Professional Documents
Culture Documents
1. What is the Swedish standard of surface preparation and how does it differ
from BS 4232?
2. State the Swedish grade of blast cleaning and compare them to BS 4232.
3. Identify three abrasives used in blast cleaning and state their use, advantages
and disadvantages.
Ceramic grits: Expensive grit. Retains their sharp cutting edges. Can be used on
hard base materials. Used at lower pressure on thin metal and on stainless steel,
non-ferrous materials as they are inert and do not stain or discolours.
The shape of a cross sectional blast finish is known as surface profile. The size of
profile as measured from the peaks to the troughs is known as the amplitude or
peak to trough height.
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5. What is the maximum amplitude on BGC painting contract?
No.
St2 Wire brushing by manual means, thorough scrapping and wire brushing.
St3 Very thorough scrapping and wire brushing by machine brushing.
10. How thick are imperial and metric values of a plastic backing of testex?
Imperial = 50 microns
Metric = 0.2 mil
Care must be taken to avoid over brushing a particular area causing Burnishing a
condition with a polished surface that has an adverse effect on coating adhesion.
Very laborious and expensive.
12. What is Jasons hammer? Where could it be used, what restrictions are
associated with its use?
Needle gun is Jasons hammer. Needle guns are used for cleaning difficult surfaces
such as rivet heads and welds. They leave sharp edge craters and rogue peaks, and
they have a tendency to push impurities into the surface.
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13. Explain the footner process and sequence of operation.
Cleaning of the surface by passing a high velocity oxyacetylene flame over the
surface to be cleaned. The process removes much of the mill scale and rust, but
leaves a dust on the surface, which has to be removed by wire brushing.
15. What is mill scale and is it more or less noble than steel?
Rogue peaks are peaks, which stand out above the required profile. They lead to
spot or flash rusting.
Surface profile needle gauge: Relies on the needle touching the bottom of the
troughs on the surface profile. Take 20 readings and calculate the average of
amplitude.
Testex tape:
1. Zero the micrometer ensuring flat contact point and clean tip of it.
2. Remove the paper backing from the testex tape and stick the testex tape to the
surface to be measured.
3. Rub the testex into the troughs using a blunt instrument, until the peaks can be
seen butting up to the transparent plastic.
4. Remove the testex tape from the surface and measure the overall thickness with
dial micrometer.
5. Deduct 50 microns for the plastic backing from the reading to obtain amplitude.
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19. Give five essential requirements for abrasive blasting at site.
Deadmans handle is used for direct operator control, to stop of the flow of abrasive
when the operator lets go of the nozzle.
21. Where should air pressure for blasting be determined and how is it done?
The pressure at the nozzle may be measured using the hypodermic needle gauge.
This is placed through the hose near to the nozzle with the hole in the needle facing
the nozzle at 45.
Straight bore nozzle concentrates most of the abrasive in the central area of the
blast pattern, fringe area of lower blasting size. For small or repair areas and softer
metals.
Venturi shaped nozzle produces a large blast pattern with the whole area receiving
relatively equal amount of abrasive. Gives an even blast pattern area over a
relatively large area.
23. Describe a test for detecting mill scale on a blast clean surface.
An acidic solution of copper solution when applied to a blast clean surface will
react by turning to bright colour on clean sheet but will turn to black colour if mill
scale is present.
BS 7079.
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Polymer produced by the growth of suitable stable molecules called monomers.
Monomers, they occur in synthetic resin, polyurethane.
Convertible coatings are those that undergo a chemical change during the drying
process that cannot be reversed e.g. alkyd epoxy.
Non-convertible coatings are those, which after they have dried may be restored to
the original liquid form by the application of solvent. E.g. Nitro cellulose and
chlorinated rubber, thermoplastic resins.
M.I.O Micaceous iron oxide: It decreases the permeability of the film. Protects the
substrate from the environment. Interferes with the corrosion reactions (inhibitors).
Binder consists of oil or resins or blend of oils and resins. Its essential is the film
formation, the ability to change from liquid film which flows to a more or less hard
plastic film.
Pigment is used for colour or to modify the physical properties of binder resins. To
provide rust inhibiting properties. To protect the film from the effects of ultraviolet
light and weather. To add body.
Evaporation: This involves the evaporation of a solvent from the vehicle, leaving
behind a film of solid material.
Chemical reaction: Polymerization molecular growth by cross-linkage of the
resins.
Oxidation: This involves the conversion of the constituents of the vehicle to the
solid state by chemical changes involving mainly oxidation by reaction with
atmospheric oxygen.
38. What is meant by pot life and how does it differ from the induction period?
Pot life is the time limit within which the mixed components can be used e.g. five
minutes at 20c.
Induction period is the time of mix to the application time.
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39. What are plasticiers and what are they used for, give e.g.s?
Plasticiers are usually liquids and must have a minimum tendency to volatize so
that they will remain in the film. E.g. camphor, castor oil, chlorinated waxes.
40. What are dryers and why they might be added to oil based paints?
42. What is cathodic disbondment and under what conditions does it occur?
If the impressed current is greater than the corrosion current then the cathodic
disbonding may result. This effect happens when excessive CP current is
sufficiently strong to begin to generate gases at the metal surface by a process of
electrolysis of moisture on the surface. The gas generated pushes the coating from
the surface and causes adhesion failure beneath the edges of the coating.
43. Explain relative humidity and dew point.
1. Brush application
2. Roller application
3. Dip coating (electrostatic technique)
4. Electrostatic spray application
5. Conventional spray application
6. Airless spray application
1. Airless spray applies most types of paint much faster than any other manually
operated method of paint application.
2. As the paint is not under pressure the pump can operate from the
manufacturers can.
3. Because no air is used, there is no over spray.
4. A uniform thick coat is produced, reducing the number of coats required.
5. A very wet coat is applied, ensuring good adhesion and flow out.
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6. Most paints can be sprayed with very little thinning.
7. No thinnages on the spray pattern means no overlapping in each stroke with
wide form pattern. This makes airless spray much faster than conventional
spray.
8. Because of the even spray pattern and cleanage, cutting at angles can be
achieved.
9. The single hose connection to the gun makes it easier to handle.
1. PAINT
1. What is paint?
Paint is a film-form in fluid that is spread in thin coats to decorate and or protect a
surface.
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5. Mechanical properties Hardness, resistance to abrasion or expansion and
contraction due to temperature changes.
Binder consists of oils or resins or a blend of oils and resins. Its essential function is
film formation. The ability to change from a liquid film that flows to more or less
hard plastic film.
Pigments are small particles that are soluble in the paint solvents that may be used
for colour or to modify the physical properties of binder resins.
To provide colour, hide the surface, protect the film from UV light and weather,
decrease the permeability of film, rust-inhibiting properties add body.
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M.I.O. Micaceous iron oxide decreases the permeability of film. Protects from
UV light and from the environment.
Extenders are added to paints to add thickness e.g. chalks, china clay, and talc.
14. What are anti skinning agents and what do they do?
A drying agent is added to an oxidative paint to speed up the drying process. E.g.
compounds of lead, cobalt.
16. Name three ways a paint system can dry. Explain each method.
1. Evaporation of solvent from the vehicle leaving behind a film of solid material.
2. Oxidation involves conversion of the constituents of the vehicle to the solid
state by chemical changes involving mainly oxidation by reaction with
atmospheric oxygen.
3. Chemical reaction polymerization. Molecular growth by cross-linkage.
Convertible coatings undergo a chemical change during the process that cannot be
reversed.
Non-convertible coatings are those that can be restored to their original liquid form
after they have dried.
18. Name two heavy-duty coatings and what are their disadvantages?
Coal tar, asphaltic bitumen. Applied at elevated temperatures 260c, fumes fire
hazardous.
