CIP Level 1 MythicalMythic Special Flashcards
Standards, Definitions, Generalizations
Define Corrosion.
The deterioration of a material, usually a metal, that results from a reaction to its environment.
What is Passivation?
A reduction of the anodic reaction rate of an electrode involved in corrosion.
What are the four elements of a corrosion cell?
Anode, Cathode, Metallic Pathway (or Return Path), and Electrolyte.
Describe what happens at the Anode.
Metal deterioration occurs at the Anode, the metal is transferred into positively charged ions, (Cations). The metal dissolves into the electrolyte.
What is the function of the Electrolyte?
Allows the passage of Ions to connect the corrosion cell.
What is the function of the Metallic Pathway (or Return Path)?
Allows the flow of electrons to connect the corrosion cell.
What is the galvanic series? More specifically, what is the list referring to, and what is the control measured in?
A list of metals in order of reactivity, (more or less noble) in sea water at 25°C.
The general rules of galvanic corrosion are:
The “less noble” (or more reactive element like Zinc) metal when connected to a “more noble” (or less active element like Gold) will corrode preferentially.
Name the five factors that affect the RATE of corrosion.
Humidity, Chemical Salts, Pollutants, Oxygen, Temperature.
General corrosion is defined as:
Corrosion that does not cause catastrophic failures, and results in a relatively uniform loss of material across an entire surface.
Localized corrosion is defined as:
Corrosion that is typically pitting and crevice corrosion, leading to a loss of integrity causing catastrophic failure.
List seven common TOOLS or METHODS used for corrosion CONTROL.
- Design
- Inhibitors
- Material Selection
- Cathodic Protection
- Protective Coatings
- Alteration of the Environment
- Splash Zone systems
Name six tests that may need to be conducted during surface preparation and coating operations? (The tests you perform as the inspector on each weld for a pipeline project.)
- Ambient Temperature
- Surface Temperature
- Relative Humidity
- Dew Point
- Anchor Profile
- Surface Cleanliness, (Chemical Salts, oils, other invisible contaminates)
What are three most important characteristics of a good report?
- Objective, (factual, not opinionated)
- Accurate
- Detailed
What is the inspector’s primary responsibility in regards to specifications, and what must they never do?
The inspector’s responsibility is verify the specification, and never change or alter it.
Name at least four of the nine types of information found on a product data sheet?
- Surface prep requirements
- Level of cleanliness required
- Recommended application method
- Recommended application equipment
- Minimum and maximum temperatures
- Dew point
- Environmental parameters
- Curing times
- Recoat windows
Name at least four of the eight types of information found on a safety data sheet?
- Toxicity
- Health effects
- First aid
- Reactivity, (flash point/explosiveness)
- Storage requirements
- Disposal procedures
- PPE
- Spill handling
Identify three defects that can be caused by incorrect application temperatures.
- Failure to cure
- Too rapid solvent evaporation/flash off
- Poor film formation/runs/sags
Describe relative humidity.
The amount of moisture in the air compared to the saturation level.
What is the Dew Point temperature?
The temperature at which moisture will begin to form on a steel surface.
Name the four effects NACE lists that wind may have on a coating project.
- Blowing abrasives
- Causing excessive drift or overspray
- Accelerating solvent evaporation/shortened pot life
- Contributing to the formation of dry spray
Explain the two step process for using the Sling Psychrometer.
Make sure the wick is wet and clean, and continue to “sling” the hygrometer until three consecutive readings are achieved.
List 10 desirable properties of a protective coating system?
- Chemical Resistance
- Impact Resistance
- Flexibility/Elongation
- Dielectric
- Water Resistance
- Abrasive Resistance
- Ease of Application
- Temperature Resistance
- Cohesive Strength (tight molecular bond)
- Gloss retention
Six broad classifications of a coating, (not curing mechanisms) are:
Convertible, Non-Convertible, Organic, Non-Organic, Thermosetting, Thermoplastic.
What are the two primary components of a liquid applied coating?
Pigment
Vehicle, (which is the resin/binder AND solvent)
Describe the three methods by which a coating provides corrosion control.
- Barrier
- Inhibitive
- Sacrificial
What are the three ways a coating can adhere to a surface?
- Polar aka Valance bonding
- Mechanical
- Chemical
During surface preparation, surface cleanliness should be inspected (at a minimum) the following three times:
- Before any surface preparation activities
- After surface preparation, and before coating begins
- Between each application of coating in a multi-coat system
List seven factors during surface preparation that may negatively affect service life.
