR0175?

Ans. National Association of Corrosion Engineers
NACE MR0175: Standard Material Requirement-Sulfide stress cracking resistant metallic
material for oilfield equipment.
2. What is the meaning of CSD?
Ans. Consulting Services Department
3. What is RTR?
Ans. Reinforce thermosetting resin
4. What is AWWA?
Ans. American Water Works Association
5. AWS D1.1 structural, dont need to qualify for WPS? (True or false)
Ans. False
6. What is the vision of an inspector?
Ans. Jaeger 1
7. What electrode used for overhead position?
Ans. 6010, 6020
8. Does the 6010 can apply over the 7018 vertical position?
Ans. No
9. Stud welding is based on AWS D1.1? (True or false)
Ans. True
10. Lack of fusion can detect by which NDT technique?
Ans. Ultrasonic test (UT)
11. Which one will be a shielding?
Ans. Flux
12. What is the purpose of shielding?
Ans. To prevent atmospheric contamination during welding
13. What is the Carbon Equivalent? Why it is important?
Ans. To determine the material capabilities
14. How to measure raised faced finish?
Ans. Surface comparator gauge

15. What is thermal expansion?

Ans. The increase of material due to increase of temperature
16. PWHT is required to apply on 1 thickness? (True or false)
Ans. True
17. In overhead position, what kind of electrode is acceptable?
Ans. 6010, 6020
18. What other American code required for testing pipeline and welder qualification?
Ans. ASME IX (Welding & Brazing Qualification)
19. Is hardness test, can be use to determine tensile strength?
Ans. No
20. Preheat is needed in tack welding in thick materials?
Ans. Yes
21. What are the types of joint?
Ans. Butt, lap, tee, corner, fillet joints
22. Which is harder, steel containing 0.1% or 0.5% carbon?
Ans. 0.5% carbon
23. What type off grooves used for SAW process? When to use this preparation(groove)?
Ans. U, V & Square grooves
24. What is GMAW mode of material transfer?
Ans. Globular, spray, pulse, short circuiting
25. Type of RTR joints?
Ans. Bell & spigot, socket, flange joint
26. Basic instrument use to measure preheat temperature?
Ans. Tempil stick, contact pyrometer
27. Circumferential seam, weld first than longitudinal seam? (True or false)
Ans. False
28. Is 6010 electrode design to apply to 7018 electrode on vertical position? (True or false)
Ans. False
29. How to repair too close root gap?
Ans. By means of grinding
30. What you will do if you found welder doing wrong?

Ans. ask the welding foreman

31. What American standard for structural welding?
Ans. AWS D1.1
32. Why 316L has low carbon content in stainless steel?
Ans. L- is represent low carbon content
33. What is a good attitude of an inspector?
Ans. Quality minded, knowledgeable, experience, impartial, informed etc.
34. Type of joint category?
Ans. Category A, B, C, D base on UW 3, table UW 13
35. Hardness test is one requirement of NACE MR0175, what the other requirements?
Ans. Nickel content shall be less than 1%
36. Ferromagnetic materials can be detected by?
Ans. (MT) Magnetic particle test
37. Code of quality inspection standard?
Ans. ISO
38. Difference between DCRP & DCEP?
Ans. No difference
39. What is ASME sec. V?
Ans. Non-destructive examination (NDE)
40. Where to apply preheat?
Ans. On weld joint plus 50mm both side of the joint
41. Where to measure preheat?
Ans. at both side of the joint (parent metal)
42. for non-magnetic materials, what kind of NDT to be used?
Ans. Penetrant test (PT)
43. Give two kinds of material that direct current (DC) welding machine can be used?
Ans. P1, P5 materials
44. Describe 3G position?
Ans. Vertical position
45. Radiographic test is the most effective to detect lack of sidewall fusion? (True or false)
Ans. False, UT is the most

46. Why preheat is needed for alloy materials?

Ans. To avoid cracking
47. What 5G position in ASME sec IX is qualified?
Ans. Flat, overhead, vertical position
48. What filler metal to be used on 304 to SA 516 GR70 material first layer?
Ans. ER309L
49. What P number for SA 516 GR70?
Ans. P1
50. As an inspector, do you reject if the NDE results have a discontinuity?
Ans. Yes, if it is exceed the limit in acceptance criteria of relevant code
51. In 100circumferential, how much @ 45 degree?
Ans. 1 feet
52. Lamination defect can detect by?
Ans. Ultrasonic test (UT)
53. How many minutes in 1 degree?
Ans. 60 minutes
54. What 6G position?
Ans. All position
55. What is the minimum tensile strength of 7018 electrode?
Ans. 70,000 psi
56. What is MILS?
Ans. Thousand of an inch
57. Give at least 3 essential variables of WPS?
Ans. Electrode, preheat, volt/amp, position, base metal
58. What is WPS?
Ans. Welding Procedure Specification- a prepared welding procedure which serve as
guidance of the welders
59. What is WPQ?
Ans. Welders Performance Qualification- is the performance testing of the welder capability
to do the weld in accordance with approved WPS
60. What is PQR?
Ans. Procedure Qualification Record- a record of welding data used to weld a test coupon

61. What is PMI?

Ans. Positive material Identification- a process use to determine the constituents of a
materials
62. What is HAZ?
Ans. Heat affected zone- a portion of base metal that was not melted during welding process
but whose microstructure & properties were altered by heat
63. What is PWHT, its purpose?
Ans. Post weld heat treatment- to relieve internal stress that has trapped inside the weld
during welding process
64. What is purpose of preheat?
Ans. To slow down the cooling rate, to reduce hardness of the weld, to avoid cracking &
brittleness
65. What is interpass temperature?
Ans. A highest temperature in the weld were immediately perform prior to welding or in the
case of multiple pass weld
66. What essential variables in WPS?
Ans. A change in welding condition which will affect the mechanical properties of the
weldment
67. Why maintenance temperature is very important for austhenetic materials?
Ans. To reduce integranual corrosion near the weld
68. What is hardness in accordance with NACE MR0175?
Ans. 22 HRC maximum @ 620 degree (Rockwell C hardness)
69. Type of toughness test?
Ans. Charpy V-notch, IZOD, CTOD (crack tip opening displacement)
70. Type of hardness test?
Ans. Rockwell, Vickers, Brinell
71. What mechanical test is an additional requirement for materials in low service
temperature?
Ans. Impact test
72. What toe cracks is?
Ans. Generally cold cracks a results of thermal shrinkage stress acting on the weld HAZ
73. Differentiate between discontinuity & defects?
Ans.

Defects- a discontinuity which exceed the permissible limit in relevant code

Discontinuity- irregularity in the normal pattern of the weld metal not necessary a defects
74. Prevention before using low hydrogen electrode?
Ans. Electrode shall be dried at 260 degree ~ 430 degree for 2 hrs. and shall stored
continuously in the oven at 120 degree
75. What is GMAW?
Ans. Gas Metal Arc Welding- often called MIG (Metal Inert Gas) welding. Widely use as
semi-automatic joining process w/c coalescence of metal is produce by heat from an electric arc
that is maintained between the tip of a consumable bare wire electrode and surface of the base
metal in the weld joint
76. What is FCAW?
Ans. Flux Cored Arc Welding- its similar to GMAW, FCAW have the highest deposition rate
& semi-automatic welding process w/c coalescence of metal is produced by heat from an electric
arc & maintain between the tip of consumable flux filled wire electrode & surface of the base
metal in the weld joint
77. What is SAW?
Ans. Submerged Arc Welding- Referred to as (Submerged) because electric arc is actually
submerged under the granular flux, currently use for thick metals & heavy steel fabrication
78. What is the acronym GTAW, describe the process?
Ans. Gas Tungsten Arc Welding- which often called TIG (Tungsten Inert Gas) welding, can
be manual joining process in w/c coalescence of metal is produced by heat from an electric arc
that is maintain between the tip of a tungsten electrode (non consumable) & the surface of base
metal in the weld joint
79. What is SMAW?
Ans. Shielded Metal Arc Welding- its commonly called stick welding, widely use arc welding
process w/c coalescence of metal is produced by heat from an electric arc that is maintain
between the tip of a covered electrode & surface of base metal in the weld joint
80. What is a straight face in a size of 3mm in Bevel?
Ans. Root Face
81. It is need to qualify the welder, if the WPS is pre-qualified in the same project?
Ans. No
82. What NDT which use illumination for testing? (RT not included in the choices)
Ans. Magnetic Particle Test (MT)
83. Give at least 3 attributes that could result form tension test.
Ans. Ultimate tensile strength, yield strength, and percent elongation

84. Enumerate at least 5 essential attributes in material test report (MTR).

Ans. Material specification/grade, mechanical properties, chemical properties, heat number,
name of manufacturers
85. Why there is a need to specify maximum interpass temperature for austhenitic stainless
steel?
Ans. To avoid excessive heat input
86. Why is it 3mm root face (in groove preparation) is important in most weld joint?
Ans. To avoid melt through weld
87. What is the minimum mechanical test required to qualify a welder?
Ans. Bend Test

PRESSURE VESSEL EXAMINATION (SAUDI ARAMCO)

1. DESCRIBE NACE MR0175.
National Association of Corrosion Engineers. Standard material requirements for
Sulphide Stress Cracking Resistance of metallic material for Oil Field Equipments.
2. HARDNESS (22HRC=235BHN) IS ONE REQUIREMENT FOR NACE
MR0175, WHAT ARE THE OTHER REQUIREMENTS?
Nickel content shall be less than 1.0%.
3. WHAT IS THE MEANING OF MDMT?
Minimum Design Metal Temperature.
4. WHAT IS THE DIFFERENCE BET. CERTIFICATE OF COMPLIANCE (COC)
AND CERTIFICATE OF MATERIAL TRACEABILITY REPORT (CMTR)?
COC certifies the whole product issued after completion of the product or
materials.
CMTR certifies the raw materials used before start of fabrication.
5. WHAT IS JOINT EFFICIENCY?
Stated how much percent of radiographic testing are required on the joint.
ASME VIII Div.1 UW-12.
6. WHAT IS JOINT CATEGORY?
ASME VIII Div.1 Fig.UW-3; location of a joint in a vessel.
A Longitudinal joint in shell, nozzle neck, head petal to petal,
petal to crown and shell to hemispherical head joint.
B Circumferential weld joints on shell and nozzle neck.
C Flange to shell and flange to nozzle neck joints.
D Nozzle to shell, nozzle to heads and boot to shell joints.