19. What are plastic coatings and how are they applied?
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object.
3. By extrusion.
Poor bonding to the substrate. Stresses induced by the heating / cooling cycle.
Sintering a powder directly to the pipe, in much the same way as an epoxy powder.
Hot extrusion on to an adhesive or mastic.
It acts as ballast and ensures that the pipeline will have negative buoyancy even
when empty.
To secure good wetting of the substrate and provide adhesion to the substrate for
the entire system. To control corrosion of steels (by inhibition).
27. What are solvents?
Rate of evaporation if too slow leads to runs or sags, if too fast it leads to dry spray
and poor film.
Flash point Fire hazard.
Toxicity Health hazard.
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29. What is the M.A.C of common solvents give values?
Binder, solvent and dilutants are pumped in correct quantities through a centrally
controlled pipe system into measuring and mixing vats, where measure quantities
of pigment and possible extenders are added.
The raw materials mixed into a batch are dispersed by means of a dissolver,
consisting of a shaft with a rotating seriated disc.
Pearl or sand mill: The paint is pumped into the sand filled mill from below in a
vertical mill or from one end in a horizontal mill. The paint is pumped under
pressure through a number of rotating discs, which creates strong abrasion effects
and can cause very fine dispersion in the short time of its travel through the mill.
Paint collected at the top of the mill at a rate upto 1000 litres.
Roller mill: This unit consists of adjustable steel rollers, rotating against each other
so that the paint is subjected to pressure and shear forces, which decrease the
conglomerate size. The paint is removed from the final roller in the row by a
scraper blade or knife.
Ball mill: This consists of a rotating drum, part filled with steel or porcelain balls of
about 2 3 cms. Dia. The mill is filled with the paint until the balls are covered and
the drum is set in motion, the pigment conglomerates are ground down due to the
abrasion between the balls. The rotation speed is slow, generally less than one
revolution per second and the pigment size is controlled by the period of time the
mill is operated.
After grinding, the paint is pumped to final batching where more binder and or
thinner are added while stirring in order to obtain the correct delivery viscosity.
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Tinting colour adjustment and quality control adjustments may be performed, prior
to loading the materials into the delivery containers.
Specific gravity is called relative density. Ratio of density of material and the
density of water (comparison).
SG = Density of x
Density of water. It is a ratio. No units.
2. How is testing for specific gravity carried out? Name the equipment.
1 to 1.75
4. What is viscosity.
Wet comb gauge: It is pushed firmly into the wet paint so that the outer most teeth
makes contact with the substrate. Held at right angles to the surface. Gauge is
removed and the teeth are examined. W.F.T. lies between the last tooth i.e. coated
and the first tooth that is uncoated. Midpoint between this is W.F.T.
9. What are the thickness of the shims used and identify by its colour?
25 microns purple
51 microns dark blue
127 microns brown
254 microns white
508 microns yellow
Pressure sensitive tape, sharp knife, and rubber eraser. No. of cuts shall be six or
eleven. Surface is clean and dry. 40-mm long space, cut 1 mm apart if carrying
11cuts, two mm apart for six cuts. Cut through the film in steady motion. Repeat
the process in the opposite plane to give 1 mm or 2 mm. Inspect the cut to establish
that the surface has been penetrated. Place the tape over the grid and smooth it by
finger, then rub with eraser. Remove the tape after 90 seconds. After making
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several cuts examine the cutting edge and discard if jagged or if tearing of the paint
film.
5B: The edges of the cuts are completely smooth, none of the squares of the lattice
is detached.
4B: Small flakes of the coating are detached at intersections less than five percent
of the area is affected.
3B: Small flakes of the coating are detached along the edges and at intersections of
cuts. The area affected is five to fifteen percent of the lattice.
2B: The coating has flaked along the edges and on parts of the squares. The area
affected is fifteen to thirty five percent of the lattice.
1B: The coating has flaked along the edges of the cuts in large ribbons and whole
squares have detached. Area affected is thirty five to sixty percent of the lattice.
0B: Flaking and detachment worse than grade 1B.
Pressure sensitive tape, sharp knife, rubber eraser are the materials required to carry
out the test. Surface should be clean and dry. Make two cuts in the coating each
approximately 40 mm that intersects near the middle with an angle of 30.
Inspect the cut to establish that the surface has been penetrated. Using a piece of
tape 75-mm, place the centre of the tape at the intersection of the cuts, smooth the
tape by finger and then rub firmly with eraser. Brush the area lightly with soft
brush, remove the tape after approximate 90 seconds by taking one end and rapidly.
Examine the cutting edge of tool for signs wear and replace when needed. Inspect
the cut area and rate the adhesion.
A dolly made of aluminium alloy is stuck on to the coating system under evaluation
using araldite adhesive. After the adhesive has cured, the dolly is removed by direct
pull-of using a special tool and the force required is measured.
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16. Explain flash point and how this is obtained?
Flash point of a material is the lowest temperature at which the vapours given of
will ignite when a flame or spark is passed over it. Flash point is obtained by the
use of Abel cup. Fill the test cup with the paint and place it in the water bath, which
is heated to the required temperature. Light the ignition device when the paint has
reached the required temperature. Carry out flame test. Raise the temperature by
0.5c and repeat ignition, in steps of 0.5c raise until the flash point is reached.
Read the thermometer reading of the temperature accurately.
18. What are acceptable application conditions for blasting and painting?
Paint should be applied only to the surfaces that are thoroughly dry and under such
conditions of humidity and temperature, as it will promote evaporation, rather than
condensation. Other factors to be aware are strong hard sunlight, strong winds
which could cause too rapid evaporation of solvents and the paint film being
impregnated with dirt etc.,
Bgas Specification
1. The air or metal temperature is atleast 3c above the dew point temperature.
2. The relative humidity is less than 90%.
3. The temperatures for the applications are within the manufacturer
recommendations.
Dew point is the temperature at which condensation of water vapour in the air
would form on the surface.
20. What equipment is used to find humidity and dew point? Explain its use.
Model 123 - surface profile gauge is a quick, direct reading and easy to use
instrument. The gauge is first set to zero by leveling the foot and the pointer on a
flat surface. When the foot is subsequently pressed against a blasted profile, the
foot will rest upon the peaks and the pointer will penetrate the valleys. The dial will
show reading. Take ten such readings and take the average of it.
Four hours.
BS 5493.
26. List blast cleaned surface i.e. give comparison of blasting grades to the above
standards.
Filter paper soaked in a barium chloride dehydrates 6% wet solution and dried. The
dry paper is then pressed against the test surface backed by a second paper soaked
in saturated potassium permanganate, contamination is absorbed and held in the
barium sulphate lattice, imparting a pink colour to those parts of the paper which
contacted sulphates.
Filter paper wetted with silver nitrate 2% wet solution and then pressed against the
steel surface for about twenty seconds. It is then peeled off and thoroughly washed
in chloride free water. Immersion photographic developer can detect any silver
chloride formed remains in the paper. Chloride sites shows brown - black areas.
An acidic solution of copper solution when applied to a blast cleaned surface will
react by turning to a bright copper solution on clean steel, but will turn to a black
colour if mill scale is present.
Shinning on ultraviolet light source on the surface causing the oil to fluorescence.
Pouring solvent across the surface, the solvent should form a continuous flow and
not break into droplets.
Use of strip of clear cello-tape 25-mm wide strip. Press the tape onto the surface
lightly rub over the tape with finger, then snatch the tape off. Any loose dust will
stick to the tape and will show up clearly when the tape is put onto white paper.
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33. Explain care of blasted surface.
4. SURFACE PREPARATION
2. What is tacking?
Coating has partially set only; surface is not wet but has a sticky feel, like tape, due
to excessive thinner, insufficient drying time, low temperature.