- Surface contaminants, (residues of oil, soil, grease and non-visible chemical salts)
- Surface condensation
- Old coatings with poor adhesion or may be too deteriorated for recoating
- Rust, mill scale, or loose/broken mill scale
- Anchor pattern
- Defects in mechanical cleaning equipment
- Existing coatings might be incompatible with the chosen coating system being applied
8 Common design defects.
- Construction Aids
- Hard-to-reach, inaccessible areas
- Sharp corners and edges
- Overlapping surfaces
- Welds, gaps (particularly skip welds)
- Bolts, nuts, washers, rivets, and other fasteners
- Threaded areas
- Dissimilar metals
Three common fabrication defects include:
- Weld splatter
- Skip welds
- Rough welds, sharp corners and edges
What are six standards to use for Power Tool Cleaning?
- NACE 5
- SSPC SP - 3
- SSPC SP - 11
- SSPC SP - 15
- ISO 8501-1 St2
- ISO 8501-1 St3
The two broad classifications for curing mechanisms are:
Convertible and Non-convertible
Two non-convertible coating types are:
Chlorinated Rubber and Vinyl
List four CONVERTIBLE coating MECHANISMS, (how do they cure).
- Oxidation
- Hydrolysis
- Fusion
- Co-Reaction, (Polymerization)
What are the three characteristics of oxidation cured coatings?
- Not suitable for immersion service
- Not suitable for use over alkaline substrates
- Limited DFT per coat
The five types of coating that cures by polymerization.
- Polyurea
- Polysiloxanes
- Polyaspartics
- Epoxies
- Urethanes
Induction time is defined as:
Post mixing the co-reaction coating into its solvent, and before applying it to a substrate. (Between mixing and application.)
Define saponification.
Oil based coatings applied over alkaline surfaces, creating a soap-like film and foam.
Name eight SSPC-SP1 pre-cleaning methods.
- Solvent cleaning
- Solvent spray
- Solvent immersion
- Emulsion cleaning (suspending a volatile active agent in a nonvolatile aqueous vehicle)
- Chemical paint stripping
- Alkaline cleaner
- Steam cleaning
- Vapor cleaning
Seven examples of power tools used in cleaning are:
- Disk sander/sanders
- Grinder
- Rotary wire brush
- Rotary scaler
- Piston scaler
- Needler
- Impact tools
Name six blasting methods.
- Water blasting
- Slurry blasting
- Shrouded water blasting
- Sand-injected blasting
- Dry-grit blast cleaning, (Air Blasting)
- Centrifugal blasting, (Wheel-a-brator)
What standard limits random staining to NONE?
SSPC-SP 5, or NACE 1
What standard limits random staining to 5%?
SSPC-SP 10, or NACE 2
What standard limits random staining to 33%?
SSPC-SP 6, or NACE 3
NACE 4/SSPC-SP 7 refer to what level of cleanliness of the substrate?
“Tightly adherent ______, ______, and ______ may remain.”
Tightly adherent mill scale, rust, and coating may remain.
NACE 8/SSPC-SP 14 refer to what level of cleanliness of the substrate?
“Traces of tightly adherent ______, ______, and _____ residues are permitted to remain on __% of each unit area.”
Traces of tightly adherent mill scale, rust, and coating residues are permitted to remain on 10% of each unit area.
SSPC-SP 5, or NACE 1 limits random staining to what?
None
SSPC-SP 10, or NACE 2 limits random staining to what?
5%
SSPC-SP 6, or NACE 3 limits random staining to what?
33%
“Tightly adherent mill scale, rust, and coating may remain.” Refers to which two standards of cleanliness?
NACE 4/SSPC-SP 7
“Traces of tightly adherent mill scale, rust, and coating residues are permitted to remain on 10% of each unit area.” Refers to which two standards of cleanliness?
NACE 8/SSPC-SP 14
Two visual guides for abrasive blasting include:
SSPC-SP VIS 1 & ISO 8501-1
Two types of abrasive blasting nozzles
Straight bore & Venturi
What are five advantages of Centrifugal Blasting
- Dust and debris are contained
- Abrasives are recycled
- General overall economy compared to air blasting
- No compressors, piping, or air handling equipment
- Blasting and priming can be an inline operation
Name 8 abrasive media types.
- Shot
- Grit
- Garnet
- Crushed slag
- Agricultural
- Special, (dry “vanilla” ice, bits of Sponge Bob’s sponge body, bones of my enemies, plastic beads, hopes and dreams, Reese’s® peanut butter cups, baking soda, etc)
- Ceramic grit
- Silicate
What abrasive medias are typically recyclable?
