NACE CIP Level 2 Flashcards
__________ is the formation of a protective oxide film on the surface reducing its chemical activity and its ability to corrode.
Passivation
How does oxygen affect corrosion?
Oxygen increases the rate of corrosion.
How does temperature affect corrosion?
Corrosion is usually accelerated with increasing temperatures.
How does chemical salts affect corrosion?
Chemical salts increase the rate of corrosion by increasing the efficiency of the electrolyte.
How does humidity (or wetness) affect corrosion?
The wetter the environment, the more likely corrosion is to occur.
How does pollutants and acid gases affect corrosion?
Acid rain, chemical byproducts, and chlorides all promote corrosion.
What are two broad categories or corrosion described as?
Generalized
Localized
__________ is an electrochemical action of two dissimilar metals in the presence of an electrolyte and an electron conductive path, which occurs when dissimilar metals come into contact.
Galvanic corrosion
__________ is the reduction or elimination of corrosion by making the structure to be protected a cathode by means of an impressed current or attachment to a galvanic anode.
Cathodic protection
Impressed current power sources include:
Generators
Solar Cells
Rectified commercial power
Fuel cells
Thermoelectric cells
Wind-powered cells
__________ is the separation of the coating from the surface through hydroxyl (OH-) formation due to increased (made more negative) potential.
Cathodic disbondment
__________ is the process of removing moisture vapor from the air to lower its dew point.
Dehumidification
When planning enclosures, what minimum requirements should be considered?
Must be large enough to contain the whole work area.
Not be larger than the performance capabilities of the dehumidification equipment.
Be sturdy enough to hold up to intended work activities, potential loads, and possible inclement weather.
Have minimal leakage to maintain proper environmental conditions and ensure the dehumidification system operates efficiently.
What does the air turnover principle do?
Eliminates air stratification, or layering, in large open spaces by recirculating the hot air that becomes trapped in the higher spaces.
What is an “air turn” considered?
The number of times air turnover principle occurs per hour.
At what relative humidity does corrosion virtually cease?
At and below 40%.
What are two ways to reduce the relative humidity of the boundary layer?
Increase the surface temperature.
Reduce moisture content by dehumidification.
What are two types of dehumidification equipment?
Refrigeration
Desiccant
What are some benefits of dehumidification?
Dries the air.
Lowers the dew point.
Permits blasting the entire surface.
Holds the blast with dry air.
Helps in cleaning the surface.
Holds the surface during coating application.
What are some general basic centrifugal blast setups?
Tumbling mill
Multi table
Plan table
Swing Table
Custom designed systems
What are centrifugal blasting conveyor systems commonly used to clean?
Plate
Rolled structural shapes
Large trusses
Girders
What are portable centrifugal blasting systems used on?
Ship decks, hull sides, and bottoms
Storage tanks
Concrete floor
Highways and bridge decks
What elements generally compose a centrifugal blast system?
Centrifugal abrasive throwing wheel
The blast cabinet (or enclosure)
In fixed systems, some type of material handling system
Abrasive recycling system
A dust collector and vent-pipe system
Abrasives
What are some efficiency factors that centrifugal blast wheels depend on?
Abrasive operating mix
Size of the abrasive
Velocity of the abrasive coming off the wheel
Quantity and direction of the thrown abrasive
Condition of the feed parts
What could low amperage readings on a centrifugal blasting machine signify?
An abrasive-starved wheel
A flooded or choked wheel
What are the functions of a centrifugal blast machine separator?
To control the sizing of the abrasive mix
To remove sand, spent abrasives (fines), rust, dirt, and any other contaminates from the abrasive stream.
To control abrasive consumption.
A well-balanced operating mix (working mix) of abrasive sizes will:
Provide consistency of the finish
Ensure uniform abrasive coverage
Ensure conditioning of the abrasive for optimum cleaning
Minimize lowest abrasive and machine part-wear and reduce downtime for maintenance
Some of the inspection concerns during centrifugal blasting include:
Monitor the dust collector
Monitor the amperage of the wheel motors/ low amperage
Monitor the handling and loading of the conveyor line for contaminates/ possible discontinuities in the steel
Monitor the speed of the line
Inspect the steel as it leaves the production line
The WJ-1 (visual cleanliness) is compared to which abrasive blast cleaning standard?