Properly made stirrer should be used which is long enough to reach the bottom of
the container and with a broad, chisel like edge and a comfortable handle.
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5. What percentage of thinner is normally required?
Ten percent.
Thin coating will result in poor durability and a lower resistance to corrosion.
In multi pack paints, it is the time of the mix to the application time.
The pot life is the time limit within which the mixed component can be used. E.g.
five minutes at 20c.
9. What condition shows when paint is stored for long periods or in poor areas?
On aging paint may tend to thicken or go out of condition. Paint tends to settle
during storage and after prolonged period.
a. Temperature
b. Paint film thickness.
c. Ventilation (concentration of solvents immediately above the surface)
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13. What data would you require from manufacturer prior to paint application?
Paint manufacturers should quote the temperature at which the drying times are
applicable e.g. 20c.
14. What improvement to a paint surface would blast cleaning have over other
methods?
The degree of surface roughness and the rate of cleaning depend primarily on the
characteristics of the abrasive grit used.
Crushed wall nut shells, glass and crushed slags, various metallic shots and grits.
19. Why is sand and flint not to be used for blast cleaning?
1. Water blasting
2. Manual cleaning
3. Flame cleaning
4. Needle gunning
5. Weathering
6. Acid pickling
7. Degreasing.
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5. METHODS OF PAINT APPLICATION
Paint application has a significant effect on the life of a paint system. By employing
skilled painters, applying paints under properly controlled conditions, and only
suitable ambient conditions outside.
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2. What method of paint application is performed for primer and why?
Brush painting is said to have achieved superior wetting and is the only acceptable
way to apply some anti corrosive primers. Brush marks leads to areas of low film
build. Rubbing action of a brush can be an additional aid to get good adhesion.
ADVANTAGES DISADVANTAGES
1. Mobility and low equipment cost. 1. Not suited for irregular surfaces.
2. Cleaner than spray gun. 2. Thin uneven coats with misses / pinholes.
3. Faster than brush. 3. Poor penetration, not suited for all types
of paints.
Objects coated by dipping are usually part of a conveyor belt system in which
stowing is also involved in order to prevent more drips.
ADVANTAGES DISADVANTAGES
1. No over spray. 1. Not suitable for water thinned paints or
heavily pigmented metallic coating.
2. Very clean to use. 2. Equipment is costly and not easily
maneuvered.
3. Great saving in paint
1. Air motors
2. Electrically driven hydraulic pump.
ADVANTAGES DISADVANTAGES
1. Very high work rate. 1. High equipment cost.
2. Good automation with little or no 2. Depends on power source.
paint fog.
3. Pole gun for awkward places. 3. Less mobile than brush / roller.
4. Only really suitable method for the 4. Risk of dry spray.
application of high builds.
5. Good penetrator. 5. Adjustments only by changing the nozzle.
Readily changeable part of the gun and are fitted by the retaining nut.
1. Controls the width of the spray pattern by varying the angle of the tip.
2. Controls the quantity of paint passing through.
To save removing, cleaning and replacing the tip each time to clear the blockage by
small particles of dust.
12. What type of fluid line hoses are used and why?
Specially designed high pressure, solvent resistant, small bore hoses, reinforced
with wire mesh, fitted with thread connection, swivel fitted between hose and the
gun allowing free movement. (For remote location application)
13. Explain the advantages of airless spray over conventional spray.
1. Airless spray applies most types of paint much faster than any other manually
operated method of paint applied.
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2. As the paint is not under pressure, the pump can operate from the
manufacturer's can.
3. No air is used. No over spray.
4. A uniform thick coat is produced, reducing the number of coats.
5. A very wet coat is applied ensuring good adhesion and flow out.
6. Most paints can be sprayed with very little thinning.
7. Faster than conventional spray.
8. Even spray pattern, clean edge, cutting at angles can be achieved.
9. Single hose, easier to handle.
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6. INSPECTION, STANDARDS AND SPECIFICATION.
The wet film gauge should be placed in the coating film at a angle 90 to the
Surface. Teeth are examined after immersion in the wet coatings on their surface
Measures less than the W.F.T., while those with no coating measures more than
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W.F.T. Mid of the values shall be taken.
6. What is BS 7079?
+ / - 10%.
Electronic gauges can be very good when they are properly calibrated. Accuracy is
very precise. Capable of storing many measurements, making statistical analysis
and printing the results on a computer pointer.
14. What is testex? How is it used and what are their limitations?
15. When are high voltage holiday detectors are used and at what voltage?
Writer is aware who will read the document, what is needed, to pass on the required
information, describe the activities etc.,
No.
Type of protection treatment, requirements of the coating, its end use, cost of
inspection, quality of supervision to be expected of the coating applicator.
29. What safety checks would an inspector carry out prior to blast cleaning?
a. Check the masking of sensitive areas of site, electronic components, plates etc.,
b. Ensure existing coaters are protected from over spray.
c. Check contaminant screens.
d. Ensure that the hazard warning signs are in place.
e. Check the equipment.
f. Check the environment conditions.
a. Visually examine the substrate prior to blast cleaning or power tool cleaning to
ensure there is no inherent defects or detrimental contamination such as mud,
oil, or construction debris.
b. Check blast-cleaning air to ensure it is free of oil and water.
c. Check that the oil and water traps are functioning and empty of water.
d. Observe the surface preparation looking for unusual surface
conditions/colouration.
e. Visually check the abrasive being used.
f. Measure anchor profile atleast once for each hour of blast cleaning.
g. Surface cleanliness - does it meet the standard.
h. Surface profile pattern.
i. Unblasted areas.
j. Make scotch tape test to ensure dust has been removed.
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7. HEALTH AND SAFETY.
1974.
Thirty years.
5. What is E.P.A?
6. What is V.O.C?
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7. What is the V.O.C. regulation on the maximum level of pounds per gallon?
Charcoal filters.
When applying more than twenty tons of paint or five tons of solvent.
Hydrocarbons solvent emission rates are less than 50 mg of carbon per cubic metre
coatings, 250 mg per litre of solvent.
1. What is corrosion?
a. Material selection.
b. Protective coating.
c. Cathodic protection.
a. Surface corrosion.
b. Pitting corrosion.
c. Stress corrosion cracking.
d. Fretting corrosion.
e. Crevice corrosion.
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f. Corrosion in acid or alkaline environment.
g. Bacterial corrosion.
a. Temperature.
b. Humidity.
c. Surface condition of the metal.
d. Time.
e. Effect of stress.
f. Atmospheric pollution.
a. Gold. b. Silver
c. Copper d. Hydrogen
e. Lead f. Nickel
g. Iron h. Zinc
i. Aluminium j. Magnesium
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10. Explain stray current effects.
Other metal structures near to the ground bed may cause CP current to flow in an
unpredictable fashion. Interfering structures to be connected to electric resistor.
If the impressed current is greater than the corrosion current they are strong enough
to generate gases at the metal surface by electrolysis of moisture on the surface.
The gas generated pushes the coating from the surface and causes adhesion failure
beneath the edge of the coating.
Mill scale is a thin black, flaky layer of oxidized iron formed on the steel during its
manufacture. Mill scale is more noble than steel.
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It is an alloy of 70% nickel, 25% copper and iron, magnesium and silicon.
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2. Describe what is meant by bimetallic corrosion.
Bimetallic corrosion occurs when two different metals are attached close together.
Th less noble of the two metals will act as an anode to the nobler one, the cathode
and will sacrifice itself.
a. The galvanic series: is that metals carry an order of nobility to corrode. This
nobility is found by testing in seawater. Gold and silver corrode less quickly
than copper mill scale, steel, aluminium and zinc. So we can use the galvanic
series to bring about cathodic protection to steel.
b. Mill scale: is a black flaky layer of oxidized iron found on steel during its
manufacture.
c. Rust grades to SIS 05-5900: There are four grades.