7. WHAT IS P Number OF SA516-GR70?

P1.
8. WHAT IS THE CRITICAL POINT WHEN YOU ARE CONDUCTING PRESSURE
TEST FOR AUSTHENITIC STAINLESS STEEL AGAINST CARBON
Water used for SS= 50 ppm max.chloride content of water; carbon steel is
potable water.
9. WHAT IS RT1 IN A NAME PLATE?
100% radiographically tested.
10. DOES THE UCS-193 IS INTENDED FOR HYDROSTATIC TEST?
No! UG-99 is intended for hydrostatic test.
11. DIFFERENCE BET. ASME SECTION VIII Div.1 and ASME SECTIONVIII Div.2?
ASME VIII Div.1 Rules for construction of Pressure Vessels.
ASME VIII Div.2 - Alternative Rules for construction of Pressure Vessels.
12. DOES THE UCS-56 IS INTENDED FOR PWHT?
Yes.
13. WHAT CERTIFICATION OF THE COMPANY QUALIFIED FOR FABRICATION OF PRESSURE VESSELS?
U stamp.
14. WHAT NDE APPLIED IN CLADDED PLATE AFTER REMOVING OF STAINLESS TO CARBON STEEL?
Acid Test.
15. WHAT IS ASME VIII Div.1?
Rules for construction of Pressure Vessels.
16. WHAT IS ASME VIII Div.2?
Alternative Rules for construction of Pressure Vessels.
17. WHAT IS ASME IX?
Boiler and Pressure Vessel Code. (Welding and Brazing Qualifications).
18. WHAT IS ASME V?
None Destructive Examination.
19. IN PRESSURE VESSEL HEAD F & D STANDS FOR WHAT?
F Flange; D dish.
20. WHAT IS THE MEANING OF CSD?

 Consulting Services Department.

21. WHAT IS THE REQUIREMENT OR DOCUMENTS NEEDED FOR TWO PIECE
DISH HEAD SUPPLIED OR SUB- CONTRACTED BY OTHER COMPANY?
Form U-2 and U-2A. Manufacturers Data Report.
22. GIVE AT LEAST 8 CHECKPOINTS TO CHECK OUT FIT-UP OF LARGE DIATER NOZZLE TO THE VESSEL.
Material identification, flange rating, orientation, elevation, projection,
rotation/ straddleness of flange bolt holes to centreline, root gap,
groove angle/ face, longitudinal seam orientation of nozzle neck.
23. WHAT IS THE LIST OF REQUIREMENTS OF HYDROSTATIC TESTING
AS PER UG-99?
All fabrication has been completed; all examinations have been performed.
24. WHAT IS MAWP?
ASME VIII Div.1 UG-98 Maximum Allowable Working Pressure.
It is the max. pressure permissible at the top of the vessel.
25. IS PEENING ACCEPTABLE OR PERMITTED IN THE CONSTRUCTION
OF PRESSURE VESSELS?
ASME VIII Div.1, UW-39 Peening is allowed when it is deemed necessary.
26. WHAT IS THE ALLOWABLE OUT OF ROUNDNESS IN PRESSURE VESSELS?
ASME VIII Div.1, UG-80 Difference bet. max. and min. inside dia. at any
cross section shall not exceed 1% of the nominal diameter at the cross
section.
27. IN WHAT SECTION CAN WE REFER THE LIST OF HEAT TREATMENT
REQUIREMENTS?
ASME VIII Div.1, UCS-56.
28. WHAT IS AUTOGENOUS WELD?
Autogenous weld is a fusion weld made without the addition
of a filler metal.
29. WHAT IS THE ACCEPTABLE DISTANCE OF WELD ENCROACHMENT TO
WELD?
20mm toe to toe of the weld.
30. WHAT IS PREHEATING?
Preheating is the application of heat to the base metal immediately before a
welding or cutting operation. Is to removed surface moisture or wet or
condensation on the weld joint.

31. WHAT IS THE HYDROSTATIC TEST PRESSURE AS PER ASME VIII

DIVISION 1?
1.3 times MAWP (as per ASME VIII Div.1 standard)
1.3 times MAWP (as per Aramco)
32. WHAT IS THE HYDROSTATIC TEST PRESSURE AS PER ASME VIII
DIVISION 2?
1.25times MAWP (as per ASME VIII Div.2 standard)
1.25 times MAWP (as per Aramco);
33. WHAT IS AT-301, DIVISION 2?
At-301 is for hydrostatic test.
35. WHAT IS THE LOCATION SAMPLE AND HOW MANY SAMPLE
ON EACH PLATE/HEAT NUMBER?
Six samples on each plate/heat number and location, one sample on edge,
one on the centre on both end of the plate parallel to rolling direction.
36. WHAT IS THE MAXIMUM ALLOWABLE HARDNESS?
VICKERS - VHN 250
37. WHAT U.S. INDUSTRY IS FABRICATING UNFIRED PRESSURE VESSEL?
ASME (American Society for Mechanical Engineers)
38. Give example of Weld Encroachment?
Saddle support, attachment ring, ladder rung.
39. DURING THE COURSE OF LONGTITUDINAL JOINT INSPECTION,
HOW PEAKING IS TO BE CORRECTED?
Rerolling.
40. WHAT IS 32-SAMSS-004?
Manufacture of Pressure Vessels.
41. WHAT IS SAES-W-010?
Welding requirements for Pressure Vessels.
43. Is it acceptable to carry out hydro testing after primer coat?
No
44. Is Hydro required for all Asme Div.1 Pressure Vessel?
Yes
45. Is minor repair welds are permitted after hydro testing?
No

46. Is tack welding requires qualification?

Yes
47. What is Radiograph Acceptance Criteria for Pressure Vessel?
ASME VIII Div.1
48. Is ASME allowed the welders to weld not employed in manufacturer?
No.

1.) What is Autogenous weld?

Autogenous weld is a fusion weld made
without the addition of filler metal.
2.) What is the acceptable distance of encroachment to weld?
20mm toe to toe
of weld.
3.) What is MR-0175? Sulfide Stress Cracking Resistance Metallic Materials
for Oil Field Equipment.
4.) What is the GTAW? An arc welding process which produces coalescence of
metals by heating them with an arc between tungsten electrode and the work.
Shielding is obtained from a gas or gas mixture.
5.) What is Preheating. Preheating is the application of heat to the base metal
immediately before a welding or cutting operation. Is to remove surface
moisture or wet or condensation on the weld joint.
6.) What is Interpass Temperature? The highest temperature in the weld joint
immediately prior to welding.
7.) What is MAWP? MAWP is the maximum allowable working pressure of the
vessel.
8.) What is UG-99 of division 1? UG-99 is for hydrostatic test.
9.) What is the Hydrostatic Test Pressure as per ASME VIII division 1?
Hydrostatic Test Pressure as per ASME VIII division 1 is 1.3 times the
MAWP of the vessel.
10.) What is the Hydrostatic Test Pressure as per ASME VIII division 2?
Hydrostatic Test Pressure as per ASME VIII division 2 is 1.25 times the
MAWP.
11.) What is AT-301, Division 2? AT-301 is for hydrostatic test.
12.) What is 01-SAMSS-016?
Qualification of Pipeline and Pressure Vessel
Steels for resistance to Hydrogen Induced Cracking.
13.) What is the location the sample and how many sample on each plate/heat
number?
Six samples on each plate/heat number and location, one sample
on edge, one on the center on both end of the plate parallel to rolling
direction.

14.) What is SMAW?

SMAW is an arc welding process which produces
coalescence of metal by heating them with an arc between a covered metal
electrode and the work.
15.) What is Post Weld Heat Treatment? PWHT is to remove the residual stress,
making it softer, refining its of changing its ductility, toughness or the other
properties.
16.) What is WPS? A document providing in detail the required variables for a
specific application to assure repeatability by properly trained welders and
welding operators.
17.) What is mean PQR?
PQR is a document providing the actual welding
variables used to produce an acceptance test weld and the results of tests
conducted on the weld for the purpose of qualifying a Welding Procedure
Specification.
18.) What is the welding requirement for pressure vessel as per SAUDI ARAMCO
standard and as per ASME? For Saudi Aramco Standard is SAES-W-010
and for ASME is ASME Section XI.
19.) What is the maximum allowable hardness? VHN250
20.) What is the tolerance of out of roundness as per ASME? 1% of the difference
of the diameter.
21.) Tolerance for out roundness will found in ASME paragraph? UG-80
22.) What is the equivalent of one mils? Is equal to 1000 of an inch.
23.) What are three type of hardness? Vicker, Brinnel and Rockwell

Paint faults and Definitions

Bittiness: Inclusions of foreign material, either from air borne or from the paint
itself. Could be
partially cured paint, out of shelf life.
Bleeding: The solvent from the top coat soften the undercoat lying material and
allows it to pass
into and through the layer, causing discolouration. Brown for Bitumen,
yellow for coal
tars.(Remedy Tie-coat)
Blistering: The formation of dome shaped projections due to Hygroscopic salts
presents on the

substrates, which cause to local loss of adhesion and lifting of the film
from the
underlying surface. Also blister can be filled with liquid, gas and crystal.
Blooming: Loss of gloss, dulling of colour, due to moisture on the WFT.
Chalking: Degradation of the binder by disruptive factors in the environment, such
as UV light.
Cissing; Local loss of Adhesion caused by oil or grease contamination.
Cracking: Causes due to as a result of ageing and the differential expansion and
contraction of the
substrates, excess coating.
Cratering: The formation of small bowl shaped depressions caused by escaping
solvent or gases.
Paint is of too high a viscosity to glow and fill the depressions.
Curtaining / sagging: A downward movement of a coat between application and
setting that
result in an uneven area of coat having a thick lower edge. The
resulting
sag is usually restricted to a local area of a vertical surface and
may have
the characteristic appearance of a dropped curtain.
Cheeking: Cracking that compress fine cracks which do not penetrate the topcoat and
are
distributed over the surface giving the resemblance of a small pattern,
Crazing: Cracking that resembles checking but the cracks are deeper and broader.
Grinning: Loss of hiding power or inadequate DFT, a showing through of
underlying substrate.
Run: A narrow movement of a coat which caused by the collection of excess
quantities of paint at
irregularities in the surface.

