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End Of Chapter Study Guides Flashcards

1
Q

Define corrosion

A

The deterioration of a metal that results from a reaction in the environment.

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2
Q

What is passivation?

A

A reduction of the anodic reation rate of an electrode involved in corrosion.

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3
Q

What are the elements of a corrosion cell?

A

Anode
Cathode
Return path
Electrolyte

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4
Q

Describe what happens at the anode.

A

Oxidation occurs at anode. Electrons flow away from anode in the external circuit. Corrosion occurs at anode and metal ions enter the solution at the anode.

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5
Q

What is the function of the electrolyte?

A

The electrolyte must be present to close the loop in the corrosion cell. The corrosion current is carried by ion transport through the electrolyte.

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6
Q

What is the function of the metallic pathway?

A

Connects the anode to the cathode and allows a passage of electrons from anode to cathode.

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7
Q

What is the galvanic series?

A

A list of materials in order of their corrosion potentials, with the most active at the top and the least active at the bottom.

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8
Q

The general rules of galvanic corrosion are:

A

When dissimilar metals are connected, the most active metal corrodes faster while the least active metal corrodes slower.
As the potential difference between the metals increase, the rate of galvanic corrosion increases.

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9
Q

Five factors that affect the rate of corrosion

A 
Oxygen
Temperature
Chemical salts
Humidity
Pollutants and Acid Gases
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10
Q

General corrosion is

A

relativelt uniform loss of material over the entire surface and is a general thinning of affected surface.

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11
Q

Localized corrosion is

A

Occurs at discrete sites on the metal surface.

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12
Q

List some of the common tools/methods for corrosion control.

A 
Design
Inhibitors
Material selection
Cathodic protection
Protective coatings
Alteration of the environment
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13
Q

How does NACE define the inspector’s role?

A

Quality control technician who observes and reports technical aspects of coating project. Observe, test, verify, report.

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14
Q

What is the inspector’s responsibility when it comes to safety on a project?

A

Safety enforcement is not the inspector’s responsibility. Be knowledgeable of safety violations.

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15
Q

Tests that may need to be conducted during surface preparation and coating operations.

A 
Relative humidity and dew point.
surface temperature.
surface contaminants.
proper abrasive media.
cleanliness of abrasive.
check air compressor.
Air supply to blast hose.
Blast nozzle for size and wear.
Blasted surface for anchor pattern.
Viscosity of coating.
Application equipment.
DFT of each coat.
Surface contaminants.
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16
Q

Documentation/reports that may be required to be maintained on a coatings project.

A 
Daily written report.
Inspection logbook.
Routine report.
Notes from weekly progress meetings.
Any reports required by client.
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17
Q

Most important characteristics of a good report?

A

Objective, accurate, detailed.

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18
Q

What is the inspector’s primary responsibility and what should the inspector not do as it pertains to the specification.

A

The inspector’s primary responsibility is to VERIFY the specification. The inspector does not make changes to the specification for any reason.

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19
Q

What type of information do you find on a Product Data Sheet?

A

Manufacturer’s Product Data Sheet answers questions about coating product. Application methods, surface cleanlinesss, parameters, temperatures, curing times.

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20
Q

What type of information do you find on a Safety Data Sheet

A 
Toxicity
Health Effects
First Aid
Reactivity
Storage
Disposal
PPE
Spill Handling Procedures
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21
Q

Explain the difference between Quality Assurance and Quality Control

A

QA - Checks whether the product or service is meeting specified requirements.
QC - Product or service is meeting the requirements of the client.

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22
Q

Identify some defects that can be caused by incorrect temperature applications

A 
Blistering
Pin holing
Cratering
Dry spray
Mud cracking
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23
Q

Describe Relative Humidity

A

A measure of the amount of moisture in the air compared to saturation level.

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24
Q

What is the dew point temperature?

A

Temperature which moisture begins to form on a steel surface.

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25
Q

Name some of the effects wind may have on a coating project.

A

Blow abrasives past the boundaries of the work area.
Cause drift or overspray of sprayed coatings.
Accelerates solvent evaporation.
Formation of dry spray.

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26
Q

What are some of the common errors when using an electronic hygrometer?

A

Reading taken in direct sunlight.
Instrument was left in place for too long.
Instrument removed before stabilized.
Calibration or equipment malfunction.

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27
Q

Explain the process for use of the sling psychrometer.

A

Saturate sock with clean water.
Whirl the instrument rapidly for about 40 seconds.
Read the wet bulb temperature.
Repeat process until the temperature stabilizes.
Once wet bulb is stabilized, record the dry bulb temperature.