Steel shot and grit.
List the pressures that pertain to each category of water cleaning:
Low-Pressure Water CLEANING
High-Pressure Water CLEANING
High-Pressure Water JETTING
Ultrahigh-Pressure Water JETTING
LPWC - 0 to 5,000psi
HPWC - 5,000 to 10,000psi
HPWJ - 10,000 to 30,000psi
UHPWJ - 30,000+ psi
The three types of water BLASTING (using an abrasive) include:
- Grit Blasting with a shroud (sand blasting, while using a cone of water to help keep the dust and debris down)
- Sand injected water blast (water moves so quickly it pulls the dry sand into the hose near the nozzle)
- Slurry blast with grit/water mix (mixed into a slick mud at the tank together prior to blasting)
The four visual guides to use with the NACE/SSPC WATER JETTING (not blasting or cleaning) standards are:
- NACE 5
- SSPC-SP 12
- SSPC-VIS 4
- SSPC-VIS 7
Three test methods for surface profile (anchor pattern) include:
- Comparator and coupons
- Replica Tape/Anvil Micrometer
- Digital Surface Profile Gauge
Two guides for enclosures on coating projects are:
SSPC Technology Guide No. 12
SSPC Technology Update No. 6, (Guide for containing surface prep debris generated during paint removal operations).
What are three high temperature concerns during coating application?
- Solvent evaporating too quickly
- Reduction in pot life
- Decreased viscosity of many two-component systems
Name four effects of high humidity during coating application?
- Slow the evaporation of the solvent
- Can leave moisture on the surface of the coating
- Could cause Amine Blush (must be removed prior to top coating)
- May affect the gloss or color
What six methods are typically used to apply coating?
Hint: four of these use a spray system.
- Roller
- Brush
- Airless Spray (including plural component)
- Conventional Spray
- High Volume Low Pressure (HVLP)
- Air-Assisted Airless
“Airless spray application system uses a large ___ ___ that pulls material from a container and forces it through a high-pressure line at up to ___ psi, which pushes it through an orifice on the end of a gun breaking it into very small droplets. The spray gun has ___ ___ on it, with an ___ ___ trigger.”
piston pump
9,000
no controls
on/off
“Plural Airless spray equipment uses two ___ ___ which synchronize at either a ___ or ___ controlled rate. Each ___ ___ is in charge of delivering both the ___ and the ___ at the spray gun in the proper ratio. The ___ is heated prior to delivery, making the gun difficult to hold during application.”
piston pumps fixed variable piston pump coating solvent coating
“Air-Assisted Airless spray consists of an Airless spray pump rig, paired with a special gun that uses ___ ___ at the tip to help ___ coating. This equipment allows for more ___ and less ___ material.”
air pressure
atomize
control
wasted
“HVLP stands for ___ ___ ___ ___, and is typically used in shops, or for touch-ups since these rigs can be very portable. HVLP reduces loss of material, which reduces overall ___ ___ ___ emissions, and strikes the surface at very low energy, stopping it from bouncing back into the air which is what causes ___.”
high volume low pressure
volatile organic compound (VOC)
overspray
“Conventional spray is most commonly used when a fine finish is required. These spray rigs have several options to control both the ___ and ___ of the ___ ___, along with the ___ of material coming out of the gun.”
size
shape
spray pattern
volume
Conventional spray has two major drawbacks. What are they, and what two other observations should the inspector keep an eye out for when the contractor uses Conventional spray?
- High-build, high-viscosity coatings cannot be pushed or atomized with low air pressure.
- Coatings with very short pot lives cannot be spray-applied effectively with Conventional spray.
- ——————————————————————- - Overspray
- Dry spray
What does BMR stand for?
Base Metal Reading
To adjust a Type ___ gauge for surface roughness, measure the blast profile of the steel to be painted at a number of spots to obtain a representative average value. The average value is the ___ ___ ___.”
Type 1
Base Metal Reading (BMR)
This gauge is described as a “magnetic pull-off gauge,” and is used to measure ___ ___ ___. The force required to pull a magnet from a ferrous surface is used to determine the ___ ___ ___. What type is it?
Dry Film Thickness (DFT)
Dry Film Thickness (DFT)
Type 1
This flashcard was intentionally left blank.
We have no idea why.
What are six reasons that can cause films to not dry (failure to cure)?