ISO SA 3
A general description of robotic weterjetting includes:
Attached using vacuum, cables, or magnets
Vertical, horizontal, or overhead surface
Controlled by single operator
Collects in excess of 95% of the water, removed coatings and rust (waster generated)
A typical waterjetting team consists of:
The nozzle operator
The pump operator
Additional operators of workers
Waterjetting is effective for removing:
Surface oil and grease
Rust
Concrete (shot-crete) spatter
Existing coatings
Water-soluble contaminates that cannot otherwise be removed by abrasive blasting
An underwater unit used to clean barnacles or other micro-organisms for ship hulls or off-shore platform legs
Describe two of the considerations with regards to “back thrust”:
Causes fatigue
Should be no more than 1/3 of the operators body weight
To ensure a safe work place, before commencing the job, the waterjet team should ensure that:
The work area is properly barricaded
Electrical equipment protected from the water
Electrical connections are not allowed to sit in water
All fittings and hoses are in good condition/ proper pressure rating
Nozzles are free of obstructions
System is flushed clean and air removed
The dump system and all control systems are operational
Proper LOTO provisions/ confined space entry requirements
Waterjetting advantages include:
Worker safety
Worker air quality
Respiratory requirements may be less stringent
No dust contamination or clean up
Friendly to the environment
Relatively cost efficient
It requires less clean up
Disadvantages of waterjetting include:
The surface must have a profile (waterjetting leaves no profile)
Equipment is very expensive
Danger of UPH hose breaking
Danger of injection into the skin or serious cuts
Collecting and disposing of the contaminated water
Proficient operators
Some of the most common hazards associated with specialized application are:
Fumes and dust inhalation
Electrical shock
Burns
Falling objects
Explosions
Environmental contamination
Thermal spray safety practices for operators include:
Use hoses rated for high pressure
Never clean powder off equipment or clean spray cubicles with compressed air
Do not use compressed air to clean clothing
Do not supply plant compressed air to a breathing apparatus
__________ is a word used to describe a coating that is normally used in immersion service.
Lining
Some resins used in reinforced linings include:
Polyester
Epoxy
Vinyl Ester
The main feature that reinforcing adds to a resin is __________.
Strength
What is a negative effect of reinforcing resin?
The negative effect reinforcing has on a resin is the ability of a liquid to travel along the fibers path (wicking) and cause corrosion to the substrate, blisters or delamination of the system.
What is the purpose pf antifouling (AF) paints?
The purpose of antifouling (AF) paints is to either make the hull of the ship so distasteful the larva of the biofouling reject it as a home or they make the hull so slick the larva cannot adhere.
What are the three main types of antifouling paints?
Ablative
Self Smoothing
Foul Release
What are the two types of fireproof coatings?
Cementitious
Intumescent
What type of coating is made of lightweight cement and can be applied several inches thick?
Cementitious
What coating is a substance that swells or bubbles up as a result of heat exposure, thus increasing in volume, and decreasing in density.
Intumescent
__________ coatings are best known for their non-stick feature and also have excellent chemical and high temperature resistance.
Flourpolymer
What two broad curing categories do powders fall into?
Thermoplastic
Thermosetting
What materials soften when heated and return to their original hardness when cooled?
Thermoplastic
What materials harden when heated and retain their hardness when cooled?
Thermosetting
What are the four stages when powders are applied to a heat source?
Flow stage
Wetting stage
Gel stage
Curing stage
This stage occurs when the particles of powder begin to flow, but are not fully liquid.
The flow stage
This stage occurs when the particles of powder absorb more heat, fully liquefy, and wet the surface.
The wetting stage
This stage occurs when the particles of the powder begin to gel, converting into a solid.
The gel stage
This stage allows for further changes to take place, permitting the powder to cure completely.
The curing stage
What are the advantages of plural component airless spray over single piston airless spray systems?
Accurate mixing of materials without human element
Ability to spray very thick solvent free materials without thinner
Ability to spray materials with very short pot life
What are the disadvantages of plural component airless spray compared to single piston airless spray systems?
Cost is much higher than cost of a single piston pump
Higher education requirement for the mechanic
High voltage electricity is required for the heaters
Applicator’s job is more difficult with multiple hoses
What are the two major classes of rubber?
Natural
Synthetic
What are the characteristics of natural rubber?
Derived from latex obtained from Hevea trees and is coagulated with acetic or formic acid.
Unsaturated hydrocarbon known as polyisoprene.
What are the characteristics of synthetic rubber?
Any one of a group of manmade elastomers with one or more of the properties of natural rubber.