Tear: A small run resembling a tear top.

Lifting: In compatibility, strong solvent coated over weak, and also loss of
overcoating time,
and by solvent strength.
Flocculation: loosely cohesive pigments with in the paint.
Flaking: Lifting of the coating materials form the substrate in the form of flakes
and scales.
Holidays: Faulty application, insufficient film thickness, complete absence of
coating materials
at random locations due to improper application technique. A void, A
miss, or
uncoated area.
Pinholing: The formation of the minute holes due to gas air bubbles in the wet film
giving rise to
Small craters that fail to coalesce before the film has set.
Orange peel: Appearance similar to citrus fruit skin. Paint application (nozzle
block) technique
for high viscosity. So no level.
Roppiness: Brush marks and over brushing on dried surface.
Wrinkling / Reveling: The developments of wrinkles in the film of a coating
material during
drying. Usually due to the initial formation of a surface skin.
Algae and mould growth: Damp environment (environmental condition) treat with
Biocidal
agent for 24 hours clean with detergent water washing,
stiff bristle
brush.
Efflorescence: A Whitish crystalline formation, usually forms under the film on the
above
substrate, and is not a paint defect, caused by soluble crystallizing
on the surface.

Residual tack: The degree of stickness remaining in the film of a coating.

Delamination: Over brushing, causing the laminal pigment to settle in correctly.
Rash rusting: Due to rough peaks.
Osmotic blister: Formation of dome shaped blister, which can be caused by water
entrapment,
solvent entrapment or hygroscopic salts left on a blast-cleaned
surface.
Chemical curing: A part from the oxidation, paint are cured due to the presents of a
catalyst in
the paint when they mix together.
Dry Spray: The production of a rough or slightly bitty film from sprayed coating
materials
where the particles are insufficiently fluid to flow together to form a
uniform coat.
Saporification: The formation of soap by the reaction between a fatty acid ester
and an alkali.
Solvent stripping: Coating with strong solvent applied over existing coating
causing part of it to
be stripped of.
Oxidation: After the painting, when the surface is coming in to contact with the
oxygen the
binder polymerized and form a strong layer.
Chemical curing:
Oversray:

Definition
1) Define the term electrolyte?
An electrolyte is a substance, which will conduct a current and be broken
down by it.
2) Define what is corrosion?

Generally corrosion is defined as Degradation of a material by chemical

or electrochemical means.
3) Define what is adhesion?
Commonly adhesion is defined as The force required to separate two
surfaces in contact.
4) Define what is dew point?
The temperature at which water vapour in the air will condense.
5) Define Relative humidity?
The amount of water vapour in the air expressed in % of the amount of
water vapour which could be in the air at the same temperature.
6) Define Flash points?
The temperature at which vapour from a solvent will ignite in the presence
of an external source of ignitions.
7) Define Damp
No sign of water, but temperature is below Dew point.
8) Define Moist?
No standing water, but a noticeable film of water.
9) Define wet?
Droplets or standing water are presents.
10) Define viscosity?
Defined as A fluids resistance to flow.
11) Define Density?
Defined as being weight per unit volume.
12) Define Pot life?
Time after opening and mixing, in which the contents must be, used (typ 68 hours).

13) Define shell life?

Expiry date, the maximum period which paint may be stored after its
manufacture date.
14) Define Induction period?
Lead time or stand time, or the period of time after mixing to allow for
thorough wetting of the particles by the binder, and for polymerization.
(typically 20-30 minutes).
15) Define Batch Number?
Manufactures Identification code.
16) Define masking out?
During the spray painting, some sensitive equipment or existing coating
protection from paint damage. (Cover out an item which are not to be
prepared and paints).
17) What is A.G.I?
Above ground installation.
18) Define Rust blooming?
First stage of a corrosion process.
19) Define Feathering?
Smoothing down of rough paint edges
20) Define T-wash?
An etch primer for zinc metal surfaces. Blue in colour it turns black upon
drying if it has been applied successfully.
21) What is sheeting for protection?
Sheeting of a non-flammable nature must be employed to protect areas not
being prepared or painted from contamination.
22) What is Water borne coating?
Water used as a solvent. (Moisture curing paints).
23) Define B-S.A.2 ?
Rust grade B, very thorough blast cleaning.

24) Define Feathering?

Smoothing down of rough paint edges.
25) Define A- ST.3?
Not possible, adherent mill scale cannot brush out.
26) Define PA9?
B.Gas specification for properties and performance requirements.
27) Define PA10?
B.Gas painting specifications.

Abbreviations.
SPASpecific paint application
BGCBritish gas council
IGEInstitute of gas engineer
BSBritish standards,
EPAEnvironmental protection act.
COSHH- Control of substances hazardous to health Act 1988
EH 40HSE guidance notes: list of all known harmful substances.
OELoccupational exposure limit.
MELMaximum exposure limit
OESoccupational exposure standard.
HASAWA- health and safety at work act 1974
TSAThermally sprayed Aluminium
CPVCCritical pigment volume concentration
SRBssulphur reducing bacterias.
MEMs- Metal eating microbes.

VOCsPVB-

Volatile organic compounds.

Poly vinyl butyrl.
General Questions and Answers BGAS Grade 3/2

1) What Kind of process is corrosion?

Corrosion is an electrochemical process (called electrolysis).
2) Define corrosion? Why do uncoated steel structures corrode?
Iron ore is an oxide with chemical balance, Iron are usually extracted from
Iron ores through the application of considerable amount of energy, and the
Iron will be at a higher than natural energy states. Certain environments
offer opportunities for the metals to combine chemically with elements to
form compounds and return to their lower energy levels. Corrosion
processes are usually electrochemical in nature.
When metal atoms are exposed to an environment containing water
molecules they can give up an electrons becoming themselves positively
charged Ions, provided an electrical circuit can be completed.
Generally, corrosion is defined as Degradation of the material by chemical
or Electro chemical means.
When the uncoated steel plates are exposed to the atmosphere, the impurities
in the air like water, acids and salts will act as an electrolyte and then the
steel will corrode.
3) What factors influence the rate of corrosion?
There are many factors to influence the rate of corrosion. They are,
Temperature, Hygroscopic salts (chlorides and sulphates), Aerobic
conditions(presence of oxygen in air),Bacteria on the surface SRBs- sulphur
reducing bacteria and MEMs- Metal eating microbes, Acids and Alkhalis,
Bi-metallic contact and relative humidity above 60%.
4) What is a mill scale? When and where does it occur? And why is it particular
problem with attempting to protect steel?
A thin, hard flaky black/blue layer of compound iron oxides (Weustite,
Magnetite and Haematite) formed during the rolling process of steel
manufacturing at a temperature of approximately 580c. Generally its
thickness is approximately 25-100microns.

Because Mill scale in more noble than steel, so steel may corrode fast, when
they come contact with each other. If the mill scale is not removed from the
substrate before painting, it may remove itself and coating system may fail.
5) What particular problems relate to the maintaining of an effective coating
system in the
Splash zone?
The area of the materials, which are neither in water nor in air due to waves,
high tide
and low tides etc are cold splash zone. There is a variation in oxygen level
on the
surface of the material, due to medium change.
Corrosion rate can be accelerated due to this reason.

6) What will happen when Hygroscopic salt presence in substrate?