Grade A - Covered with mill scale, with little or no rust.
Grade B - A mixture of mill scale and rust.
Grade C - No mill scale, surface is slightly rusted.
Grade D - Heavily rusted and pitted.
d. Blast cleaning grades to SIS 05-5900: There are four standards.
Sa 1 - Light blast clean.
Sa 2 - Thorough blast clean.
Sa 2 1/2 - Very thorough blast clean.
Sa 3 - Blast cleaning to visually clean steel.
Water blasting is carried out at very high psi and with added abrasives to remove
the most contaminations - can cut a profile in steel. Also very good in removing
toxic coatings. It is excellent at cleaning tube bundles. Pressure washing is a low-
pressure water system mainly used for cleaning painted surfaces, it can also be used
with a detergent for removal of salts, chlorides, and contamination from substrates.
Very useful tool in the maintenance paint field.
5. Name two tests used to determine the presence of hygroscopic salts left on a
blast cleaned surface.
7. Name the three basic constituents of a solvent carrying paints and the
functions each performs in the paints.
a. Binder: It binds the particle together, holds them in suspension and gives the
paint its finish, flexibility, gives good adhesion to the surface. It converts to a
solid dry film and gives resistance to water, alkalis and abrasion.
b. Pigment: Gives colour and opacity to the paint. Gives resistance to acids,
alkalis, light.
c. Solvent: Forms the evaporative part of the drying process. Thins the paint for
easy application. Washes out the equipment and brushes can act as a degreasing
agent if approved.
9. Describe what qualities a laminar pigment gives to paint and name four
pigments.
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A sacrificial paint coating is usually zinc or aluminium based paint, which is less
noble than the steel substrate that is being coated. So the less noble is coating
(anode) sacrifices itself to the nobler steel substrate (cathode).
11. Describe what a tie-coat is and give three reasons why we may require one.
A tie-coat is a paint, which can tie two normally incompatible systems together,
mainly used for maintenance painting. It is used in anti-fouling system.
Reasons: To get proper adhesion, to avoid bleeding, to avoid solvent stripping.
12. Describe a typical paint manufacturing process and give the two types of paint
mill which could be used.
Select raw materials, mill the paint, carry out any QC testing requirements, can the
paint, store in the warehouse and then distribute the paint.
Direct charge mill, ball mill, attriator mill.
Ball mill- it grinds all the raw ingredients together. Premix mill takes all the
premixed ingredients and refines this mixture to high quality paint used in large
batch in run.
13. Describe what you know of viscosity and out line one method of testing.
Viscosity is the measure of fluid resistance to flow. It is used to find the amount of
solvent that is added to the paint. It is tested at 20 +/- 0.5c.
Ford flow cup # 4 is used. Bring your paint temperature to 20c. place your finger
over the hole of the cup, fill with paint, level off the paint with ruler.
Note the time taken i.e. how long the paint flows before the break comes in the
flow of the paint when you remove the finger from the hole.
a. An M.I.O coating - No
b. An aluminium substrate - No.
c. A galvanized surface - Yes provided it is over steel surface.
16. Describe a destructive test for determining the dry film thickness of paint.
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PAINT INSPECTOR'S GAUGE (P.I.G): Cut a 'V' cut shaped channels over the
paint film coated over an area. Place it over a microscope and measure the
thickness of the paint and how many coats are there. To determine the compatibility
between different coats.
17. Give four artificial weathering devices and describe what they simulate.
18. What is the name of the instrument which measures opacity and give two
examples
Cryptometer - a) Pfund Cryptometer, b) Hiding power chart.
a) Conventional spray setup is used for relatively low pressures and thin materials.
Also the cup gun does not hold big quantities of paint. So you are forever filling
them up. Also the gravity and suction guns can only be used in the upright
position.
b) Airless spray system is a very fast system for applying paint to very large areas,
roughly one square metre perminute, large spray pattern and applies thick
coating in one application.
c) Electrostatic spray system requires a special spray gun, which applies charge to
the paint particles. The substrate is positively earthed and the paint particles are
given a negative charge at the tip as they leave the gun. So the paint particles go
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to the earth and wrap themselves around the normally tubular components and a
even coating is obtained, very little wastage of paint.
It specifies 100 colours out of the 237 in BS 5252. It is used to identify the existing
colour paint for which maintenance painting has to be done. It is useful for the
manufacturer's to verify with the standard colours given in BS 4800 (100 colours).
22. What are the essential differences between blister and osmotic blister?
Expansion or contraction of the paint film against the substrate usually causes dry
blisters. Osmotic blister is a blister, which contains gas, liquid, or crystal. It is
caused by the entrapment of solvent, hygroscopic salts. It is usually dome shaped.
23. What shall painting equipment comply with when being used on the Bgas site?
Bleeding is a discolouration of a new paint applied over an old one. Bitumen and
paints contain red pigments are particularly problematic.
Blooming. It is where a finishing paint assumes a milky type appearance and the
loss of gloss due to colour or dampened air settling on the paint before it was dry.
Chalking. Paint becomes powdery or chalky. Break down of the binder due to
ultraviolet light and also due to poor weather condition.
Cissing. In-complete paint films due to paint over oil and grease.
Grinning. Seeing the underlying surface through the finish coat. Colour contrast,
lack of opacity.
Flocculation. Separating out paint constituents in the tin and the refusal to be stirred
back together again.
Lifting. Attempting paint over, underneath a coating, which is not fully cured. The
evaporating solvent will lift up, picking up.
Roopiness. Brush marks in a painted surface.
Solvent stripping. Paint with a powerful solvent will lift the coating underneath due
to the power of the solvent.
Oxidization. The drying process between certain binders and oxygen e.g. alkyd
resin.
Chemical curing. The mixing of two components which produces drying in a two-
pack paint.
Overspray. Paint which is not going to substrate. Paint, which falls over an area
which, is not required to be painted.
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25. Define the following, Dew point, Rh, Induction period, Pot life, Flash point,
Shelf Life, Batch No., Masking out A.G.I, Rust blooming, Water borne
coating, B Sa 2 1/2, Feathering, A St3, PA 9, P 10.
Dew point: The temperature at which condensation would form on a substrate.
RH: The amount of water vapour in the air expressed as a percentage and calculates
from the wet and dry bulb temperatures.
Induction Period: The length of time a paint is required to stand after mixing and
before application, to allow the air bulb to escape and or chemical reactions to take
place and is specified by the paint manufacturer.
Pot life: The length of time (following induction) that a paint remains in an
applicable condition according to the manufacturer's instructions.
Flash point: The lowest temperature at which a given material will flash, if a flame
or spark is present.
Shelf life: Maximum interval in which a material may be stored in a usable
condition.
Batch number: Manufacturer's data number for production date.
Masking out: Must be carried out on items to be protected during preparation and
painting, items normally masked out are control equipment, fire protection
equipment, weld ends, sensing and spraying heads, name plates.
A.G.I: Above ground installation.
Rust blooming: It is caused by moisture or humidity on new blasted steel and
shows up before priming.
Water borne coating: One whose solvent is water. It dries by coalescent.
B Sa 2 1/2 : Rust grade B. Mixture of mill scale and rust. Prepared by very
thorough blast cleaning.
Feathering: Smoothing back the coating edge to allow repair. Paint to flow into and
produce a smooth edges i.e. smoothing down of rough paint edges.
A St3: Not possible.
PA 9: B gas document properties and performance requirements refer to the
ordering of paints and performance of paints systems. Any paint used on B-gas
work must comply with PA 9.