__________ is a physicochemical (physical and chemical) change resulting from the cross-linking of the unsaturated hydrocarbon chain of rubber (polyisoprene) with sulfur, and the application of heat.
Vulcanization
Three factors affect the properties of the vulcanizate (vulcanized product):
Percentage of sulfur and accelerator used
Temperature of the curing process
Time of cure
What are some methods to cure (vulcanize) rubber?
Autoclave (vulcanizer) cure
Internal steam cure
Atmospheric steam cure (also called exhaust steam cure)
Hot-water cure
Chemical cure
What are the three categories of natural rubber?
Soft
Semi-hard
Hard
A __________ lining construction is used to form a sandwich which is semi-hard, or hard, rubber between two layers of soft rubber.
Tri-Ply
What are some types of synthetic rubber?
Butyl rubber
Neoprene rubber
Nitrile rubber
Chlorobutyl rubber
Hypalon types
What are some causes of failure when using rubber linings?
Incorrect product selected for the intended service.
Using rubber after the shelf life has expired.
Using rubber lining that was not properly stored. Rubber must be kept cool in storage because, with heat, it can vulcanize on the roll. If this occurs, the material should be discarded.
Incorrect application process.
Inadequate cure.
What are three methods for applying polyethylene?
Melting the resin and extruding in onto the surface of the article
Heating the work piece and then immersing in into a fluidized bed
Flame spraying
This document applies collectively to codes, specifications, recommended practices, classifications, test methods, and guides, which have been prepared by a standards developing organization or group, and published in accordance with the established procedures.
The Standards Engineering Society (SES)
__________ are standards established generally by private-sector bodies and that are available for use by any person or organization, private or government.
Voluntary standards
__________ are standards that require compliance because of a government statue or regulation, an organization internal policy, or contractual requirement.
Mandatory standards
What is used to refer to the one-per-country standardization organization which is that country’s membership to International Organization for Standardization (ISO)?
National Standards Body (NSB)
What is used to refer to the thousands of industry or sector-based standards organizations that develop and publish industry specific standards.
Standards Developing Organization (SDO)
What are the three NACE standards classifications?
Standards Practice (SP)
Test Method (TM)
Materials Requirement (MR)
What are some properties of concrete?
Extremely durable
Inorganic
Hard
Has good compressive strength
Improves with age
Concrete cures with a process called __________.
Hydration
Poured concrete can be affected by:
Ambient conditions
Vibration
__________ is the process of spraying or slinging shotcrete onto a surface as a coating to restore concrete to its original grade.
Guniting
What are some reasons to coat concrete?
Decoration
Waterproofing
Enhancing chemical resistance
Protection from freeze-thaw cycles
Protection of reinforcing steel
Decontamination
Surface sealer
Protection against abrasion and erosion
Color coding
Protecting purity of water or other products contained
Improving and simplifying cleaning
Skid resistance
__________ is a weak surface layer of water-rich cement mixture on the surface of fresh concrete caused by the upward movement of water.
Laitance
__________ is caused by moisture passing through the concrete and carrying soluble concrete salts with it to the surface. The salts react with carbon dioxide in the atmosphere creating a fluffy white crystalline deposit on the surface.
Efflorescence
Surface preparation is generally performed on concrete by:
Abrasive blast cleaning
Hand and power tool cleaning
High-pressure water-jetting or blasting
Acid etching
Stoning
Centrifugal blasting
Scarifying
__________ is the Joint Surface Preparation Standard for Surface Preparation of Concrete.
NACE No. 6/ SSPC-SP 13
What are the advantages to waterjetting and wet abrasive blasting concrete?
Fast cutting of the surface
Washing dust away
Reducing abrasive and concrete particles in the air
__________ consists of scrubbing a mixture of cement mortar over the concrete surface using a cement sack, gunny sack, or sponge rubber float.
Sacking
__________ is similar to sacking, except that a carborundum brick, or other appropriate block, is used to smooth the surface of the concrete.
Stoning
Several generic types of coatings may be used over concrete including:
Bituminous cutbacks
Chlorinated rubber
Vinyl
Epoxy
Novalac epoxy
Elastomeric polyurethane
Sheet materials (e.g., rubber)
Glass-fiber reinforced plastics
Furan resins
What are some tests to determine the presence of moisture in concrete?