The Hygroscopic salts will attract water and dissolve in it. If a coating is
applied over them, water will be drawn through the film and builds up the
pressure under the film. Then the film is forced up to form Blisters are called
Osmotic or hygroscopic Blisters.
7) What is the number of the Swedish standard contained with in the BS 7079
& list the rust
and blasting grades together with their brief titles.
The Swedish pictorial standard 05-59-00 is contained with BS-7079
preparation of steel
Substrates prior to the application of paint and related products.
Rust Grades:
Grade-A: Steel surface largely covered with Adherent mill scale with little
if any rust.
Grade-B: Steel surface, which has began to rust and from which the mill
scale has began
to flake.
Grade-C: Steel surface, on which mill scale has rusted away or from which
it can be
Scraped, but with slight pitting visible under normal vision.
Grade-D: Steel surface on which the mill scale has rusted away and on
which general
Pitting is visible under normal vision.
Blast Grades:

SA-1 : Light Blast cleaning

SA-2 : Thorough blast cleaning
SA-2 : Very Thorough blast cleaning
SA-3 : Blast surface to visually cleaned steel.
Grades of wire brushing:
ST-2
: Thorough hand and power tool cleaning (manual)
ST-3
: Very thorough hand and power tool cleaning (mechanical)
8) Give the essential requirements for abrasive blasting?
Compressor to provide air supply( max 100psi), pressurized pot, vapour
trap, carbon impregnated hose to reduce static electricity, reinforced hoses,
dead mans handle for direct operator control, blasting nozzles (correct size),
external bayonet Chicago type hose couplings, whiplash prevention
converters.
Personnel equipments: airfed helmet, ear defenders, safety boots, gloves,
leather apron, and hypodermic needle gauge to control the air pressure.
In addition to this, scaffolding with accept tag, skilled personnel, lighting
arrangements, work permit and second man for help, safety to IGE SR 21.
9) Some metals are hard to prepare and paint, name three and how you might
prepare them?
New Galvanized- Sweep blasting, hand abrade, T-wash (etch primer) where
first two options are impractical
Weather galvanized- Brush damaged area and patch with primer.
Aluminium-sweep blast, hand abrade for thin gauge Aluminium, an etch
primer is used prior to intermediate and finish coats. Not to be blast cleaned.
Chlorinated hydro carbon solvent shall not be used. etch primer (PVB)
polyvinyl butyl
Stainless steel-sweep blast only Aluminium oxide used as blasting medium.
10) Give reasons why different surfaces require different paint systems?
Compatibility, surface operational temperature, environmental conditions,
expected
Service life, surface cleaning and preparation method available, limitation of
various
Paint system. The specification requirements, rust grade, paint properties
cost.
11) What is rough peak? What problem can it cause?

Rouge peaks are peaks, which stand out above the required profile and
should be
avoided. When applying thin coatings as they may lead to spot or flash
rusting.
12) How do you measure surface profile? Explain the method?
The surface profile may be measured by a number of methods including the
use of surface replica tape (testex tape), surface profile needle gauge, or a
surface comparator.
Surface replica tape:
Testex tape or press-O-film is commonly used surface replica tape. It is used
in conjuction with a dial micrometer has an advantage of providing a
permanent record. The procedure for carrying out this test is as follows.
Zero the micrometer ensuring the flat contact points are clean.
Remove paper backing and stick testex tape to the surface to be measured.
Rub the testex tape in tot thorough using a blunt instrument until peaks can
be seen
butting up to the transparent plastic.
Remove the testex tape from the surface and measure the overall thickness
with dial
micrometer.
Deduct 50mic from the reading to obtain the amplitude. The plastic layer to
which the
testex paste is attached is 50 thick.
13) Give the three basic ingredients with in a solvent carrying paint
A traditional solvent carrying paint consists of three basic ingredients, they
are
Binder, pigment and solvent. Their properties are
Binder- It binds the particles together and holds them in suspension, gives
the paint its
finish, makes the coating adhere to the surface, gives flexibility to the paint
film.
Converts the coating to a solid dry film, give resistance
to water, chemical and abrasion.
Pigment- Gives colour to the paint, gives opacity to the paint, gives
resistance to acids, alkalis and light.

Solvent- Forms the evaporative part of the drying process, thins the paint so
it can be applied easily, washes out brushes and equipments and acts as a
degreasing agent if approved.

14) Name four binders / solvent combination?

Binder
Solvent
Epoxy
Acetone
Chlorinated rubber
Xylene
Alkyd resin
White spirit
Emulsion paint
Water
15) Name six opaque pigments and give their respective colour?
Carbon- black
Compound of calcium- red, yellow
Compound of cobalt- blue
Compound of chromium- green, yellow, orange
Compound of Iron- brown, red, yellow
Titanium dioxide- white.
Opaque pigments are inert particles with excellent light scattering properties
in order to
give covering power (opacity) and colour.
16) What factor influence how clean & how rough the surface becomes after
blast cleaning?
The cleanliness of the steel surface and its amplitude are governed by the
abrasive factors and by human factors as follows,
Abrasive factors
human factors
Size
Speed
Shape
Angle
Density
distance
Hardness
Time
17) Name 5 paints and give their drying & curing methods?
Emulsion
Coalescence
Alkyd
Solvent evaporation followed by oxidation
Chlorinated rubber
Solvent evaporation only
2 pack Epoxy
Solvent evaporation followed by chemical curing
Fusion bonded epoxy
heat cured

18) State at what condition paint must be stored?

In a dry, lockable, well ventilated building away from any source of heat.
Material should be stored atleast 5C below the flashpoint and current
legislation and manufactures instruction should be followed.
19) Give six type of Anti corrosive (rust inhibitive) primer?
Zinc chromate- yellow,
Red lead-red,
Zinc Phosphate-white,
Coal tar-black,
Calcium plumbate-white,
Red Iron oxide-red.
Metallic pigment- May be used to anti corrosive properties or to give
metallic finish
Cathodic production- Zinc and Aluminium.
20) Name three tests for locating soluble iron salts and mill scale on a blast
cleaned
Substrate?
Mill scale- Copper sulphates test
Soluble iron salt- Potassium ferrysynide test
Soluble Chloride- Silver nitrate test.
21) Name 5 methods of applying paints & compare the advantages and
limitations of each
method?
Brush Application- Advantages:
Effective for applying primer as it works paint well into substrate, which
gives optimum
coverage and mixes in any dust particles. Thus achieving optimum adhesion.
Do not
produce overspray, less environmental hazard, less wastage as less spotting.
Limitations:
Slow production, May not have uniform thickness, high quality brushes
quite expensive,
suitable for only small area, not suitable for all places, wastage of paint will
be more,
cannot extend.
Roller application- Advantage:
Quicker than brush for large flat surfaces, with extension poles easy to
access at elevated

locations.
Limitations:
Non-uniform paint thickness, paint does not worked into the surface, specs
not permitting
roller application, skills required compare to brush.
Conventional spray- Advantage:
Suitable for applying thin material, good finish, less operating pressuremove safe, less
equipment and maintenance cost, less over spray, quicker than brush.
Limitations:
Less production, gravity fed guns to be operated at upright positions only,
high viscous
paint application not possible.
Airless spray- Advantage:
Higher (more quality) production, highly viscous paint easily applied, more
portable,
uniform coating can be achieved, high DFT.
Limitations:
More wastage & over spray, higher equipment & maintenance cost, high risk
of safety
due to high pressure operations.
Electrostatic spray- Advantage:
More uniform thickness can be achieved, good finish, less over spray.
Limitations:
High equipment cost.
22) Regarding hand and power tool cleaning state what always concludes this
process and to
What standards?
BS-7079 SIS-05-59-00
ST-2 Thorough hand and power tool cleaning (Manual)
ST-3 Very thorough hand and power tool cleaning (Mechanical)
Rust grade B, C & D only.
23) State the advantages of airless spray over conventional spray?

High rate of production, uniform film thickness can be achieved, less fog &
rebound, size and angle of the tip can be easily control the quality of flow
pattern; high viscous paint can be easily applied.
24) Describe what is meant by Bi- metallic corrosion?
If two different metals attached together, low nobility metal become anode
and sacrifies itself to protect high nobility metal. Eg- mill scale--- steel,
steel---zinc.
24) Describe Galvanic series?
All the metals have an order of nobility which found by testing with sea
water at ambient temperature.
25) Which paints have to be considered when brush painting? Or what method of
paint application is performed for primer and why?
Primers have to be considered when brush painting because brushing works
as paint into a substrate surface, which gives optimum coverage and mixes
in any dust particles, thus achieving optimum adhesion .
26) Define the tie coat and give an example?
The tie coat is the layer of paint, which ties two incompatible system
together (where adhesion problem, solvent stripping or bleeding might
occur).
Eg- Aluminium leafing primer for the application of Alkyd over bitumen due
to bleeding.
27) Describe barrier paint system and sacrificial paint coating?
Barrier paint system: The substrate is isolated from the environment,
which causes corrosion by using a coating of low permeability. This may be
achieved by applying a thick coat of paint having low permeability. ExEpoxy, polyurethane.
Sacrificial coatings: Sacrificial coating contain pigments, which
cathodically protect the
iron or steel substrate to which the paint is adhered. These pigment particles
eventually
corrode thereby sacrificing themselves to corrosion. In order to have these
properly, the
sacrificial pigment must be ignoble to the material to be coated. Zinc and
Aluminium are

the most common type of pigments employed

28) Describe what laminar pigment is and name four pigments?
Pigments having a leafing effect like fallen leaves overlapping each other
results in
excellent resistance to the passage of water also create a very strong coating.
MIO, mica, glass flakes and Aluminium flakes are Eg of laminar pigments.
29) Describe the difference between water blasting and pressure washing?
Water blasting is a high pressure process (6000psi) and it can remove mill
scale and cut a
profile. Toxic contamination removes with out dust, with or without
abrasive.
water wash is a low pressure (100psi) to use clean painted surfaces. It can
remove salt and chlorinated contamination from surfaces, with or without
detergent.
30) Briefly describe the mechanisms of the two theories of adhesion?
Molecular interference: The surface is rough and uneven the paint wets and
locks into
the profile. Physical (analogy Velcro).
Molecular attraction: Negatively charged particles attracted to positive
areas and vise
versa. Chemical (Analogy magnet)
31) Name four advantages of centrifugal blasting over open blasting?
They are ideal for long production runs.
The abrasives are used efficiently because the system is fully enclosed.
Therefore the quality can be controlled by adjusting the feed roller speeds.
And it is more
reliable too.
Gives more productivity than open blast unit.
31) How is abrasive cleansed in a wheel abrator system?
The conveyor carries the used abrasives from the recollected hopper to the
top of the
machine. Then the abrasive passes over the edge of the weir plate, a current
of air is

drawn through it. This air removes the rust, mill scale, flakes of paint etc.
this is
known as air wash separator.
32) Describe the Duplex process?
Footness duplex system involves the pickling process followed by
passivation using
chromate or iron phosphate salts, which passivates the surface and increase
the adhesion
properties. They are also extremely resistance to cathodic dibondment.
33) What would be considered to be advantages of wet blasting over dry
blasting?
Removes toxic coating without dust,
Removes chlorides from surfaces,
Simple to operate,
Spark free operation,
Removes algae and mould growth,
Environmentally safe and
Low cost.
34) What are the disadvantages of wet blasting over dry blasting?
Safety associated with pressure up to 20,000 psi,
Availability and drainage of large Quantities of water,
Disposal of sludge (large amount of slurry)
Cost of supplying and mixing substrate inhibitor,
Problems of drying large surface area,
Cuts no profile and flash rusting.
35) Describe the phosphating process?
The phosphating process is only applies to the footner or duplex process.
The final
treatment in a 1% to 2% phosphoric acid solution held at 80C for 1 to 2
minutes. This
leaves a thin rust inhibitive phosphate coating, which acts as a rust
preventive for a
limited time.
36) What are the advantages and disadvantages of Venturi and straight bore
nozzles?
Venturi Nozzles- Advantages:

Very high speed, faster operation, large area coverage and large blast pattern.
Dis- advantages:
Less accuracy more costly and more wear.
Straight bore- Advantages;
More accuracy, low cost and less wear.
Dis- advantages:
Low speed, slow operation, covers small concentrated area, operator fatigue,
and small
blast pattern.
37) If corrosion occurs at Anodic areas, why does steel corrode evenly all over
the surface?
Trace elements (nickel, carbon, Aluminium etc) in the steel provide million
of anodes and
cathodes though bi-metallic contacts.
38) Name four expendable abrasives and state the difference between
expendable and
re-usable abrasive?
Copper slag, crushed glass, Ice, walnut shells and ceramic grit.
Expendable abrasives- are used in open site blast cleaning and they are
expendable. Can
be used only once. When they hit the substrates at high speed they shatter on
impact.
Re-usable Abrasive- are used in a closed cleaning system. They are not
expendable,
because they do not shatter on first impact and it is very expensive and can
be re used
up to 20 times.
39) Describe how you would carry out a check on air pressure of a blasting
operation?
First alert the operator, stop the abrasive flow, insert the hypodermic needle
gauge in to
the hose at very near to the nozzle at an angle of 45 towards the flow
direction and
read the pressure.
40) Name some advantages and disadvantages of chlorinated rubber?

Advantages: high resistance to mould growth, Non flammable after solvent

release,
good resistance to acids and alkhalis, very high resistance to water vapour
transmission,
one component physically drying.
Dis advantages: low resistance to solvents, i.e only resistance to Aliphatics
and water,
low temperature tolerance, 65C maximum, Spray application resulted in
Cobwebs.
41) Name some properties of binders?
Ease of application (flow properties or viscosity)
Adhesion to the substrate for the expected life of coating
Resistance to abrasion
Resistance to chemical attack according to environment
Cohesive strength, its ability to hold together as a film
Diaelectric strength (Resist the passage of electrons)
Ability to resist the passage of water
Ability to change from a liquid state to solid state.
42) Name some pigments and their respective colour?
Calcium plumbate
White
Zinc phosphate
White
Zinc chromate
Yellow
Red iron oxide
Red
Red lead
Red
Graphite
Black
Coal tar
Black
43) Name some extenders pigment and why it is added in paint?
Clays, chalk, talcum and slate flour are the extenders pigment. It is added to
paint to expect the main properties of the film such as adhesion, cohesion,
film strength and durability.
44) What does a fineness of grind gauge measure?
It measures the degree of dispersion of paint. Also known as Hegman grind
gauge.
45) What does a crypto meter measure and two examples of crypto meter?
The crypto meter measures the opacity or hiding power of paints possesses.

Pfund crypto meter and hiding power charts.

46) What determines the degree of gloss of paint may posses?
The degree of gloss determined by
Degree of pigment dispersion,
Size of pigment particles,
The pigment volume concentration,
Binder type- measured by gloss meter.
47) What is a flash point? Describe the procedure for determining of flash point?
The temperature at which vapour from the solvent will ignite in the presence
of an external source of ignition.
Flash point determination of paints or solvents may be carried out in
accordance with BS3900 part A9 using a closed cup of abel type.
Procedure:
Fix the Abel cup containing the substance for the assessment into a water
bath.
Activate the source of ignition every c rise in temperature.
Apply a heat source to the water baht monitor the air/vapour temperature in
the Abel cup.
The flash point temperature is identified when a blue flame flashes over the
substance being assessed.
48) What is Density? Hoe do you assess it? Give two reasons for its use?
Density is weight per unit volume of a substance possess.
Density = mass/volume unit=gm/cc
By using laboratory balance weigh the cup to the nearest decigram with
sensitivity of
0.19.
Remove the cover and fill with paint to within 2.5mm of the brim.
Carefully replace the cover so that air and any excess paint is expelled
through the vent.
Wipe off any surplus paint from the cover then reweigh
Determine the weight of the paint by subtraction.
Divide the weight by 100 if the density in gm/cc is required.
Purpose:
To determine whether two pack paints have been mixed in the correct
proportions.
This procedure can be used to determine the quantity of any added thinner.

49) What is viscosity and what equipment is used to measure viscosity of the
free flowing
paint and thixotropic paint?
Viscosity is a measure of a fluids resistance to flow. Viscosity of free
flowing paints can
be measured by using a flow cup, there are many types including Ford cup,
red wood and
Zohn flow cups- Procedure for measuring viscosity using ford cup No 4.
Bring temperature of paint to within 20 0.5c
Level the apparatus, Keep one finger and close the orifice at the bottom of
the cup and
rapidly fill it with paint. Allow a moment for air bubbles to rise, then draw a
flat edge
across the top of the cup to wipe off the excess paint. Remove the finger
from the orifice
and start the stop watch simultaneously with the commencement of the paint
stream
The watch is stopped when the first distinctive break in the paint stream
occurs.
The time in seconds is taken as the viscosity. Check the time against
manufacturer
recommendation.
For thixotropic paints, the viscosity can be measured by a rotation
viscometer or another
type of viscometer, which works the paints.(Kerb-stormer viscometer, cone
and plate
viscometer and rotothinner).
50) What is specific gravity and how is testing for specific gravity carried out?
Relative density or specific gravity is the density of any substance compared to
the density
of water
Specific gravity= Density of given substance
Density of water
51) Name three adhesion tests and describe how one of them is carried out?
Adhesion is the force that resists the separation of two surfaces in contact.
There are three types of test: Dolly test, cross cut test & cross hatch test
Procedures for pull of Dolly test:

Clean and degrease the surface to be tested.

Roughen the surface with fine / medium grade emery cloth.
Mix regular araldite and stick dolly to the surface, leave it for 24Hrs at 25C.
Cut paint around the dolly down to the substrate using a special cutter.
Attach of pull off instrument and apply pulling force. Check at what PSI
failure occur
Check whether failure was adhesive or cohesive.
52) Name four artificial weathering device and what are these designed to
stimulate?
Artificial weathering devices are designed to create accelerated weathering to
speed up to
the duration of different test to be carried out to determine the coating systems
behavior at
specific condition.
Tropical box- to simulate high humidity environment
Salt spray box- simulates a marine environment
Water soak test- to assess paint systems resistance to water absorption
Cold check test- test for low temperature contraction cracking
Temp cycling- to assess film flexibility at alternate hot and cold temperature.
53) State 2 drying curing tests & how they are operated?
Ballotini test:
Tiny glass balls known as Ballotini, are allowed to fall on to a freshly painted
test panel.
The test panel moves slowly beneath the falling ballotini over a preset period
of time, the
time of the test is variable and the speed can be adjusted so that a panel 300
mm long can
take between 1 to 24 hour to test, where the Ballotini fails to stick, to the
painted panel
drying has occurred.
Stylus test:
The stylus test employs a series of trailing needles which pass over the wet
painted panel,
because the needles are set at different tensions it can be established when the
paint is in
tack dry, hard dry and fully cured.

54) What is WFT? How do you measure it? What are the advantages of using?
WFT is the thickness measured immediately after a coating has been
applied. The WFT may be found by using a comb gauge or an eccentric
wheel.
Procedure for measuring WFT using comb gauge.
Immediately after the application of paint the comb gauge should be firmly
placed on to the surface in such a way the teeth are normal to the plane of
the surface.
The gauge should then be removed and the teeth examined in order to
determine the shortest one to touch the wet film. The film should be
recorded as lying between the last touching tooth and first non touching
tooth.
Atleast two further readings should be taken in different places, in a similar
manner, in order to obtain representative results over the painted area.
Advantages:
If the WFT is known, any deviation from the thickness range can be
immediately rectified. And the approximate DFT can be calculated if the
volume of solid is known.
DFT= WFT x VS/100
55) What is DFT? State the principle of being able to use a banana gauge for
taking DFT?
State calibration procedure for a banana gauge?
DFT is the dry film thickness of the coated surface and is measured in
microns.
The banana gauge is only used for measuring the thickness of nonferromagnetic coating
applied over a ferromagnetic substrate.
Calibration procedures:
Choose a magnetically insulated shim of known thickness, close to the
thickness of the
paint you expect to find.
Place the shim on the same substrate surface finish as the surface finish on
which the paint to be measured is attached. For Eg, if the paint is on a
blasted surface, calibrate the gauge on a uncoated blasted surface.