PA 10: It is the technical name specification for new and maintenance painting at
works and site for above ground pipeline and plant installations and is arranged into
three sections. Primary information, general painting information, information for
specific painting applications.
SPA 1: Applies to the painting at work or site of new installation and components
and maintenance paint. (CS)
SPA 2: For indoor use and short term uses.
SPA 3: New installation and maintenance, above 100c, upto 340c, and above.
SPA 4: Painting of damp ferrous surfaces.
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SPA 6: Painting of non-ferrous surfaces.
Rapid change in oxygen, salt spray, growth of marine life, access to the working
area is difficult. Wave impact and erosion. Mechanical damage due to ship
movement.
4. What ills mill scale and why it is a particular problem when attempting to
protect steel?
Mill scale is an oxidized iron. Mill scale is nobler than steel so the exposed areas of
steel (anode) will sacrifice itself to protect the mill scale (cathode).
5. What is the number of the Swedish standard contained within BS 7079 and list
the rust and blasting grades together with their brief relevant titles?
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Rust grade A - Covered in mill scale with Sa 1 - Light blast clean.
little or no rust.
Rust grade B - A mixture of mill scale and Sa 2 - Thorough blast clean.
rust.
Rust grade C - Mill scale, rusted with Sa 2 1/2 - Very thorough blast clean.
slight surface pitting.
Rust grade D - Heavily rusted and pitted. Sa 3 - Blast clean and visually clean.
6. Name three tests for locating hygroscopic salts and mill scale on a blast
cleaned surface.
Using the correct abrasives ensuring that size, hardness, density and shape are the
correct for the substrate.
Operator's ability to ensure proper speeds, angles and distance plus speed (time).
Surface profile and cleanliness.
8. Regarding hand and power tool cleaning state what always concludes this
process and to what standards.
Wire brushing: Brushes must be made from phosphor, bronze or beryllium bronze.
St 2 - Thorough hand & mechanical cleaning (manual).
St 3 - Very thorough hand & mechanical (mechanical). Used on rust grades B,C,D.
10. What are the functions of each of these three in a solvent carrying paint?
Binders: It binds the particles together and holds them in suspension. Gives the
paint its finish, makes the coating adhere to the surfaces, gives flexibility. Converts
to a solid dry film, resistance to water and chemicals.
Pigments: Gives colour and opacity to the paint. Resistance to alkalis, acids and
light.
Solvent: Brushes & equipment cleaner, thins the paint, degreases if approved.
forms the evaporative part of the drying process.
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11. Name five items that can be included in paint to improve its performance or
suitability for a certain use.
Epoxy - Acetone.
Chlorinated rubber - Xylene.
Alkyd resin - White spirit.
Emulsion - Water.
14. Name six opaque pigments together with their respective colours.
The laminar pigment (M.I.O, Mica, glass flakes) particle shape tiny hands or
leaves, upon drying they interweave and overlap each other to form a leave type.
Surface provides a low permeability to water.
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The length of the time, the two pack has to stand after mixing, before applying for
allowing the air bubbles to escape and chemical reaction has to take place and is
stated by the manufacturer.
The length of time after induction the two-pack paint remains in an applying
condition, according to the manufacturer's instructions.
This type of coating isolates the substrate from the environment by providing a low
permeability coating system.
20. Define the term tie-coat and give an example of its use.
A coat used to apply over two incompatible coatings e.g. during maintenance
painting.
Thermosetting: They can be formed by heating and curing heat cured plastic. After
setting they will not soften or degrease.
Thermoplastic: They can be formed by heating and curing heat cured plastic. After
setting, when they are re-heated it will become softer and become liquid and again
can be reused.
22. What is impressed current. What problem can arise from its incorrect setting
up?
23. Name two types of paint mill and give two examples of each.
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DIRECT CHARGE MILL PRE-MIX MILL COLLOID MILL
Ball mill Big mill (Ballotoni) Simple roll
Attritor mill Sand pearl and Bead mill Dried roll mill
High speed disperser mill Slurry mill Triple roll.
Grind gauge measures pigment grain size, how finely the pigment has been
(grained) ground in the milling process.
It is the minimum temperature at which the vapours of a liquid begin to ignite when
the external source of ignition is introduced.
The closed cup Abel type determines flash point.
27. What is viscosity and what equipment is used to measure the viscosity of a free
flowing paint and Thixotropic paint?
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b) Thixotropic paint viscosity is determined by rotating viscometer/rota thinner,
krebs stormer viscometer. Set the r.p.m through the window at 200 r.p.m. to
make it a free flowing paint. Paint is put in the viscometer and paint is thinned
similar to the ford flow cup no.4 test, note the time taken for the paint to be
broken to droplets. Time taken in seconds will give the visocity.
Small black cup of 100 cc, which is made of aircraft alloy, is known as density cup.
The lid in it has a hole in the top. Pour the paint inside the density cup. Close it
with the lid. Wipe of the extra paint coming out of the hole from the cup. Weigh it
by using the formula Density = Weight / volume. Find out the density of the liquid.
Density cup is used for,
a) To check the amount of solvent added to the paint.
b) Whether the two-pack paint has been mixed to the correct ratio.
29. Calculate the volume of solids of the paint if the W.F.T was 186 microns and
the D.F.T - 93 microns.
31. Calculate the D.F.T. of paint if Vs % was 44 and W.F.T was 234 microns.
33. Calculate the density of two pack material if part A paint was 1.5 g/cu.cm and
part B catalyst was 0.5 g / cu.cm (assume ratio 1:1)
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34. Name an example of a nondestructive D.F.T. gauge and destructive D.F.T.
gauge.
35. Name four artificial weathering devices and say what they are designed to
simulate.
36. Name two drying / curing tests and state how they are operated.
Drying / curing test: Ballotini test- hardened steel balls put over the wet paint film
panel.
Stylus test: It consists of a series of trailing needles. To find out tack dry, hard dry
and fully cured.
Cold leaf test: It is moved over the wet film since they are used in different
tensions.
37. What does a Cryptometer measure and give two examples of a Cryptometer.
It is used to measure the opacity. Hiding power charts and P-fund Cryptometer.
39. Name three adhesion tests and describe how one of them is carried out.
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Clean, degrease and roughen the surface. Apply dolly with regular araldite and give
24-hrs time at 25c. Cut around the dolly to isolate the substrate. Apply the pull off
force and find out,
1. At what pressure (psi) failure occurs.
2. What type of failure occurs. Cohesive/adhesive.
40. State the conditions under which B-gas allows painting to take place.
a) The ambient or surface temperature should be atleast 3c and above the dew
point temperature.
b) The relative humidity should be less than 90%
c) Temperature condition for applying paint should be within the manufacturer's
instruction. (maximum and minimum temperature)
43. Name three methods of applying paint and compare the advantages and
disadvantages of each in-terms of quality and cost effectiveness.
Brush: Cheap easy method, best for applying primers. Disadvantages - slow, covers
small areas and messy to handle.
Roller: Cheap and easy to apply. Disadvantages - uneven coating, orange peel
effect.
Conventional (air): Expensive (four to five times costlier than others), covers large
areas. Disadvantages - overspray.
44. What does BS 2015, glossary of paint terms refer to and give three examples?
It is arranged of 100 standard colours taken from the 237 colours contained in
BS 5252 and used in the construction industry. It can be used to identify existing
colours when maintenance painting and is a method by which all manufacturers can
make exactly the same colour.
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47. What is the procedure for removing oil and grease from a surface before
preparation commences?
Because of oil & grease paint will not spread properly. White spirit should not be
used. Use only approved solvent with safety precaution to be followed. For
applying solvent use disposable swab. Do not use cotton rags. After solvent
cleaning use a detergent pressure washing followed by clean water, rinsing and
then drying it.