ASTM D 4263, Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method
ASTM F 1869, Calcium Chloride Test
Electronic Testing: Concrete Moisture Meter
__________ is the Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method.
ASTM D 4263
__________ is the Calcium Chloride Test.
ASTM F 1869
In pipeline mainline and filed joint coatings, construction materials may include, but are not limited to:
Steel
Aluminum
Stainless
Plastic
Typical plant-applied or mainline coatings include:
2-Layer PE
3-Layer PE
Fusion bonded epoxy
Tapes
Coal tar enamel
Asphalt
Insulated
Concrete
Polyethylene (PE) can be extruded by:
Side extrusion for large diameter pipe
Crosshead extrusion
Common characteristics of FBE include:
Typically green or red and looks like a “painted” finish
May be a single layer or a two-layer “dual power”
DFT from 250 and 500 microns (10 to 20 mils)
The FBE application process includes:
Preheating the pipe
Grit or shot blast the area to NACE No. 2/ SSPC-SP 10
Optional: pre-treat the area with an acid bath
Heat the pipe to the specified temperature
Apply the FBE coating
Curing the FBE coating application
Quench the coating in a fresh water bath
Stencil
What are the advantages of coal tar enamel pipeline coatings?
Ease of application
Long life in some environments
What are the disadvantages of coal tar enamel pipeline coatings?
Subject to corrosion and damage from soil stress
Environmental and exposure concerns
Use of coal tar is regulated in some locations
The general application process for coal tar enamel includes:
Prime the pipe
Apply coal tar enamel dope
Wrap the application with glass fiber mat
Apply a second layer of CTE dope
Wrap the application with a second layer of glass fiber mat
Apply an outer wrap of coal tar impregnated glass fiber felt
Cool the application
Concrete coating characteristics include:
Used in conjunction with other coating such as FBE
Used to reduce buoyancy so the pipe will sink
Can be applied in many thicknesses
Can be applied to any diameter of pipe
Pipeline coating field joints include:
Heat shrink sleeves
Insulated half shells
Field foam
Liquid epoxies
Cold applied tapes
Hot applied tapes
FBE field joints
Petrolatum (wax) tapes
Non-destructive tests for heat shrink sleeves include:
Visual inspection
Physical inspection
Holiday detection
Destructive tests for heat shrink sleeves include:
Holiday detection (if the voltage is set too high)
Peel test. A 25 mm (1”) wide strip cut, peeled from the pipe
The following materials can be used to repair FBE:
Epoxy FBE melt sticks
Liquid epoxy
Repair patches
Heat shrink sleeves
What are some common reasons wood might be painted?
Decoration
Protection
Sealing
Stabilization
Preservation
Flame retardance
Non-ferrous substrates include:
Stainless steel
Nickel
Copper/ nickel alloys
Aluminum
Aluminum bronzes
Copper
Bronzes
Brass
Tin
Cadmium
Lead
Magnesium
Zinc (includes hot-dipped galvanized and thermal spray)
What are some special substrates that have tightly adherent oxide films?
Stainless steel
Nickel
Tin
Cadmium
__________ __________ __________ are defined as applying coatings over a substrate that has been installed in its final environment and has been placed in service.
Maintenance coating operations
The life cycle of a coating system can be affected by:
The steel in question Costs The service atmosphere Product Maintenance
When determining the coating system life cycle, the following should be considered:
The particular coating system to be used
The initial cost
Time until first maintenance coating will be applied
Maintenance cost during the life of the coating system
The length of time the product will last
The maintenance cost per year
The cost over the life of the system
Maintenance coating selection process should take the following into consideration:
Compatible with the existing coating system
Condition of the existing coating
Limitations on surface preparation
Manufacturer’s recommendation
With regards to maintenance coatings, all parties should agree on:
Spot repair requirements
Feathering
Appearance of repaired areas
__________ is performed at the repaired area by working the edges of the repaired area back, to achieve a fairly smooth transition from the repair area to the sound coating.
Feathering
If a maintenance coating to be applied is incompatible with the existing coating system, __________ may occur.
Curling
Some service situations in which permeation may occur include:
Sour crude storage tanks
Cooling towers
Fertilizer
__________ __________ is the process of coating iron or steel with a thin zinc layer, by passing the steel through a molten bath of zinc at a temperature of around 820-860 F (460 C)
Hot-dip galvanizing
The usual galvanizing coating consists of three distinct iron-zinc compounds:
Gamma - 75% zinc and 25% iron
Delta - 90% zinc and 10% iron
Zeta - 94% zinc and 6% iron
Eta (outer layer) - 100% zinc (not considered a separate layer)
What is considered “Gamma” when galvanizing?