Place the magnet on the shim and press firmly on the instrument, wind the
scale wheel forward until the magnet is definitely attached to the
shim/substrate.
Gradually wind the wheel backwards slowly until the magnet detaches itself.
At this point, move the curser on the instrument to the thickness of the shim
as shown on the scale wheel. With some instrument the scale itself may be
moved to line up with fixed cursor. The instrument is now calibrated and
may be used to measure the DFT of any non magnetic film to within a
claimed accuracy of 5% in some cases.
56) Describe a destructive test for determining the DFT calculation?
Paint inspector gauge (PIG)
PIG is one such type pf destructive test gauge. A small V shaped channel is
cut into the
Coating at a fixed angle governed by a cutter built into the gauge. The width
of the channel is then measured on a gratitude scale my means of
microscopic which is again built into the instrument. It is also useful to
determine the number of coatings.
57) Describe the Cathodic disbondment test?
If the impressed current exceeds the corrosion current, hydrogen gas bubbles
are evolved from the metal substrate i.e. at the interface between the
material and coating. This is a
Significant problem when curing defects are present due to stripping action
caused by the hydrogen bubbles, the coating disbondment is known as
cathodic disbondment.
The test incorporates a coated test panel with hole drilled into the coating;
this simulates a paint film defect. Surrounding the hole a plastic tube is glue
down and filed with sodium chloride solution to act as an electrolyte. Wires
from a battery are attached to the panel and to a metal rod set into the liquid
of plastic tube; a current is then impressed to make the panel Cathodic.
The coating is assessed after a period of time.eg a few weeks, for the amount
of stripping which has occurred from the boundary of the hole.
58) Name 3 environmental conditions when would you stop painting? Or when
shall coating
not be applied?
3 environmental conditions: Rain, Snow & High wind.
It is not permissible to apply paint when the following conditions apply.
During rain, snow or high wind.

When the air or metal temperature is down to within 3C of the dew point
temperature.
When the relative humidity is above 90%.
59) Explain how environmental test are carried out? What equipment is used to
find RH and
DP? Explain its use?
Environmental conditions like RH and DP are measured using hygrometer of
which there
are many types. The whirling hygrometer consists of two mercury
thermometers set side
by side in a frame which is provided with a handle and spindle so that the
frame and thermometer can rotated quickly about horizontal axis. The bulb
of one thermometer is called wet bulb thermometer. It is covered with a
closely fitted cylindrical cotton wick, the end of which dips into distilled
water or clean rain water contained in a small cylinder attached to the end of
the frame.
The frame is rotated by hand for 30 to 40 seconds as fast as possible so that
the bulbs pass through air atleast 4m/s. This causes the water to evaporate
from the wet bulb. The wet bulb cools down to a constant wet bulb
temperature due to the evaporation rate of water from the wet wick. Always
read the wet bulb temperature before dry bulb temperature immediately after
the rotation. Repeat the operation until consecutive readings of each bulb
temperature agree to with 0.2C.
If it is 100% RH, the wet bulb will be same temperature, because no
evaporation can occur, i.e. the air is saturated. If wet bulb and dry bulb
temperature are the same the current temperature is the dew point. The RH
and DP cannot be read directly from the apparatus, hygrometer tables or
special slide rules must be used.
60) Why the environmental test carried out during a paint project?
In order to verify the weather conditions are acceptable to the specification
to carry out the painting operation.
61) Explain RH, DP, Ambient temperature and steel temperature?
RH: Relative humidity is the amount of water vapour in the air expressed in
a percentage.
DP: Dew point is the temperature at which condensation would form on a
surface.

Ambient temperature: It is the surrounding air temp also referred as dry bulb
temp.
Steel temperature: it is the temperature of the substrate prior to painting.
62) How do you calculate DFT, WFT & VS%?
DFT = WFT VS / 100
WFT= DFT 100 / VS
VS = DFT 100 / WFT
63) What does BS 2015- GLOSSARY OF PAINT TERMS refers to and give
three
examples?
Faults, which occur with paints, are described in BS 2015- glossary of paint
terms.
These faults are due to three main caused.
1. Fault in the can (manufacturing fault)
2. Problem, which occur due to poor preparation.
3. Problem, which occur due to incorrect or poor application or interference
by weather.
Examples:
Bleeding: The action of a material in penetrating and discoloring a coating
applied on top
of it.
Blistering: The formation of dome shaped blister in a paint film. They can
be dry blisters
which are usually caused by the expansion and contraction of the paint film
against the
substrate or Osmotic blister which can be caused by water / solvent
entrapment or
hygroscopic salts let on a blast cleaned surface.
Chalking: The breaking down of a paint film to become chalky or powdery
usually due
to disintegration of the binder caused by attack from UV light or severe
weather
condition.
64) What are the essential difference between a blister and an osmotic blister?
Blister: Formation of a dry dome shaped blister in a paint film. Due to
expansion and .
contraction of the paint film

Osmotic blister: Is one which contains liquid, gas and crystal. It can be
cause of water,
Solvent , hygroscopic salt entrapment on a blast cleaned surface.
65) Name five items that can be included in paint to improve its performance or
suitability for a certain use?
Plasticizer (prevent paint film and opacity)
Drier or catalyst
Extenders- improve flow and opacity
Thixotropic agent
Stabilizers.
66) What is BS4800 & how it is used in construction industry?
Bs 4800- Paint colours for building purpose specifies 100 colours which have
been
Selected from the frame work of the 237 colours contained in BS 5252.
Each colour in BS4800 is identified by three as Hue, Brightness and
saturation.
Hue- refers to basic colour Red, green, yellow, blue etc from 00 (neutral) to
24 even
numbers only.
Brightness: The darkness or lightness of the colour.From A (max white) to E
(max black)
Saturation: 01 to 56 Higher number =stronger colour, Lower number=
greyer the colour.
Black and white and all the grey colours in between are Achromatic, colours
as they
lack Hue. Anything having colour is said to be Chromatic.
BS 4800 can be used to identify existing colours when maintenance painting
and is a
method by which all manufactures can make exactly the same colours.
67) What is the procedure for removing oil & grease from a substrate after
preparation has
taken place?
Wash out the area with 2% detergent wash and immediately wash with clean
water and
dry. Reblast surface.

68) What is the procedure for removing oil & grease from a surface before
preparation
commences?
Small areas of oil and grease shall be removed with an approved solvent.
Where as large
areas can be given to low pressure detergent washing, which must be
followed by rinsing
with clean water and thorough drying.
69) What is the procedure to removing algae and mould growth?
Algae and mould growth shall be treated with a biocidal agent and left for 24
hour atleast
in order to that biocide can kill the spores. It
shall then be removed by scrubbing with stiff bristle brushes and clean
water or by use of high pressure water wash.
70) What distance must be left at areas to be welded when painting?
For zinc rich paint 75 mm shall be left from the end preparation.
71) How much new paint overlap required over old paint?
Minimum 100mm.
72) What must pneumatically and electrically operated power tool equipment
be?
All equipments shall be earthed. All equipments shall be non-spark and the
flame proof.
73) What type of sheeting may or may not be used for protection against spillage
& spotting?
Sheeting of a non-flammable nature must be employed to protect areas
against spillage
and spotting. Tarpaulins must not be used.

74) What areas of work, do PA 10 does not cover?

PA-10 not covers painting work of the following,
Below ground (buried), offshore installations, internal coating of pipes &
strore enamel
coating.

75) How do BGAS define the following?

New galvanizing: a galvanized steel surface upon which cohesive oxide layer
has not yet
formed. (Bright and shiny, Less than 3 months old)
Weather galvanizing: A galvanized steel surface upon which a cohesive oxide
layer has
formed by natural weathering (dull & lacking in shine).
Long term protection: The estimated period for the corrosion protection is
typically 10 yrs.
Medium term protection: Typically 5 years.
Short term protection: Typically 2 3 years.
76) As an inspector what do you consider as your main responsibilities?
To assess the condition of substrate prior to treatment.
To inspect surface preparation in accordance with BS 7079, measure and
record amplitude
once daily.
To ensure material used on site are to client specifications.
Relative humidity, dew point, air temperature and steel temperature to be
checked and
recorded atleast four times daily.
Wet and dry film thickness to be checked and recorded at frequent intervals.
To witness and inspect application of each coat and inspect competed paint
system in
accordance with the clients specifications.
To submit daily and weekly reports, recording all the relevant information as
required by
client. Copies to be retain by the inspector.
77) Conditions for final surface preparation?
When conditions in the working area are such that metal surfaces are moist,
damp or wet,
final preparation shall not be carried out.
Any surface preparation, procedure or method of cleaning shall not be allowed
to.
contaminate wet paint film.
Equipment used shall be of non-sparking type. Electrically operated tools are
not permitted.
Power tools operated by compressed air shall have oil and vapour trap fitted to
the

compressed air lines. All contaminants shall be removed by means of an

approved solvent.
Algae and mould growth when in evidence shall be treated with a Biocidal
agent and left
for atleast 24 hours in order that the biocide can kill the spores. It shall then be
removed by
scrubbing with stiff bristle brushes and clean water or by use of a high
pressure water wash.
All surfaces shall normally be dry before painting commence.
78) What is BGAS PA-9 and PA-10?
PA-9 refers to paint properties and performance requirements.
PA-10 refers to the technical specifications for New and maintenance painting
at works
and site for above ground pipeline and plant installation.
79) What is document state health & safety at work? And what do you know about
that?
H.A.S.W.A. Health and safety at work act 1974.
It deals with the responsibilities and duties of the employer and employee at
work site.
The duty of the employer is to provide safe working environment to the
employee.
The employee duty is to work safely at all time to protect himself and other
self.
They have legal responsibilities to report any accident, incident and or
spillage.
80) What year was the Health & safety Act passed? And what do you know about
that?
Control of substance Hazardous to health regulations 1988 came into force on
st
1 oct 1989.
COSHH Regulations.
It deals with handling, storage, packing, transportation and labeling of many
hazardous
substances. In our industry it deals with mostly solvent, sand and dust.
81) How long would records of personnel exposed at work?
Employers must keep records of examination / monitoring test for 5 years, 30
years for
identifiable employees.