- Not adding the curing agent
- Adding the incorrect curing agent
- Adding the incorrect amount of curing agent
- Problem with the material caused by the manufacturer
- Environmental concerns (heat, cold, moisture)
- Contaminates (oil, salts, chemicals, etc)
Five problems that can be caused by Amine Blush are:
- Surface tackiness or greasiness
- Incomplete curing
- Poor adhesion
- Discoloration
- Poor gloss retention
Name five causes of runs, sags, or wrinkles.
- Applying the coating too thick.
- Too much or the wrong thinner.
- Surface too hot to apply coating.
- Application of coating at the end of its pot life.
- Wrong thixotrope used in manufacturing.
___ is a powdery, friable layer on the surface of a coating that is most common with epoxy coatings.
chalking
What are three issues that can cause Cratering?
- Air trapped in the coating on the surface, then bursting
- Air trapped in coating during improper mixing in the container
- Air trapped in the coating during improper application, (did not have air on the surface initially, but was introduced due to sloppy/quick movements)
- Air trapped inside the lower bowels, then released into the coating while laughing at how it gurgles under the buttocks
- Air trapped inside Britney Spears head, when someone exclaims, “Hey look! Justin Timberlake!” inevitably leaving a crater in the ground as it explodes in anger.
Voids (air bubbles/vacuoles) in coating are typically caused by what?
Running the mixer too fast, causing foam. They could be so small they could sometimes be invisible.
Pinholes are:
Similar to cratering, but much smaller and caused by air or solvent trapped in porous film or escaping. Pinholing can also be caused by a burn-through while using a holiday detector on too high of a setting.
A common cause of blistering is:
Surface contamination under the applied coating.
When is cracking of a coating noted by the inspector?
When the crack extends to the substrate.
Checking can be described as:
Fine cracks in the surface of a coating that do not extend through to the substrate.
Name six reasons for adhesion failure of a coating.
> Contamination on the surface.
Wrong surface preparation specified.
Failure to inspect surface preparation.
Insufficient surface profile/anchor pattern.
Exceeding the topcoat window.
Application of incompatible coatings.
“The High-Voltage AC Holiday Detector uses a range from ___ volts or ___ volts power supply. The AC detector is based on the principle of the ___ ___ and does not use a ___ ___. The probe emits a blue corona, which is attracted to any ___.”
110 220 Tesla coil ground wire ground
“The High-Voltage Constant Current DC Holiday Detector is used to detect coating holidays in ___ coatings.”
dielectric (insulating/electrically resistant)
“The High-Voltage Pulse-Type DC Holiday Detector is ideal for use in ___ conditions.”
moist
….moist
MMMMMMOOOOIIIIIIIIISSSSSST!
(It’s also the most commonly used on transmission pipelines.)
“The Low-Voltage Holiday Detector is a sensitive, low-voltage electronic device, powered by ___ with output voltages ranging from ___ to ___ volts, and uses a ___ ___ as its probe to detect holidays.”
batteries
5
120
wet sponge
What makes up the vehicle of the coating?
Binder/Resin and Solvent
Generic marine coatings are often referred to by their generic type, what are the 3 types?
Alkyde
Epoxy
Polyurethane
Define Induction time.
The period after mixing the binder and solvent, which lets the cooking process begin, before applying. (Post mix, pre application.)
What are the five ISO comparator grades?
Finer than fine, fine, medium course, courser than course.
What are the two types of replica tape?
Course, XtraCourse
What are the profiles listed on Course XtraCourse repica tape?
Course: 0.8 - 2.5mil
XtraCourse: 1.5 - 4.5mil
Standards for using replica tape?
ASTM D 4417 method C
NACE SP0287-2002
What are the four types of holiday detectors?
Low Voltage DC
High Voltage DC
High Voltage Pulse DC
High Voltage AC
What are the three types of chemical salts?
Nitrates
Sulfates
Chlorides
What are the four grades listed, and what do they represent on the visual comparator for SSPC-VIS 3?
They represent mill scale and rust, and are listed as A, B, C, and D.
Define Rust Grade A on the SSPC-VIS 3.
Steel surfaces completely covered with adherent mill scale; little or no rust visible.
Define Rust Grade B on the SSPC-VIS 3.
Steel surface covered with both mill scale and rust.
Define Rust Grade C on the SSPC-VIS 3.
Steel surface completely covered with rust; little or no pitting visible.
Define Rust Grade D on the SSPC-VIS 3.
Steel surface completely covered with rust; pitting visible.