75% zinc and 25% iron
What is considered “Delta” when galvanizing?
90% zinc and 10% iron
What is considered “Zeta” when galvanizing?
94% zinc and 6% iron
What is considered “Eta” when galvanizing?
Outer layer - 100% zinc (not considered a separate layer)
A few safety issues the inspector should know when working around hot dip galvanizing are:
Hot-dipped articles stay hot and to make sure the article is cool before touching it.
Molten metal can splash out of the kettle and travel some distance.
Nascent hydrogen may burn off in the air.
What are some major stages in the hot-dip process?
Surface preparation
Fluxing
Dipping
Post treatments
Inspection
When __________ __________, the steel is immersed in a caustic solution to remove the dirt, oil, and grease from the surface of the steel.
Caustic cleaning
When __________, the item i immersed in a tank filled with either hydrochloric or sulfuric acid, which removes oxides and mill scale.
Pickling
The __________ ___________ is typically operated at a temperature ranging from 820-860 F (438-460 C)
Galvanizing kettle
What type of surface depends on friction to hold the structural elements in place and should not be hot-dip galvanized, because the treatment greatly reduces the possible coefficient of friction between the surfaces.
Faying
What are the different methods of thermal spray application?
Flame spraying
Arc spraying
Plasma spraying
High-velocity oxyfuel
A _________ __________ is a task performed in an organized, rational manner on assets (bridge, oil rigs, chemical plant, refinery, paper mill, etc.) that have been previously painted/ coated to gather information on the performance of the installed protective coating system.
Coating survey
What are some of the primary reasons surveys are performed?
Aid in planning future maintenance
Work prioritization
Budgetary purposes
Aid in determining asset’s value
Legal compliance
What are the two categories of curing?
Non-convertible
Convertible
What is non-convertible curing?
No chemical change occurs during the cure cycle.
What is convertible curing?
Some chemical change occurs during the cure cycle.
What are some examples of non-convertible coatings?
Chlorinated rubber
Vinyl coatings
Acrylic coatings
Bituminous coatings
What is a polymerization cured coating?
Coatings that cure through a chemical reaction.
What are some examples of convertible cured coatings?
Alkyds
Epoxy coatings
Polyester/ vinyl ester coatings
Polyurethane
Polyureas
Silicone coatings
Inorganic zinc
What is the cause of chalking on an epoxy coating?
Caused by exposure to UV (sunlight) and other radiation.
When using solvent borne inorganic zinc, what would be one common reason for failure to cure?
Low humidity, these coatings cure by solvent evaporation and chemical reaction by absorption of moisture from the surrounding atmosphere.
Handheld electronic hygrometers can be used __________?
After stabilization in accordance with the manufacturer’s requirements.
Standalone data loggers have the following characteristics:
Automatically measure and store environmental conditions.
May have alarms when conditions are not met.
Could be some handheld hydrometers with special attachments.
The pH of a solution that is between 0.0 and 6.5 is considered to be __________?
Acidic
You are the inspector of a project that requires the use of a pH meter. What steps are required to assure the owner that the results given are accurate?
Calibration of instruments.
Verification of calibration and buffer solution.
You are the inspector on a project where bronze is the coated substrate. To determine the DFT nondestructively you would use which of the following gauges?
Eddy current
Ultrasonic DFT gauges are designed to measure the film nondestructively by sending _________?
A sound pulse through the coating.
Moisture meters would commonly be used to determine the moisture content in __________?
Concrete
Plaster
Wood
What standards are most commonly used for the determination of dry film thickness (DFT) of coatings on concrete by ultrasonic gauges?
ASTM D6132
SSPC PA 9
Which of the following materials are likely to be used to check moisture content in concrete?
Plastic Sheet
Holiday detection of fusion bonded epoxy, having a DFT of less that 500 microns (20 mils) is most commonly performed using __________?
High voltage DC holiday detection.
According to ASTM D 3359, Method B (Crosshatch) can be performed on coating thickness of __________?
2 Mils (51 Microns)
4 Mils (102 Microns)
DFT measurements by destructive means (ASTM 4138) requires the use of which of the following?
Tooke Gauge
Saberg Drill
ASTM D 4752 is a destructive test to determine the curve of ethyl silicate inorganic zinc by rubbing the surface with __________?
Fifty (50) double rubs using methyl ethyl ketone (MEK)
When applying an adhesion dolly to a painted concrete surface, you should be sure to __________?
Remove excess adhesive.
