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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
8. Does the 6010 can apply over the 7018 vertical position?
Ans. No
18. What other American code required for testing pipeline and welder qualification?
Ans. ASME IX (Welding & Brazing Qualification)
23. What type off grooves used for SAW process? When to use this preparation(groove)?
Ans. U, V & Square grooves
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
35. Hardness test is one requirement of NACE MR0175, what the other requirements?
Ans. Nickel content shall be less than 1%
43. Give two kinds of material that direct current (DC) welding machine can be used?
Ans. P1, P5 materials
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
48. What filler metal to be used on 304 to SA 516 GR70 material first layer?
Ans. ER309L
71. What mechanical test is an additional requirement for materials in low service
temperature?
Ans. Impact test
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
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.
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)
Cracking: Causes due to as a result of ageing and the differential expansion and
contraction of the
substrates, excess coating.
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.
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.
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.
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.
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
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.
Abbreviations.
SPA- Specific paint application
BGC- British gas council
IGE- Institute of gas engineer
BS- British standards,
EPA- Environmental protection act.
COSHH- Control of substances hazardous to health Act 1988
EH 40- HSE guidance notes: list of all known harmful substances.
OEL- occupational exposure limit.
MEL- Maximum exposure limit
OES- occupational exposure standard.
HASAWA- health and safety at work act 1974
TSA- Thermally sprayed Aluminium
CPVC- Critical pigment volume concentration
SRBs- sulphur reducing bacterias.
MEMs- Metal eating microbes.
VOCs- Volatile organic compounds.
PVB- Poly vinyl butyrl.
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.
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.
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)
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.
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.
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.
21) Name 5 methods of applying paints & compare the advantages and
limitations of each
method?
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.
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 .
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.
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.
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.
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.
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.
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 non-
ferromagnetic 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 include-
1) moisture curing polyurethane,
2) High solid multi- component epoxy paint.
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.
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.
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).
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.
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)