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28
Q

List 3 desirable properties of a coating.

A 
Chemical resistance.
Water resistance.
Ease of application.
Adhesion to substrate.
Cohesive strength.
Flexibility and elongation.
Impact resistance.
Abrasion resistance.
Temperature resistance.
Dielectric strength.
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29
Q

The 2 broad classifications of a coating are:

A

Organic coating

Inorganic coating

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30
Q

What are 2 primary components of a liquid applied coating?

A

Pigment
Resin/Binder
Solvent
Vehicle

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31
Q

Describe 3 methods by which coating provides corrosion control.

A

Barrier - impedes ingress of oxygen, water, soluble salts
Inhibitive - slows down reaction occuring on substrate.
Sacrificial - anodic metal that corrodes preferentially.

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32
Q

What are 3 different ways a coating can adhere to the surface?

A

Chemical
Mechanical
Polar

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33
Q

The 2 broad classification for curing mechanisms are:

A

Nonconvertible

Convertible

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34
Q

List 2 nonconvertible coating types.

A

Vinyl

Chlorinated Rubber

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35
Q

List 3 convertible coating curing mechanisms.

A

Oxidation
Co-reaction (polymerization)
Hydrolysis
Fusion

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36
Q

List 2 characteristics of oxidation cure coatings

A

Cure by reaction of atmospheric oxygen.

Not suitable for immersion.

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37
Q

3 coatings types that cure by polymerization.

A 
Epoxies
Urethanes
Polyureas
Polyaspartics
Polysiloxanes
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38
Q

Induction time is:

A

Time required between mixing the coating and application.

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39
Q

What is the main requirement for a hydrolysis coating to cure?

A

Moisture.

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40
Q

Industrial and marine coatings are commonly referred to by:

A

Generic Resin Type

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41
Q

Oil based coatings applied over alkaline surfaces may result in

A

Saponification

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42
Q

List 5 of the formal sections usually contained in a good specification.

A 
Scope of work
Terms and definitions
Reference standards and codes
Safety
Pre-job conference
Coating materials
Sampling coatings
Workmanship
Application
Work schedule
Repairs and remedial coating work
Inspection
Documentation
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43
Q

What are 2 of the inspector’s responsibilites as it relates to the specification?

A

VERIFY the specification.

Do not change the specification.

44
Q

During surface preparation, surface cleanliness should be inspected at a minimum the following 3 times:

A

Before any surface preparation activities.
After surface preparation, before coatings begin.
Between each application in a multi-coat system.

45
Q

Factors during surface preparation that may effect service life include:

A 
Residues of oil, grease, soil.
Residues of chemical salts.
Rust on the surface.
Loose or broken mill scale.
Rust scale.
Anchor pattern.
Defects mechanical cleaning equipment.
Surface condensation.
Old deteriorated coatings.
Incompatible existing coatings.
46
Q

Common design defects include:

A 
Hard to reach/inaccesible areas.
Rivets, bolts, or other connectors.
Welds.
Gaps/skip welds.
Overlapping surfaces.
Angles, complex arrangements.
Threaded areas.
Dissimilar metals.
Sharp edges/corners/rough cut plate.
Construction aids.
47
Q

Common fabrication defects include:

A

Weld splatter.
Skip welds.
Rough welds.
Sharp corners and edges.

48
Q

4 typical SSPC SP1 pre-cleaning methods include:

A 
Solvent wipe with cloth or rag.
Immersion of the substrate in solvent.
Solvent spray.
Vapor degreasing.
Steam cleaning.
Emulsion cleaning.
Chemical paint stripping.
Use of alkaline cleaners.
49
Q

1 standard for use with power tool cleaning is:

A

SSPC SP11

50
Q

4 examples of tools used for power tool cleaning are:

A 
Rotary wire brushes
Impact tools
Needle scaler
Rotary scaler
Piston scaler
Grinders and sanders
Disc sanders
51
Q

2 abrasive blasting methods include:

A 
Centrifugal blasting
Sand-injected water blasting
Slurry blasting
Wet abrasive blasting
Dry grit (air) blasting
52
Q

Visual standards for abrasive blasting include:

A

SSPC-VIS1

53
Q

SSPC-SP10/NACE2 limits staining to ___ per each unit area.

A

5%

54
Q

SSPC-SP5/NACE1 limits staining to ___ per each unit area.