The solvent sensitivity test ASTM D5402 can be used to determine cure for which coating?
Epoxy
Which test determines a coatings resistance to indentation or impression?
Durometer
You are the inspector on a project where a coating failure has occurred and the owner is asking for samples. What collection procedures would be important to follow?
Identification of material to be analyzed.
Chain of custody process.
PDS and SDS of material being shipped.
Which laboratory instruments analyzes the composition of an organic coating binder?
Infrared Spectrophotometer (FTIR)
Electronic hydrometers can be used to determine:
Relative Humidity
Air Temperature
Dew Point Temperature
Advanced environmental testing instruments have the ability to store data that can be transferred to a computer and other devices. Transfer methods include:
USB
IR (infrared)
Bluetooth
What ASTM is the Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method?
ASTM D 4263
A segment of a 1.0mm (4.0 Mil) thick, clear polyethylene sheet approximately 457 x 457 mm (18 x 18 in.) is taped over the concrete to be tested so that the concrete is tightly sealed from the atmosphere and sunlight. The test patch is allowed to remain for a minimum of 16 hours. What ASTM is this?
ASTM D 4263, Standard for Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method.
Who produces a set of comparator plates for various surfaces of prepared concrete?
International Concrete Repair Institute (ICRI)
DFT of coating on concrete can be measured by:
Estimated from WFT
Estimated from quantity of coating used.
Verified by paint inspection gauge (Tooke)
Determined by a modified gauge based on ultrasound.
What standards are used for dry film measurement of coatings over concrete?
ASTM D6132-97 Standard Test Method for Nondestructive Measurement of Dry Film Thickness of Applied Organic Coatings over Concrete using an Ultrasonic Gauge.
SSPC PA9 Measurement of Dry Coating Thickness on Cementitious Substrates
What ASTM is the Standard Test Method for Nondestructive Measurement of Dry Film Thickness of Applied Organic Coatings over Concrete Using an Ultrasonic Gauge?
ASTM D6132-97
What SSPC is the Measurement of Dry Coating Thickness on Cementitious Substrates
SSPC PA9
Describe the proper safe operating procedure for a low voltage holiday detector.
Ground cable is attached directly to the substrate.
Sponge saturated with a solution of tap water/ wetting agent.
Minimum rate of 30 cm/s (1 linear ft/s) double stroke.
Used on coatings up to 20 Mils.
May be used on concrete.
What are some of the errors that may occur while using a high voltage DC holiday detector?
Failure to keep the probe in contact with the surface.
Moving the electrode too quickly or slowly.
Lack of display (low battery or bad/ missing fuse).
Continuous alarm due to damp surface or quick movement.
No alarm due to low voltage/ sensitivity settings.
No spark due to a lead or connection failure.
These tests are accelerated procedures to determine the comparative degree to which the tested coating may be loosened from the substrate, or may develop holidays as a result of the action of normal soil potentials and/or impressed current cathodic protection?
Cathodic Disbondment
List some of the specialized test or equipment that may be encountered by the coating inspector, particularly if involved in the investigation of coating failures/
Atomic Absorption/ Emission (AA/AE) and Induction Coupled Plasma (ICP) Spectrophotometers.
Gas Liquid Chromatogrpahs (GLC)
Infrared Spectrophotometers (IR and FTIR, and FTIR-ATR)
Differential Scanning Calorimeters (DSC)
What information should be included when providing a sample for the laboratory?
The identity of the materials to be analyzed.
The inspector should ensure that the samples are properly packed and labeled. A chain of custody form should accompany the samples. A copy of this should be retained by the inspector.
The type of analysis required.
Expected concentrations of concentrations of interest.
The principle component of mild carbon steel __________?
Iron (Fe)
The formation of a thin surface layer on metals, whether an oxide, carbonate, or other compound, that slows the rate of corrosion process is called?
Passivation
Which is the part of a corrosion cell where metal dissolves?
Anode
Which of these elements is likely to accelerate corrosion on a steel structure?
Salts
High Temperatures
Pollutants
In a cathodic protection system the metal being protected is the __________?
Cathode
When parts of a metal surface are shielded from full exposure to the environment because of the close proximity of another metal, corrosion at that location is identified as __________?
Crevice Corrosion
Cathodic protection using impressed current is most commonly used on __________?
Pipelines
Impressed current systems anodes include ________?
Graphite
High Silicon Cast Iron
You are the coating inspector on a project with dehumidification provided by a rotating bed type dehumidifier. The silica gel has become contaminated. What do you expect to happen with the silica gel?