82) What is EPA and VOC?

Environmental protection Act and Volatile organic compound.
83) What is the impressed current & and what problem can arise from its incorrect
use?
Impressed current is a type of cathodic protection system e.g. used for large
areas of pipes.
If the impressed current exceeds the corrosion & current, hydrogen gas
bubbles are evolved
from the metal substrate i.e. at the interface between the material and the
coating. This is a
significant problem when curing defects are present due to a stripping action
caused by the
hydrogen bubbles leads coating disbondment is known as cathodic
disbondment.
84) What is the difference between thermosetting & thermoplastic?
Coating which do not melt after the application of heat is known is thermo
setting coating.
Paint which melt when heat is applied are known as thermo plastic coatings.
85) What are the metallic pigments and why it is used?
The metallic pigments are zinc and Aluminium, which is used to protect the
steel substrate
by cathodic protection.
Zinc - better for galvanic protection and Aluminium better for solar
protection.
86) Explain about CPVC?
CPVC is critical pigment volume concentration. This is divided into three,
they are,
below CPVC, Near CPVC and above CPVC.
Below CPVC- Poor opacity, high gloss, blistering (low cohesive strength).
Near CPVC- Good opacity, cohesive strength, low gloss, impermeability.
Above CPVC- porous, low cohesive strength, poor adhesion and increase
viscosity.
Low pigment/higher binder high gloss, good water resistance
Low binder /higher pigment good opaque coating, poor water resistance.
87) Define galvanic series? How to use galvanic series in cathodic protection?

Metals and metal compounds are arranged in order of nobility is called

galvanic series.
E.g. Gold, silver, copper, mill scale, steel, Aluminium, zinc and magnesium.
There are two ways to use the galvanic series in cathodic protection.
1) Bi- metallic corrosion. When two different metals are attached together the
less noble one will act as an anode to the more noble one. The less noble
one sacrifice itself and preserve more noble one.
2) Sacrificial coating: When a coating, whose have the metallic pigments are
less noble than steel are coated on to steel, they will sacrifice themselves in
order to preserve steel.
E.g. Zinc or Aluminium pigment will be around 90% of the coating.
88) Define method of arresting corrosion? (Coating system)
a) Barrier principle b) Sacrificial principle c) Galvanizing d) Sheradising
e) Passivation- chemical reaction between the rust inhibitive pigment of the
primer and
steel substrate.
f) Metal spraying
g) Sacrificial anodes.
89) State the advantages and disadvantages of using an Epoxy paint system for
long term
protection?
Advantages: Chemically curing-two components, good resistant to water
chemical
solvents oil etc., good resistance against mechanical strains, more flexible, can
be used in
modified form for high temperature and damp surfaces, high solid content.
Dis-advantages: Required special solvent, maximum curing time required for
successive
application, poor UV resistants, chalk in sunlight, temp dependent +10C,
require good
predeterminat blast clean. Cannot apply on top of others paint types, risk of
dissolution
(lifting) other paints. Epoxy is not cured by oxidizing but cured by chemical
reaction
between two components.
90) What is T-wash? An etch primer for zinc metal surface.
What is it used for? To provide a key for new galvanized surface.

What colour is it? Blue

How do we check for a correct reaction when using it? Blue in colour it turn
black upon
drying.
91) State the qualities of poly urethane finish coat can give a paint system?
Polyurethane finish coats are often used to replace epoxy finish coats. They
have the .
following qualities.
High gloss, retain the gloss, hold the colour, abrasion resistance, easily
cleaned, good
resistance to UV light, chemical and weather resistant cures down to 0C.
Dis-advantages: Two components may cause skin problem.
92) Describe the attribute of MIO?
Ultra violet A&B reflection, retards permeation, durability, provides adhesion
to next layer.
93) What are the advantages and disadvantages of water borne coating?
Advantages:
1) Suitably low viscosity for any application method, brush, roller, and spray.
2) Recyclable, abundant, non toxic, non flammable.
3) No harmful to environment, the ozone layer and to humans.
4) Water can be applied over any existing binder type with impurity.
5) Several coats can be applied in one working day.
Dis advantages:
1) Water is usually needs a small amount of solvent for modification.
2) During high humidity time drying process will be delayed.
3) Needs controlled storage conditions.
4) Not as versatile as Hcs for application window.
94) Determination of Volatile and non volatile?
Take thoroughly cleaned dry glass, stirring rod and watch glass, and weigh on
a sensitive
balance to the nearest milligram. Put approximately 2gm of paint in to the
watch glass and
weigh again. Place the watch glass with paint into a hot air oven, no naked
flame or
element, repeatedly stir to drive away the volatile content. Take a final weight
of the glass,

rod and dry paint and simple calculations will give volatile and non volatile
ratio by weight.
95) Which test is carried out for soluble salts in a marine environment?
Potassium ferricyanide test commonly used. The other name for this test is
potassium
hexa- cyanoferrate (marine & industrial).
Silver nitrate test 2% with distilled water is most commonly used in marine
environment
for detecting chloride.
96) Why etch primers are used? Where and when?
Etch primers are used to etching New galvanizing. For surface preparation of
new
galvanizing and Aluminium surface. When the preferred and first option of
surface
preparation is not feasible. (Sweep abrasive blast and hand abrading
respectively).
97) Duties of Inspector?
1) Understand the procedures,
2) Understand the plant and equipment,
3) Understand the personnels,
4) Ensure all personnels relative to painting work are aware of spec.
5) Monitoring the process,
6) Assess conditions of substrate,
7) check correct materials has been used.
8) Wet and dry film test, check dew point, relative humidity and metal
temperature,
9) Making reports.
98) List the contractor malpractices?
Using untrained personnel,
Substituting new materials with out of date materials,
Substituting approved products with unapproved products,
Reusing expendable abrasives,
Not observing recommended over coating time,
Missing out one coat,
Using incorrect paint,

Incorrect of storage paint,

Not observing induction and pot life time,
Continuing with the next stage of operation without inspection clearance,
Painting coating over area of inadequate preparation,
Working in condition outside of specified requirements,
Insufficient attention for awkward area,
Using cotton clothes for cleaning.
99) What are the documents to be prepared and submitted at the end of the
contracts?
Daily painting inspection report / weekly reports,
Manufacturing data sheet,
Painting / coating materials certificate,
Instrument calibration certificates,
Testing reports.
100) State the advantages and disadvantages of conventional and airless spray?
Conventional spray: Advantages:Disadvantages:More accuracy,
Low deposition rate,
Good atomization,
High viscosity fluids cannot
be used.
Inexpensive nozzle,
Heavy hose line,
Concentrated flow pattern
Separate container to be used,
Low working pressure,
operator fatigue,
Less cleaning after use.
Airless spray: Advantages:High deposition rate,
Can be apply high viscosity fluids,
Versatile (No air hose),
High transfer efficiency,
Lower waste,
Large area coverage,
Manufacturer container can be used.
increased safety risk.

Disadvantages:Low accuracy
Poor atomization,
Expensive nozzle,
Narrow flow pattern,
Coatings limitations,
Increased maintenance,
High skilled required,

101) What is polymerisation?

Monomers link together with other monomers to form polymer. This chemical
process
known as polymerisation. This takes place during the drying of a paint film.

102) Briefly describe the difference between saturated and unsaturated when
referring to
oils and polymers?
Oils:
Saturated oil cannot be used as a binder, because it will not
solidify by
polymerisation to form a film.
Unsaturated oil can be used as a binder, because it has the ability
to combine
with Oxygen, solidify by polymerisation to form a film
Polymers: The atoms or molecules which form the polymer will join on at
the end of the
structure, when structure gets saturated. (E.g. methane and
ethane).
The Ethylene and Ethyne molecules is defined as being
unsaturated.
103) What is meant by convertible and non convertible coating?
A convertible coating is permanent or non reversible, and therefore cannot be
returned to
Its original liquid stage, it is generally thermosetting.
Non convertible coating is said to be reversible as re-application of the
solvent will soften
the binder and return the coating in the original liquid form. This resulting
drying
mechanism is by solvent evaporation.
104) Identify six paints by their binder names?
Epoxy, Acrylic, Alkyd, Emulsion, polyurethane and cellulose.
105) What does a CRYPTOMETER measure and give two examples of a
cryptometer?
Opacity---Hiding power chart and pfund cryptometer.
106) Under what conditions must paint be stored?
Less than 5C of flash point, dry lockable well ventilated building, away from
any source
of heat and following any legal storage requirements and following paint
manufacturer
instruction.

107) What two coats of paint are applied at works?

High solid Epoxy primer minimum 75, Epoxy MIO coat 75 minimum.
108) What additional information you should when maintenance painting a
pipeline without
removing the existing coating?
The following additional information to be recorded are:
Nature of the existing system must be established to decide the type of
preparation to be
carried out.
Amount of surface contamination
Extent of paint breaks down.
Extent of corrosion.
Compatibility of the existing system with the new system. If not compatible
select the
appropriate Tie-coat.
In service environmental condition.
109) What determines the degree of gloss paint may possess?
Amount and type of binder, Fineness of grind of pigments, method of
application, skill of
applicator, absorbency of surface. The gloss is measured by gloss meter by
reflective
light. Polyurethane- high glossness
110) What are the 2 coats applied @ work?
Primer and first mid coat.
111) What are the points to be considered for selecting a surface preparation for a
paint
project?
a) Demands of the specifications,
b) Location (environment of the systems,
c) Type of paint being applied,
d) Operational restrains etc,. (control service temperature)
Because correct and effective preparation will providing the length of life and
quality of finish of the paint systems being used.
112) What are the potential fire hazards in an operational are?