A

NONE

55
Q

SSPC-SP6/NACE3 limits staining to ___ per each unit area.

A

33%

56
Q

The 2 types of abrasive blasting nozzles include:

A

Straight Bore

Venturi

57
Q

The specified level of surface cleanliness must be achieved and maintained:

A

Immediately prior to coating applications.

58
Q

Advantages of centrifugal blast equipment include:

A

Dust and fines are contained.
Abrasives are recyclable.
Blasting and priming can be done inline operation.
General overall economy.
No compressors, piping, or air handling equipment needed.

59
Q

The inspector’s checklist for surface preparation should include:

A 
Ambient conditions
Conditions of substrate
Pre-blast surface cleanlinesss
Shot/grit size selection
Shot/grit cleanliness
Abrasive blasting equipment
Surface profile
Surface cleanliness after abrasive blasting
Operator qualifications
Safety
60
Q

Abrasive media types include:

A 
Shot/grit metallic
Crushed slag
Ceramic grit
Silica sand
Garnet
Agricultural abrasives
Specialty abrasives
61
Q

Abrasive media typically used for recycling include:

A

Steel shot

Steel grit

62
Q 
List the pressure ranges that categorize:
Low pressure Water Cleaning
High pressure water cleaning
High pressure waterjetting
Ultrahigh pressure waterjetting
A

<34 MPa 5000 PSI
34-70 MPa 5k-10k PSI
70-120 MPa 10k-30k PSI
>210 MPa 30k PSI

63
Q

3 types of water blasting include:

A

Grit Blasting with Shroud
Sand Injected Water Blast
Slurry Blast Grit/Water Mix

64
Q

The visual guide for use with the NACE-SSPC waterjetting standard is:

A

SSPC VIS 4

NACE VIS 7

65
Q

3 test methods for surface profile include:

A

Comparator and Coupons
Replica Tape
Digital Gauge Depth Macrometer (profilometer)

66
Q

Types of soluble salt contamination include:

A

Chlorides
Sulfates
Nitrates

67
Q

If inspection is to be effective with regards to soluble salts, the specification should very clearly state:

A 
Limits to be accepted
Specific salts to be limited
Test method to be used
Frequency of testing
Locations in which tests should be administered
68
Q

Tests for soluble salts include:

A

Bresle Patch
Sleeve Test
Soluble Salt Meters
Conductivity Meters

69
Q

Depth of surface profile can be evaluated by several methods:

A

ISO Comparator
Replica Tape
Digital Profile Gauge

70
Q

The ISO comparator grades may be recorded:

A 
Finer than fine grade
Fine grade
Medium grade
Coarse grade
Coarser than coarse grade
71
Q

2 types of replica tape that are commonly used:

A

Coarse

Extra Coarse

72
Q

List the standards for using the replica tape

A

NACE Standard RP0287
ASTM D 4417
ISO 8503-5

73
Q

When using replica tape, common errors include:

A

Variation in point-to-point profile over the surface being tested
The presence of particles of dirt on either the replica tape or gauge
Gauge accuracy
The rubbing or burnishing technique

74
Q

Goals of a pre-job conference include:

A

Discuss health, safety and environment (HES) Requirements
Address/ clarify emergency procedures
Review and discuss scope of work (SOW)
Review logistical support
Discuss line communications between parties
Review known critical hazards
Establish list of critical point of contacts (POCS)
Discuss and clarify inspector (s) responsibilities and authority
Clarify the chain of command (Reporting System)
Discuss and Clarify areas of concern in the project specification (Omissions, clarifications, testing)
Agree on critical hold points for inspections
Conflict resolution between the inspector and applicator
Change orders

75
Q

People who may be required to attend the pre-job conference include:

A 
Owner
Owners contract manager
Engineer
Specifying Engineer
Operations personnel
Specifier
Purchasing agents
Coatings manufacturer (Preferably tech. service representative)
Coating inspector (s)
Project safety personnel
Coatings applicator (Supervision personnel)
76
Q

Before the start of the pre-job conference, the inspector should obtain a copy of, read, and understand the :

A

Specification
Any standard / Procedure referenced in the project
Manufacturer’s product data sheets MPDS
Safety Data Sheet

77
Q

Documentation may include:

A 
Detailed written daily reports
Inspection logs
Routine Reports
Reports for weekly progress meetings
Daily entries in a project log book
A daily inspection report using standardized forms
Routine Reports
Monthly or quarterly reports
78
Q

Inspection records show:

A 
Environmental conditions
Pretreatment Details
Cleaning details
Materials Details
Coating applications Details
Results of work and all tests
79
Q

Good records allow management to:

A

Detect and tag design defects for future work
Evaluate coating performance
Determine annual cost data on each coating system
Develop ongoing maintenance program

80
Q

Project inspection documentation provides:

A

Inspection (QC) records
Management information
Verification of work performed by the contractor
Details of non-conforming work

81
Q

One guide to enclosures for coatings projects is

A

SSPC Technology Update #6

SSPC Technology #16

82
Q

Low temperature concerns during coatings application include

A

Slow the curing of chemically curing coatings

Increases viscosity

83
Q

High temperature concerns during coatings application include

A

Solvent evaporates too quickly
Pot life decreases
Viscosity decreases
Tired workers

84
Q

High humidity during coating application may

A

Slows solvent evaporation
Leaves moisture on coating surface
Coating reacts to moisture instead of resin causing blushing
May effect gloss or color

85
Q

Coatings may be applied by the following methods

A 
Roller
Brush
Airless spray
Conventional spray
High volume low pressure
Air assisted airlesss spray
86
Q

Coatings Product Data Sheets (coating spec) provide users with the following:

A 
Surface preparation
Storage
Mixing and thinning
Application procedure
DFT requirements
87
Q

SDS contains the following:

A

Provides workers and Emergency personnel with the critical information on composition, handling or working with the substance
Includes information such as MELTING POINT, BOILING POINT, FLASH POINT, TOXICITY, HEALTH EFFECTS, FIRST AID, REACTIVITY, storage disposal, protective equipment, and spill handling procedures.

Provides information regarding the safety issues associated with any hazardous ( or potentially hazard) material

Provides Instructions for the correct action to take in the event of a spill, explosion, fir or hazardous exposure.

88
Q

Non-drying films (failure to cure) may be caused by:

A

Not adding curing agent, Wrong curing agent or incorrect amount of it
Problem with material from the manufacturer
Environmental issues (too cold, hot, or humid)
Wrong or contaminated thinner (Solvent)

89
Q

Some of the problems that can be caused by amine blush are:

A 
Surface tackiness or greasiness
Incomplete curing 
Poor adhesion
Coating Discoloration
Poor gloss rentention
90
Q

Runs, sags, and wrinkles may be caused by:

A 
Applying the coating too thick
Too much or the wrong thinner used
Surface too hot to apply the coating 
Application of coating at the end of its pot life
Wrong thixotrope used in manufacturing
91
Q

____ is a powdery, friable layer on the surface of a coating that is most common with epoxy coatings.

A

Chalking

92
Q

Cratering may be caused by:

A

Air trapped in the coating and forming a bubble which then bursts
Air trapped in the coating during mixing if the proper procedures are not followed

93
Q

Voids are typically caused by:

A

Running the mixer too fast

94
Q

Pinholes are:

A

Very small holes in a coating typically cause by air or solvent trapped in porous film and escaping.

95
Q

A common cause of blistering is:

A

Surface contamination under the applied coating

96
Q

Cracking of a coating is noted:

A

When the crack extends to the substrate.

97
Q

Checking can be described as:

A

Fine cracks in the surface of a coating that don’t extend through the substrate

98
Q

Adhesion failures may be caused by:

A 
11/11
Fine cracks in the surface of a coating that don't extend through the substrate
Checking can be described as:
Contamination on the surface
Wrong surface preparation specified
Failure to inspect surface preparation
Insufficient surface profile
Exceeding the topcoat window
Application of incompatible coatings
99
Q

General types of holiday detectors include

A

Low-voltage DC
High-voltage DC
High-voltage Pulse DC
High-voltage AC

100
Q

Low voltage (wet sponge) holiday detectors are powered by a battery with output voltages ranging:

A

5 to 120 V DC

101
Q

Descrive low voltage (wet sponge) holiday detectors:

A

Wet sponge detector
Sensitive, low voltage
Ground cable
5-120V DC Battery

102
Q

High voltage DC holiday detector types include:

A

DC Pulsed

DC Constant Current

103
Q

Describe high voltage DC holiday detectors

A

Ground cable to metal or ground
800 to 6k volts
Constant current for dielectric coatings
Pule current for moist conditions

104
Q

What is a standard?

A

An established norm or requirement that is written by industry professionals
A formal document that establishes uniform engineering or technical criteria, methods, processes and practices

105
Q

What percentage of NACE standards relate to coatings?

A

50%

cip (2 decks)

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