48. What is the procedure for removing oil and grease from a surface, found after
preparation has taken place?
Use approved solvent and after degreasing, do pressure washing with 2% detergent
followed by clean water rinsing and drying it off. Reblast and clean it.
49. What is the procedure for removing Algae and mould growth from pipe
work?
Apply antifungicidal bi-oxidant over the algae and mould growth and give
minimum twenty-four hours time. Leave it free for this period. After this time
elapse use stiff wire brushes to scrub off, pressure wash with a detergent followed
by clean water rinsing.
In ad dry, lockable, well ventilated building away from gas areas, flames, heat
sparks and rays of the sun and follow any special storage condition.
51. What is T-wash? What is it used for? What colour is it? How do we check for
a correct reaction when using it?
It is an etch primer.
When applied first it provides a key for new galvanized steel.
Blue in colour.
Turns black upon drying. *T-wash should not be used in aluminium. Use PVB*
Hundred mm.
55. What is the maximum allowed time for priming to take place following the
preparation and by what method is primer applied?
Maximum four hours follow completion of blasting. Except Spa 4 where priming is
immediate. By brushing or spray as appropriate.
One which reaches a temperature of above 99c, when (it is working) in use.
57. What must all pneumatically and electrically operated power tool equipment's
should be done before use?
Properly earthed.
58. What type of sheeting may and may not be used for protection against spillage
and spotting?
59. What must not be used to clean out kettles or dispose of rubbish?
Fire or flames.
Upto five litres may be mixed by hand. Above five litres must be mechanically
mixed.
61. What are osmotic blisters and what can cause them?
Osmotic blisters are blisters, which contain liquid, gas or crystals (chlorides). Main
causes are solvent entrapment, water entrapment, hygroscopic salts left on the blast
cleaned surface.
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62. Some metals are difficult to prepare. Name three and describe how you might
prepare them.
63. Where does a pipeline leave the ground and what problems would you find
and how might you treat this?
Sketch:
64. What additional information would you record when maintenance painting a
pipeline without removing the previous coats?
65. Name five paints and state their drying or curing method.
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1. Emulsion - Coalescence - Evaporates without chemical action but it also gets
dries like a non-convertible but acts like a convertible coating.
2. Alkyd - Solvent evaporation followed by oxidation.
3. Chlorinate rubber - Solvent evaporation only. Non-convertible coating.
4. Two pack epoxy - Solvent evaporation followed by chemical reaction.
5. Fusion bonded epoxy - Heat cured - Thermosetting, convertible coating.
66. Name a black pigment in common use apart from coal tar.
Carbon blocks.
67. What is a holiday detector and a pinhole detector? What does it detect, and
how does it work?
68. If you worked on a contract where frequent stoppages occurred for poor
weather, what additional information would you record?
69. If a pipeline was in direct contact with acoustic cladding what paint system
might be applied if we wished to maintain it every three years or not at all?
70. What is important about selecting a paint system suitable for a certain
environment?
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Each and every paint has its own characteristics. Select a paint system that should
with stand the environmental conditions and comply with the specification
requirement. Marine conditions, high humid condition, too low temperature
conditions.
71. 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.
72. What is unusual about the preparation of surfaces which are dealt by SPA 4?
HASWA - Health and safety at work act 1974. It deals with duties of employer and
employee with regard to health and safety. Employee should report accident,
spillage. It is a statutory requirement. COSHH - Control of substances hazardous to
health 1988.
74. Give one advantage of using testex tape and plastic disposable W.F.T combs.
75. State the principles of being able to use a banana gauge for taking D.F.T.
readings.
When using the banana gauge on ferrous metal (substrate) coated with non-ferrous
coatings, then the D.F.T can be measured with banana gauge. It works on the
principle of magnetism.
76. Briefly describe the various paint application methods and its limitations.
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Brush application:
Brush painting is said to achieve superior wetting and is the only acceptable way to
apply some anti corrosive primers. Brush marks leads to areas of low film build.
Use of brush is slow, and time consuming. Rubbing action of a brush can be and
additional aid to good adhesion. A brush of suitable size for the work in hand
should always be selected, as a small brush on a large area makes it difficult to
apply an even coating and slows down the rate of working, whilst using a large
brush on a narrow area makes accurate working impossible.
Rollers:
Quality of roller application depends partly on the covering or sleeve of the roller
and partly on how conscientious the applicator is. It is not suited for anti-corrosive
and anti-fouling paints.
Dip-coatings:
Paint must have a fast drying time. The paint in the dipping tank must be stirred
continuously as the viscosity of the paint is important. Rapid withdrawal from the
dip tank can cause too thin a coating.
Powder Coating - Fluid bed & Electrostatic Technique.
A fluid bed is one in which a mass of broken up solid is kept in a state of agitation
by mechanical or other means. Fluid beds for coating purposes consist of finely
powdered pigmented resinous solids through which air is blown to keep the
particles in motion.
Electrostatic Spray:
Paint is sprayed from a pressure feed tank through a fluid hose to the gun in the
usual way. At the same time paint is given a -ve electrical charge. As the
electrically charged paint leaves the gun, it atomizes and each particle is attracted to
any earthen object, in its path i.e. the article being sprayed.
Conventional spraying:
This involves using a compressed air to both atomize the paint and to convey it to
the substrate. In high pressure, the painting is stored in a pressured container from
which large quantities can be delivered quickly.
Airless spraying:
Paint supplied by a hydraulic pump is forced at high pressure through a narrow
orifice in a tungsten carbide nozzle. The pressure is such that the paint is atomized
and carried to the substrate by its own momentum.
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1. PAINT / PAINTING INSPECTION - PAPER 1
B-gas Grade - 1
3. List the safety measures required for over the side working in descending
order of preference if scaffolding is not practicable.
3 Rail barrier
Safety net
Safety belt line
Rescue boat and radio
Full life jacket.
Heli-deck
Spider-deck
Drilling-deck
Cellar-deck.
Falling overboard, fire explosion and adverse weather (gales & storms)
By arrows cut out of reflecting strips and fixed on top of the non-skid designated
deck. Deck coating: 100-mm - Prime route, 50-mm - Sea route.
9. What precautions must be observed when boarding and travelling in
helicopters?
All as described in the C.A.A. course which you must attend before travelling
offshore.
10. How often is medical treatment required for personnel working offshore?
11. List the essential items of clothing and equipment for an offshore painting
inspector.
Riggers boots, safety helmet, 100% cotton overalls, safety glasses, and life belt -
jacket and weather and paint instruments.
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13. Are painters permitted to erect scaffolding?
No. It must be the work of a qualified scaffolder holding a C.I.T.B card. Painters
paint only, but they can refuse to work on the scaffold if they are not sure of its
safety for their job or personnel safety.
H - stands for hydrocarbon. 120 stands for the time in minutes, that the fire
protection system is designed to stop the passage of flames, smoke, to allow
personnel to escape to safety.
16. Name the two types of fireproof coatings. say which type is used mostly and
describe how it works.
Cementious and Intumescent are two types of fireproof coatings. Intumescent
coatings are the preferred ones for offshore coating in hydrocarbon fires and
cellulosic fires. They swell upto many times their thickness thus delaying the fire
spread upto 200%
17. What application requirements are specified for the spray application of paint
to large surface areas?
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c) What standard is specified for power tool cleaning.
ST-3.
e) Coatings must not be applied when surfaces are less than - 3c above DP,
when RH % is above 85%.
c) What distance and angle should a spray gun is held from the surface?
Distance - 18", 450 - 600mm, at an angle of 90.
He is a look out person. He keeps in three way contact during and over the site
operation. He should also be on hand where the people are working in vessels or
enclosed space in offshore. To summon help in case of accident in the radio
operator's office.