Sources of ignition
Naked flame, hot surfaces, smoking, striking metal surfaces, electric power
supply and
static electricity.
Fire and explosions hazards.
- Concentration of vapour in air is above UEL.
- Flammable liquids are contact the temp above its flash point.
113) Surface preparation and painting what are the points you will record or
report?
General:
Date, project and job identification, name of contractors, inspection location
and time,
safety aspects.
Ambient condition: Air and surface temperature, relative humidity, dew
point, presence
of wind or dust, sunlight.
Surface preparation:
Condition of surface before cleaning, cleaning method, abrasive used, nozzle
used and
pressure, achieved surface profile in micron.
Coating application:
Manufacturer type, Batch #, ratio of paint and thinner, over coating time,
application
method, equipment used, spray nozzle size, inspection test, WFT / DFT,
holiday etc,.
including instrument calibration details, repairs etc.
114) What is the title of BS 3900?
Method of test of Paint,
How many test sets are there?
And how are they numbered?

Eight
From letter A-H

115) Recording of information following project completion?

To have record of work stoppage due to adverse weathering condition
down time.
To have records of materials, consumables (equipments and instruments)
qualitities and batch certificates.
Man power deployed and equipment used.
Record of wastage of materials.

Cost effectiveness
Estimation of project cost.
116) Preparation of 2 packs paint for use?
Plastic paper to be laid underneath of the paint tin.
All dust to be removed.
Lid to be open with out damaging of the ring.
All solidment at bottom of the tin to be mixed by stirring.
Solvent or catalyst to be added, according to the manufacturer instruction
(quantity). Slowly and gradually mixed thoroughly.
Up to 5 liter can mixed by manually, if more than 5 lit can be mixed bt
mechanically.
Tin should cover with out opening.
Never mix the paint in open dust area.
117) Profile reduction; what will be the action?
If the blasted surface has the profile higher than the specification
requirement is called profile reduction.
a) Change the blasting nozzle type
b) Reduce the abrasive size
c) Increase the distance between the nozzle to surface.
116) If you worked on a contract where frequent stoppages occurred for poor
weather, what additional information would you record?
Time of starting and stopping
Progress of work at stopping time
Record of waste materials
Record of damaged to newly blasted or partially cured or painted area.
Calculate the stand down time.
117) Pipe line leave on ground, what problems would be occur?
Rapid change in O2 wet / dry
Contamination caused by rain splash up lower part
Impact damage
Soil damp chemically active change dark / or light.
Up grade coating system, wrapping with tape, polyethylene heat shrink
sleeves

118) If a pipe line was in direct contact with accoustic cladding, what paint
system might be applied if we wished to maintain it every three years, or
not at all?
Rust inhibitive primer only every 3 years maintenance
Full system specified, finish coat not required.
119) What is important about selecting a paint system suitable for a certain
environment?
Selecting a coating system which is suitable for particular environment as
per MDS of manufacturer.
120) What information do B.Gas require to be on a paint tin and what B.Gas
document deals with the properties and performance of paints?
Pot life, induction period, PA-9 stamp (MDS).
121) What is unusual about the preparation of surfaces which are dealt with
under S.P.A.4?
Damp surface, further they shall not be used when ice is present. Type of
material modified satisfactory for use on damp metal surface include1) moisture curing polyurethane,
2) High solid multi- component epoxy paint.
122) Limits for coarse and X coarse?
Coarse only 50 microns
X coarse only 37 to 100 microns
Grain size- coarse grain 0.37 micron and X coarse grain 37-112microm.
123) Principle for using the Banana gauge?
It works on a magnetic principle, on a ferrous surface (substrate) with non
ferrous coating, i.e measuring the thickness of non ferromagnetic coatings
applied on ferromagnetic substrate.
124) Actions taken when coating are applied out of sequence?
Stop the job, inform to engineer or client representative, find out the
problem, if wrong type of paint is applied it must reblasted off, restart
with correct system, note down the area blast cleaned and quantity of
paint mixed, area of wrong coating, prepare the report.
125) Problems occur when the density and viscosity of the paint are not
correct?

Thin coating will result in poor durability and lower resistance of

corrosion.
Poor opacity and slow drying, poor gloss and finish, it may be creating the
surface like runs and sag.
126) Rust inhibitive pigments properties on paint system?
To protect the piping or pipelines by the use of rust inhibitive primer,
which will retard corrosion to take place.
127) How the contractor has to maintain the relationship with client?
To fulfill the requirement of the client according to the client inspectors
priority.
Good communication about fulfillment of scope and relevant activities
carried out.
Submission of the document without undue delay.
Incase any deviation against the standard and specification submit those
document for his decision making, (or approval).
Incase any changes in priority, inform and get permission from the client.
Good coordination and relation ship will contribute to understanding the
job more precisely.
128) Function of primer; midcoat; and finish coat?
Primer: To provide maximum lasting adhesion to substrate for the next
paint layer and retard corrosion.
Mid coat or under coat: Barrier to prevent the passage of water. Also build
up the film thickness provide more even surface.
Finish coat: It gives the final appearance, degree of colour and gloss,
resistance to abrasion, UV light, weather etc. also allow the water to flow
more readily from the surface.
129) What are the risk assessments under taken when coating and painting?
All site work normally subject to a permit system.
Tool box talk shall be carried out before the work start, points to be
discussed regarding hazards involve in the job.
All equipment whether electrical or pneumatic shall be earthed.
No smoking regulation shall be observed.
Fire / flame shall not be used to dispose or rubbish or clean of paint
kettles.
Non spark tools and flame proof equipment shall be compulsory.
Tarpaulin sheets must not be used.

Display warning boards and barricading the work area.

Appropriate P.P.E. shall be used during job. E.g. (air fed helmet, boots,
goggles, mask, gloves etc).
130) What of abrasives used for open site blast cleaning?
Normally use the expendable abrasive i.e. use only once which cannot be
re-used or recycled. E.g. copper slag, walnut shell, garnet, ceramic grid,
crushed glass, etc.
131) Reasons for different types of surface preparation?
Areas which are inaccessible for mechanical buffers we go for hand
abrade by emery paper.
Area is small and spot repair, we go for mechanical cleaning by brush
(ST3).
Large area and open site, we go for expendable abrasive blasting.
Area have existing coating with toxic, we go for water blasting,
Also depend upon the coating systems will get differ the surface
preparation.
It depends on coating system.
132) Describe the sequence of the events for inspection before calling the 3rd
party inspector?
Carry out the internal inspection of the components prior to offering 3rd
party inspection.
Request for inspection.
Make availabilities of the relevant documents and reports for inspection.
Make availabilities of all the personal involved in the inspection with
relevant testing equipment and with calibration certificates.
Give the clearance for further activities.
133) What is the use of QC plan in paint project?
Quality control plan precisely represents following activities.
QC plan indicates responsibility and sequence of activities involved and
inspection frequency involved in the process.
Identify the nature of inspection to be conducted.
Who shall conduct the inspection and whose witness required for the
inspection.
Whether the activities can be proceeded till the clearance is over.
Identify the standard and specification requirements for inspection.

Whether the activities need any additional qualification for the people
who involved.
Identify the equipment and instrument used for the inspection and key
personal responsibilities.
The purpose of the QC plan is setting out the specific quality practice to
achieve the desirable quality to meet the specification requirements
following the various stages of inspection.
134) What are the important things for selection of a paint system?
Appropriate cost effective methods of surface preparation..
Appropriate cost affective paint system to meet the required service life.
New painting:
Consider the specification requirement.
Location of the system. (Environmental system).
Purpose of the system (paint system) Industrial or degeneration
Operational restrains (service temp)
Cost effective of the paint system
Maintenance Painting:
Need to established whether the existing system contains any toxic
coating for surface preparation.
Terms of compatibility with existing system,
Adhesion,
Possibility of solvent stripping,
Possibility of bleeding,
Further information required like,
Extent of surface contamination,
Extent of paint break down,
Extent of corrosion.
Flammable substance are contact the temp above its flash point.
Vapour of the paint constituents are in air above the UEL.
Due to involvement of the ignition source.(Naked flame)
Important safety requirements.
Use correct tip.
Fluid line in good condition. Ensure no leaks in fluid line.
Ensure safety catch on when hot in use
Never point the gun to any one and your self.
Never attend to clean or adjust the gun when line under pressure.
Ensure equipment to be earthed to avoid static shock.
Wear an air fed helmet.

135) How does the Air less spray work, define?

A non pressurized container is held remote from the gun.
The fluid pump will suck the paint from the container and fed through the
high pressure reinforced fluid line.
The pressure is supplied from the compressor approximately 100psi.
This air inlet pressure is adjustable.
The fluid pump will multiple the pressures by 1: 35 ratio.
(100psi=3500psi).
Spray tips are normally lined with tungsten carbides.
A titan tip exists which can adjust the tip hole size.
Size of the orifice governs the amount of fluid delivered (flow).
Angle of the orifice governs the size of the pattern.
136) What is holiday and pin hole detector, what does it detect, and how does
it?
The holiday and the pinhole detector detect the discontinuity of the
coating and painting system. Both the techniques are similar.
Holiday - missed or poor coated area.
Pinhole minute defect caused by escaping air bubbles.
Process of detection and cure:
Earth the substrate to be tested.
Pass metal brush (Holiday) or wet sponge (pinhole) over the painted
surface at a preset voltage (Typically around 5V per micron) and at a
controlled speed.
When defect is found an audio or visual warning is given.
The area must mark and repaired and re tested.
137)