Visual Inspection Categorisations

Table 1: Categories of coating breakdown and metal loss for carbon steel
Category 99 0 1 2 3 4 5 Description Unknown / Unobserved Coating intact and in good order Coating intact though aged Coating intact but some spots or small stains Substantial topcoat breakdown no exposed substrate. Coating loss, substrate exposed. Substrate corrosion evident Thin brittle sheets or loose powdery deposits, easily removed by hand wire brushing. No hard tenacious scale. Metal loss estimated to be < 0.5 mm Brittle layered sheets or discrete scabs and carbuncles, difficult to remove completely by hand wire brushing. 7 Metal surface is likely to have areas of wastage whose severity may not be obvious before cleaning. Metal loss estimated to be 0.5 to 2 mm Brittle layered sheets or discrete scabs and carbuncles, difficult to remove completely by hand wire brushing. 8 Metal surface is likely to have areas of wastage whose severity may not be obvious before cleaning. Metal loss estimated at more than 2 mm Thick adherent scale, fractured because volume of corrosion product is ~7x that of the metal consumed. Usually requires a chipping hammer to remove. Considerable wastage may be anticipated. Significant Corrosion Significant Corrosion Risk assess. Remove scale and measure metal loss. Record estimate of metal loss. Classification Not seen Coating condition acceptable Coating condition acceptable. Coating loss only, no corrosion evident. Coating loss only, no corrosion evident. Coating loss only, no corrosion evident. Superficial corrosion Recommended Inspection Action Reported as such None None Record degree of coating breakdown Record degree of coating breakdown Record degree of coating breakdown Scrape back coating to establish if there is measurable metal loss Scrape back coating and/or scale to confirm metal loss is less than 0.5mm

Superficial corrosion

Assess risk before removing scale to measure metal loss. Carry out radiography to determine wastage if necessary. Record estimate of metal loss.

Severe Corrosion

Conduct Radiography immediately. Initiate remedial work upon confirmation of findings.

Bolting condition 0 Not visible, hidden by insulation 5 Coating condition acceptable 6 Coating breakdown with superficial, no loss in wall thickness 7 Scale present but generally within 2mm and thread definition has not been compromised 8 Significant scale and / or thread definition lost 9 Severe corrosion, loss of nut or bolt cross section, remaining strength a concern.

Exposure Levels 1 Modular, indoor minimal deluge 2 Sheltered, open module, minimal exposure 3 Open Module, exposure possible depending on conditions 4 Exposed, constant access to environmental conditions 5 Very Exposed Platform Extremity