Incharge of designated areas of the platform. Issuing hot and cold permits.
Receiving completed work permits, checking work carried out on permit. Area
authority O.I.M.
4. Why are areas encapsulated and give ways in which this could be done?
To protect instruments and fire protection equipment's during blasting, cleaning and
painting operations. During maintenance work, completely cover the areas in
plastic sheets or mask off, for climatic or safety reasons.
Usually meet for half an hour or so at the shift change, if there was a serious
problem to explain or leave a hand written report for him in his logbook.
7. How would you determine that a contractor's plant and equipment was safe to
use?
8. Why is masking carried out and what areas might need this?
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Submerged zone is difficult to paint because of its position. Also because of water
and lack of oxygen present, the rate of corrosion is not so serious and also
sacrificial anodes are used.
10. What are the two ways in which galvanized surfaces can be prepared before
painting?
12. Other than temperatures and RH what could stop blast cleaning from being
carried out?
Where different types of cleaning is needed usually power or hand cleaning due to
maintenance or other type of problems-weather conditions, operation or production.
13. What are the two types of test, which are carried out for cathodic
disbondment?
14. What is the title of CPC - 155 and which is the current issue?
Title -175C, Paint council-1998 Issue 2, CPC - company practices for paint.
AL - Aluminium
BS - British standard
CS - Carbon steel
Cu - copper
HSE - Health safety environment
LAT - Lowest astronomical tide
MIO - Micaceous iron oxide
NI - Nickel
SI - Statutory instrument
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SS - Stainless steel
ZN - Zinc.
For V.O.C. coatings pigments carry more water emulsion binders. It is water based.
Solvents are greatly reduced.
Method of use (brush or spray), type of paint, production date, shelf life,
confirmative with B-gas specification are the things that should be printed on a
paint tin.
The following are the results that have to be published by the manufacturer.
Composition (pigment, binder & volatiles) Manufacturer's name
Product description Volume of solids
Viscosity Opacity
Covering power (gloss) Abrasion resistant
Impact resistant Density and adhesion.
19. What information does the paint manufacturer have to supply to the
contractor?
Material data sheets, health and safety information regarding the products.
20. Who is responsible for choosing a paint system for use on a particular job?
21. What are the two BS codes used in connection with colour schedules?
22. What must happen to any weld splatter which was not removed during the
fabrication process?
Surfaces shall be free from dust, moisture, oil and grease and other contaminants.
24. How shall heavy or metallic pigment be kept in suspension when applying
paint?
Automatic stirrer, air or power operated in the paint pot during application and
constantly in motion can keep it in suspension.
It is a brush-applied coat to the weld areas to make sure that the proper D.F.T is
attained. It is an extra coat to welds and edges.
27. Describe how test panels are prepared and painted and what is their purpose.
Test panels are blasted to Sa 3 standard, then according to test required instructions.
For rust grade after blasting it is left in the atmosphere for 2 - 3 months. Test panels
are then dipped in seawater. Dry for 2 or 3 minutes, then coat.
29. How do you decide what grade of preparation needs to be carried out?
30. When wet blasting, what will you to areas likely to be affected by water and
abrasive contamination?
31. When can a brush be used to apply paint for offshore structures?
32. If B-gas decide to inspect work being carried out what must not happen?
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All other work must be stopped.
34. Who advises of the voltage to be used when holiday detection tests are being
carried out?
As per specification - 5 volts per micron or as per the engineer of the paint
manufacturer.
35. What is the procedure for rectifying coatings, which have an inadequate
thickness?
Rub down with sandpaper and blow them down. Apply mist coat to bring up the
required D.F.T.
36. What document should be used as a reference for the procedures to remove
contamination from a surface?
BS 7079.
37. What type of risk assessments are looked for when undertaking a cleaning and
painting procedure?
3 bar rail, scaffolds, board toes, safety net, safety line, life belt, boat with radio
contact.
40. What things might you note when carrying out visual inspection for -
a) Preparation procedures: Correct procedure, condition of substrate i.e. free from
contaminants, scaffolding requirement, blasting equipment's, checks for air
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purity, observation of rogue peaks i.e. uneven amplitude, high points should be
abraded.
b) Painting procedures: Correct usage of paints as required by the specification,
colours, visual check for any skinning or jelling of paint, whether tin is sealed
before first use, shelf life, pot life, paint mixing ratios and appropriate thinner
quantity added to the paint, visual observation of the paint system for any paint
defects.
c) Cleaning up of area of operations: Removal of paint debris and disposed as per
local rules, don't fire.
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PAPER - 3. (B-gas, Painting Grade 1) COATINGS
1. Give as much information as you can for the following surfaces preparation
and paint systems.
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i) Top side maintenance: Operations to be carried out by power cleaning to St 3.
Apply alum epoxy primer. Mostly hand cleaning preparations only carried out.
Brush applied coating with urethane acrylic upto 70 microns d.f.t.
j) Galvanized steel structures: Sweep blast and apply.
Power wire brush - apply two damaged areas, epoxy mastic chlorinated resin.
k) Pipeline riser in the splash zone: It should be coated same as all other steel
work in that zone.
l) Deck coatings: It should be non-slip escape system. Over the top coating
screened coat and seeler should be applied. 3-pack copolymer is applied 2-4mm
PAPER - 4. PAINTING GRADE 1 (B-gas)
S1 - 1019
It must be inspected by competent qualified personnel only, every seven days and
always after adverse weather.
5. List the safety measures required for over the side working in descending
order of preference if scaffolding is not practicable.
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7. What documentation is required prior to entering a vessel at offshore?
A permit may be required over and above the hot or cold ones issued by a
competent person to check whether oxygen is in excess of 20%. A stand by person
at the entry, K9 sniffer to determine explosion levels, M.E.L, O.E.L. are also
required before entering a vessel.
It is identified by operator's name, name of oil or gas field. Letter designation sign
is black and yellow in colour.
14. List three safety considerations for all offshore workers working on a
production platform.
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16. For how long must a person work offshore before offshore survival training
becomes compulsory?
A visitor who visits a platform does not stay overnight, for not more than four
times a year and must register his visit every time on the rig.
17. How often is a medical check required for personnel working at offshore?
By reflective strips, by arrows over the specified deck coat, primary routes
-100Mts, secondary routes - 50 Mts.
19. Name three methods of keeping a platform in fixed position?
21. List the essential items of equipment and clothing for an offshore painting
inspector
100% cotton overalls, rigger boots, safety helmets, safety glasses, gloves, life jacket
and safety suit are the equipment's required for the inspector.
22. Eddy current paint thickness metres and electrical thermometrs may not be
allowed at offshore, why?
Possibility of spark from batteries is the reason for not allowing the above said
meters.
24. Which documents are you required to have before boarding a helicopter to go
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offshore?
Intermittent siren and flashlight prepare to abandon rig, whereas continuous siren
and red light indicates to abandon rig.
30. What are the problems associated with the preparation and painting of
helidecks and, splash and tidal zones?
Problems associated are weather conditions, limited time factors, air traffic and tide
levels.
31. When would helidecks, tidal and splash zones are painted?
They will be painted when there is low tides and when there is no helicopter
activity and in day light working only.
Removal of boards after work as the tides will wash away loose boards. It should
be checked regularly.
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33. Why are rigger boots worn at offshore?
Due to static electricity which can occur. They may also melt.
Steel piling, matt support and sea tanks are the three methods.
It is a vessel for laying offshore oil and gas pipelines and setting topsides, risers
and for piling of jackets.
It is the lowest deck. Splash zone walkway between braces and conductors.