It can no longer absorb moisture.
What effects does the rotating bed dehumidifier have on on the treatment of ambient air?
It is heated and the humidity is decreased.
In a centrifugal blast operation, the degree of cleanliness is determined primarily by __________?
Speed of travel
Which of the following are advantages of portable centrifugal blast cleaning?
Can be used for multiple substrates.
Dust can be collected for disposal.
Abrasives can be recycled.
Which of the following are abrasives that can be used in centrifugal blast units?
Steel Shot/ Grit
Glass Beads
Garnet
Walnut Shells
When compared to abrasive blast cleaning, which of the following are advantages of waterjetting?
Typically less stringent respiratory protection required.
No abrasive waste disposal requirements.
The waterjetting standard allowing for the least amount of contaminates is:
NACE WJ-1 / SSPC-SP WJ-1
What are the flash rust designations for waterjetting?
No flash rust;
Light;
Moderate; and
Heavy.
When viewing NACE WJ-2 / SSPC-SP WJ-2 - Very Thorough Cleaning, the allowable tightly adherent thin coatings that can remain on the surface after preparation is:
5%
When using UHP waterjetting with an inhibitor, the steel surface after cleaning will appear __________?
A dull matte finish.
Waterjetting can be an effective method for __________?
Removing Rust
Cleaning Pits
Removing Barnacles
As the coating inspector on a high pressure waterjetting project, what safety gear would you expect to see?
Metatarsal Guard
Whip Lock
Hose Shroud
What cleaning method uses water at pressures from 34 to 70 MPa (5,000 - 10,000 PSI)?
High Pressure Water Cleaning
You are a new inspector on a UHP waterjetting project. What is the typical distance between the waterjetting tip and surface that you would expect to see?
2 inches (5 cm)
Which of the following are some of the physical dangers in application of polyester coatings?
Central nervous system damage.
Skin and respiratory irritation.
Damage to the eyes.
Brass chills are most commonly associated with which process?
Thermal Spray
What is one of the most common safety risks associated with electrostatic spray application?
Electrocution/ Burns
Thermosetting materials are materials which ___________?
Harden when heated and retain their hardness when cooled.
The feed mechanisms for a plural component spray unit are where the __________.
Components are blended in a manifold and mixed in a static mixer.
Components are mixed at the spray gun tip.
Which of the following are common methods for the electrostatic application of liquid or powder coatings?
Post atomization charging
Direct charging
Tribo charging
You are the inspector on a project where the application is required on a large surface consisting of 200 radiators, connected and stacked 1” (25 mm) apart. The configuration will not allow a dip process, so the most logical application would be __________?
Flood and flow coating.
The basic function of fireproofing is __________?
Providing temporary protection to living or work spaces.
Bio-fouling of the submerged portion of ships in minimized through the application of __________.
Ablative coatings.
Self-smoothing coatings.
Which of the following components are contained in powder coatings?
Pigments.
Resin/ Binder.
Flow control additives.
You are the inspector on a project that requires coating the internal of 4 in (10 cm) diameter piping. The owner asks for an example of an application process for coating the internals. What would be the best choice?
Centrifugal Spray
The benefits of electrostatic spray over conventional spray are __________.
Produces somewhat thicker coatings on sharp edges.
Transfer efficiency improved.
Coating materials that soften when heated and return to their original hardness when cooled are known as __________?
Thermoplastic materials
What are the most common curing methods for a field applied natural rubber lining project?
Atmospheric steam or internal steam.
Which component cross links with the natural rubber giving a physicochemical change that makes the rubber harder?
Sulfur
Typically polymeric sheet materials are __________.
Thermoplastic
Heat welded together at seams
Primed with suitable adhesive
The formal process in which a standard is changed or updated is __________.
Change Control
You will inspect a project in 6 months’ time where the requirements of a consensus standard is being interpreted differently by the various parties. What would be the best course of action to resolve the matter?
Request interpretation from the originating organization.
The standards produced by NACE international are considered to be __________.
Consensus Standards
Cement mortar coatings have prevented reinforced steel from corroding when when subjected to which solution?
Potable Water
Concrete cures by which process?
Hydration
Many grades of steel are passivated by concrete when the pH of the concrete reaches _________.
> 11.5 (greater than 11.5)
The term Gunite refers to:
Shotcrete Application
What type of coating has a long history of successful application nd use in swimming pools?
Chlorinated Rubber
What is the joint abrasive blasting standard for the surface preparation of concrete?