Blast cleaning and spray equipment shall be continuously electrically bonded from
nozzle to the surface being painted and backward from nozzle to the compressor,
which shall be earthed.
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H - Hydrocarbon and 120 minutes is the time for the fire proof, which is required to
protect you.
It is the ratio of the heated premier of the steel to its cross-sectional area.
1. Cementious
2. Intumesceen Intumescent.
45. Describe a typical method used to keep a very thick fire proof coating adhered
on to a steel substrate.
A typical method is by the use of wire netting (reinforced), pinned to the substrate
by welding.
46. Name four types of anti-fouling coatings and briefly describe how they work.
1. Soluble matrix type: Water-soluble binder, release of resins.
2. Contact insoluble matrix type: Insoluble binder, release of cuprous oxide.
3. Diffusion type: Chlorinated rubber or vinyl binder releases organic solvents and
diffuses out.
4. Wash off or self polish type: Copolymerised acrylic binder. Erosion washes off.
It is used in offshore structures.
47. On what parts of an offshore structure are anti-foulants applied?
Sub and splash zone legs and upto eight metres of the L.A.T.
49. Name four environmental factors that will govern the effective life of an
anti-fouling coating.
1. Wave speed
2. High salinity of water
3. Water temperature erosion
4. High pH levels
The area is fully enclosed working area usually for safety or climate.
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51. What type of fire proof coating swells up when it reaches high temperature of
200c?
Intumescent.
52. Name four considerations for selecting the thickness of a specific fire proof
coating for protecting structural steel.
1. Type of fire
2. Duration of protection
3. H / PA of the structural formation
4. The critical temperature of the steel (400c is most common)
Hydrocarbons are fuel by oils or gases. Cellulosic fires take longer time to reach
their maximum temperature. (High thermal shock-1250c, short time)
54. Name five ways a fire protective coating can insulate from fire.
55. What type of fire proof coating is currently in favour for use at offshore?
Intumescent.
57. The B-gas draft specification entitled ' Specification for painting and coating
of offshore structures related equipment properties and performance of paints
and coatings' is the - BG / OS / PS / 1206
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Splash zone has a dimension in area. No other deck has this dimension. It is -2.5
Mts. to +12 Mts. of the L.A.T.
59. Are copper nickel surfaces painted? If so discuss the reasons for painting
them.
Yes, copper nickel surfaces are painted, for colour coding and cosmetic coating on
pipe work.
60. Whose responsibility is it to provide up to date data and product safety sheets
for the paints / coatings and solvents used on the contract?
Coating manufacturers.
61. What is the minimum surface preparation standard for internal coating on
caissons?
SA 3.
62. What is the amplitude range required for blast cleaned surfaces?
50 - 75 microns.
63. For what distance must surface preparation overlap onto adjacent painted
areas.
50 mm.
64. What surface preparation method is used within one hour of abrasive wet
blasting?
66. What is the temperature, dew point and relative humidity restriction for finish
blasting?
Dew point should be above 3c above the substrate temperature. RH should not be
higher than 85%.
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68. What type of cleaning is normally specified for repair and maintenance work
and to what grade?
Wire brushing to St 3.
In special occasions by agreement by B-gas engineer. When other methods are not
suitable follow by brushing to St3.
No. Dew point is less than 3c of the metal substrate. It should be over three
degrees. RH % is not known. Manufacturer recommendations are to be followed.
72. What application requirements are specified for the spray application of paint
to large surface area?
73. Name six areas on the offshore structure that must have coatings applied
-BS729.
Gratings, ladders, cages, handrails, standard walkways, kick plates and duct work.
74. Can stainless steel surfaces be painted? If so discuss the reasons for painting
them.
Yes, they can be painted, if the area is under insulation to prevent chloride-
instigated corrosion and for protection from heat.
75. Which procedure would take precedence if there is a conflict between the
project specification and the 12 - 06 / A.
76. Does the B-gas inspector has the right to check scaffolding?
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Yes, but cannot approve.
77. Can authorization for over coating be given verbally by the B-gas inspector?
78. How are painted surfaces, damaged to bare steel during transistor installation,
prepared prior to repair?
By using testex tape & micrometer, by profile gauge, surface needle gauge.
They are measured with an elcometer type, dry film gauge called magnetic banana
gauge. Except for M.I.O. where W.F.T. to calculate D.F.T. is Vs x WFT
IN
For all coatings from below cellar to seabed, coal tar epoxy, glass flake epoxy and
poly siloxane.
83. How many coats of anti-fouling paint are applied to specified areas?
Three to four coats after tie-coat.
84. What paint / coating system is specified for splash zones and to what
thickness?
Coal tar epoxy - 200 microns, epoxy primer - 30 microns, total 630 - microns.
Glass flake epoxy - 2 x 250 microns, epoxy primer - 30 microns, total - 530
microns.
85. Discuss the full system from dry blast preparation to find coat, for coating the
underside of a cellular deck onshore.
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Blast clean to Sa 2 1/2, zinc rich epoxy primer - tie coat, then 3 coats of high build
epoxy.
86. What type of primer is to be used on the underside of a cellar deck if wire
brushing is used instead of blasting?
Heavy duty deck areas, major wear, non-skid areas, copolymers screed, escape
route, helideck, skid deck and drill deck.
91. What finish coat is specified for the topside zone and why?
Ultraviolet, urethane acrylics are the finish coats specified. It has good resistance,
gloss retention, easily cleared and strong binder impermeable.
Yes. Because the hot dip surfaces must be in compliance with BS 729 also there are
systems for O/coating galvanized items and the repair of damaged galvanized areas
by epoxy mastics. Colour code to be given.
The surface has to be degreased, lightly abraded and washed with fresh water and
dried. Coat with urethane or epoxy etch primer only on aluminium. Do not blast
clean.
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94. For what application may zinc silicate with a sealer be specified?
95. How are damaged coatings prepared and repaired when they have not
exposed the metal surface?
96. Coating must not come within fifty mm for preparing welds.
It is used for conserving heat, cold, for personnel protection, frost and anti-
condensation.
98. Name the three general types of materials used in an insulation system.
Calcium silicate, rock wool, expanded perlite and modified slag wool.
BGC - PS - PW C1
Metallic and non-metallic banding must be made from the same material as that of
the jacket.
104. What are the requirements for mastic sealant and rubber or neoprene bedding
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strips?
It must be suitable for use at temperature between -20c to +50c and in rare
occasion upto 80c.
They are made of either stainless steel or zinc coated mild steel.
106. What are the four basic operations for applying acoustic cladding?
1. Preparation
2. Insulation and fixing
3. Repeat insulation and fixing if required
4. Metal cladding and fixing.
107. What is the minimum overlap for the metal jacket on to itself?
25 mm.
BGC - PS - PW C2.
111. Name six materials that could be used for thermal insulation.
Foamed glass, rock wool, modified slag wool, expanded perlite, calcium silicate
and phenolic foam (not to be used in buildings).
Wire netting, binding wire, self taping screws, binding tape, nuts and bolts and
adhesive joint sealant.
117. List four basic operations for applying insulation for heat conservation and
protection?
Preparations repeat insulation and fixing if required, metal cladding and fixing or
self-setting or hard setting cement.
118. List the five basic operations for applying insulation for cold conservation and
cryogenic service.
Stagger insulation, first layer of vapour sealing compound, scrum cloth embedded
in first sealing, second layer of seal then cladding and banding seal, vapour seal and
metal cladding are the five basic operations.
119. How frequently is binding wire used when insulating pipe works?
At 150 mm intervals.
300 mm.
450 mm.
122. What is the minimum metal cladding overlap on pipes greater than 40-mm
diameter?
75 mm.
124. What is the temperature range applicable to the B-gas specification for
thermal insulation?
- 200c to + 1000c
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