NACE 6/ SSPC SP-13
Linings are applied to the inside of pipelines in order to __________.
Maintain product purity.
Reduce resistance to flow.
All 2-layer polyethylene (2LPE) applies directly to steel with a __________.
Black mastic (asphalt and rubber) adhesive applied beneath the polyethylene (PE)
You have taken an assignment as a coatings inspector on a pipeline being installed in your locality. The mainline sections of the pipe have already been coated in the fabrication facility. To ensure the field joint coatings are properly applied you will need to know which of the following?
What mainline coating was originally applied.
The field joint coating specified.
Which coating is in limited use due to environmental and exposure concerns?
Coal Tar Epoxy
What is the most common application method for Petrolatum (wax) tape on a pipeline?
Hand
Inspection considerations for heat shrink sleeves include which of the following?
Ensure the sleeve is in full contact with the pipe.
Ensure there is adhesive flow-out beyond the sleeve edge.
Holiday detection at proper voltage.
Liquid applied epoxy coatings for pipelines typically require that you ensure which quality control steps?
Pre-cleaning surface to remove contaminants.
Surface preparation conforms to the specification.
Ensure mixing per the manufacturer’s recommendations.
You are the coating inspector on a pipeline project where field applied foam will be used for insulation. Which of the following are quality concerns regarding the cutback?
Squared cutback edges.
Cutting into the anti-corrosion coating.
Minimum overlap at joints.
You are the coatings inspector on a project where stainless steel is the substrate. What challenges should you anticipate in the process?
A smooth surface that needs to be abraded.
Dirt, oil, or grease.
A protective oxide.
On which substrate would you expect to encounter tightly adherent oxide film?
Anodized Aluminum
Which of the following are some primary reasons for coating wood?
Decoration
Flame Retarding
Sealing
Which substrates should be protected from contact with highly alkaline materials?
Zinc
Aluminum
Lead
You are the inspector on a project that is planning for repairs and overcoating an existing structure before any work is performed what pre-inspection challenges might you look for?
Blistering
Loss of adhesion
Under-film corrosion
Contaminants such as chalking, oil, grease, and dirt
You are called to inspect a project where the existing coating system is unknown. It is good practice to __________ prior to the overcoat process.
Evaluate the adhesion of the existing coating.
Attempt to determine the existing coating composition.
Remove contaminates and abrade surface.
The process of working back or “sanding” the edges of existing coatings to achieve a “fairly” transition to the sound coating is called __________.
Feathering.
Which of the following are elements of a good maintenance coating operation?
Pre-job inspection
Surface preparation
Application
Inspection and reporting
The major surface preparation steps for hot dipped galvanizing include which of the following?
Solvent cleaning by caustic immersion.
Acid pickling by hydrochloric or sulphuric acid.
Annealing is a term used to define the process of __________.
Of converting the galvanized coating into an alloy.
You will be the inspector for a hot dipped galvanized project. Which of the following are likely reasons for rejection of the galvanized material?
Gross dross protrusions
Gross ash inclusion
Gross flux inclusion
The development of a dull gray appearance in freshly hot-dipped steel often occurs as a result of?
High silicon steels.
What is a method of applying zinc to metal substrates by heating the object in an air-tight container with zinc powder?
Sherardizing
In the protective coatings industry, the application method known as thermal spray metalizing is which of the following?
Spraying molten metal on substrates.
Thermal sprayed coatings are most typically applied to __________.
Iron (steel)
Which thermal spray application method applies a film with the least porosity?
High-velocity oxyfuel (HVOF)
Which standard defines the minimum level of surface cleanliness for thermal spray coatings in atmospheric exposure?
NACE 2/ SSPC-SP 10 or ISO 2 1/2
Which of the following are primary reasons for performing coatings surveys?
Provide budget information.
Prioritize the coating work.
Meet legal compliance guidelines.
Plan the meeting process.
A coating film that involves a chemical change within the resin/ binder during curing is called a __________.
Convertible Coating
Which resin type is commonly blended with other resin types because of its excellent resistance to UV degradation?
Acrylic
Coatings that cure by chemical reaction yet are package in a single container are?
Alkyds/ Oil Enamels
Moisture Cured Urethane
Which of the listed coatings failures is common to both convertible and non-convertible coatings?
Incorrect Film Thickness
Pure silicon coatings typically require a two-step cure process where the first step is solvent evaporation. What is the second step?
Heat (fusion) curing
