Download NACE CIP Level 1 Study Guide: Surface Preparation and Coatings Inspection and more Exams Nursing in PDF only on Docsity!
NACE CIP Level 1 Study Guide
Define Corrosion - ansThe deterioration of a substance, usually a metal from a reaction with its environment What is passivation? - ansA layer of oxides formed on the surface of a metal that provides corrosion protection. What is an example of passivation? - ansStainless Steel What are the elements of a corrosion cell? - ansAnode, Cathode, Metallic Pathway, Electrolyte Describe what happens at the anode. - ansThe metal dissolves into the electrolyte What is the function of the electrolyte? - ansAllows the passage of ions to connect the corrosion cell What is the function of the metallic pathway? - ansAllows the flow of electrons to connect the corrosion cell What is the galvanic series? - ansA listing of metals in order of reactivity (more or less noble) in seawater at 25 C The general rules of galvanic corrosion are: - ansThe less noble (or more reactive) metal when connected to a more noble (or less reactive metal) will corrode preferentially Name the five most important factors that affect the rate of corrosion. - ansHumidity, oxygen, chemical salts, pollutants, temperature General corrosion is: - ansResults in a relatively uniform loss of material over the entire surface, Results in a general thinning of the affected surface, Relatively easy to inspect, Does not casue catastrophic failures Localized corrosion is: - ansTypically pitting and crevice corrosion. It is typically of the most concern as damage is concentrated and loss of integrity or structural failure can result. List some of the common tools/methods used for corrosion control. - ansDesign, Inhibitors, Material Selection, Cathodic Protection, Protective Coatings, Splash Zone Systems, Alteration of the Environment How does NACE define the inspector's role? - ansThe inspector's role is that of a quality control technician responsible for observing and reporting conformance or deviation from the project specification.
What is the inspector's responsibility when it comes to safety on the project? - ansSafety enforcement is not the responsibility of the inspector; however, it is his/her responsibility to report any issues that may affect the project. Name some tests that may need to be conducted during surface preparation and coating operations. - ansTemperature, Relative Humidity, Dew Point, Anchor Profile, Surface Cleanliness Name some of the documentation/reports that may be required to be maintained on a coatings project. - ansDaily/weekly summary, material usage reports, manpower and equipment, non conformance, and conformance What are the most important characteristics of a good report? - ansObjective, Accurate, and Detailed. What is the inspector's primary responsibility and what should the inspector not do as it pertains to the specification. - ansThe Inspector's primary responsibility as the inspector is to "enforce" specification. The inspector is NOT to make changes to the specification for any reason. What type of information could you expect to find on a Product Data Sheet? - ansSurface preparation and application information such as recommended level of surface cleanliness, recommended application methods and equipment such as tip sizes. Also, environmental parameters for application such as max and min temperatures, curing times, recoat windows. What type of information could you expect to find on a Safety Data Sheet? - ansHealth, safety and environmental. The PPE required. Physical characteristics. Emergency responder information. Explain the difference between Quality Assurance (QA) and Quality Control (QC). - ansQuality Assurance - Any systematic process of checking to see whether a product or service being developed is meeting specs. Quality Control - A procedure or set of procedures intended to ensure that a manufactured product or performed service adheres to a defined set of quality criteria or meets the requirements of the client or customer Identify some of the defects that can be caused by incorrect application temperatures. - ansFailure to cure, too rapid solvent evaporation, poor film formation Describe relative humidity. - ansThe amount of moisture in the air compared to saturation level What is the dew point temperature? - ansThe temperature at which moisture will begin to form on a steel surface. Name some of the effects wind may have on a coatings project. - ansblowing abrasives, causing excessive drift or overspray, accelerating solvent evaporation, contributing to the formation of dry spray
What are two of the inspector's responsibilities as it relates to the specification? - ansEnforce the specification, NOT to make changes to the specification During the surface preparation, surface cleanliness should be inspected (as a minimum) the following three times: - ansBefore any surface preparation activities, after surface preparation - before coating begins, between each application of coating in a multi-coat system Factors during surface preparation that may effect service life include: - ansresidues of oil, grease, and soil. rust on the surface. loose or broken mill scale. rust scale. anchor pattern. surface condensation. Common design defects include: - ansHard to reach or inaccessible areas. rivets, bolts, or other connectors. welds. gaps. overlapping surfaces. threaded areas. dissimilar metals. construction aids Common fabrication defects include: - answeld spatter, skip welds, sharp corners & Edges Four typical SSPC SP1 pre-cleaning methods include: - ansSolvent wipe with cloth or rag, immersion of the substrate in solvent, solvent spray, vapor degreasing, emulsion cleaining, chemical paint stripping, use of alkaline cleaners One standare for use with Power Tool Cleaning is: - ansISO St2. ISO St3. SSPC SP-
- SSPC SP- Four examples of tools used for Power Tool Cleaning are: - ansrotary wire brushes, impact tools, needle scaler, disc sanders, piston scalers Two Abrasive Blasting methods include: - ansCentrifugal blasting, sand-injected water blast, slurry blast, wet abrasive blast, dry grit blasting Visual Standards for abrasive blasting include - ansSSPC-Vis 1, ISO 8501- SSPC SP 10/NACE 2 limits staining to ___ per each unit area - ans5% SSPC SP 5/NACE 1 limits staining to ___ per each unit area - ans0% SSPC SP 6/NACE 3 limits staining to ___ per each unit area - ans33% The two types of abrasive blasting nozzles include: - ansStraight, Venturi The specified level of surface cleanliness must be achieved and maintained - ansimmediately prior to coatings application Advantages of centrifugal blast equipment include: - ansDust and fines are contained, abrasives are easily recycled, blasting and priming can be an inline operation, general overall economy compared to air blasting, no compressors, piping, or air handling equipment needed for wheel blasting
The Inspector's checklist for surface preparation should include: - ansambient conditions, conditions of substrate, pre-blast surface cleanliness, shot/grit size selection, shot/grit cleanliness, abrasive blasting equipment, surface profile, surface cleanliness after abrasive blasting, operator qualifications, safety Abrasive media types include: - ansshot& grit (metallic), crushed slag, ceramic grit, silica sand, garnet, agricultural abrasives, specialty abrasives Abrasive media typically used for recycling include: - anssteel shot, steel grit List the pressure ranges that categorize - anslow pressure water cleaning: <34 MPa (5,000 psi), high-pressure water cleaning: 34 to 70 MPa (5,000 to 10,000 psi), High- Pressure water jetting: 70 to 210 MPa (10,000 to 30,000 psi), Ultrahigh=Pressure water jetting: >210 MPa (30,000 psi) Three types of Water-Blasting include: - ansComparator and coupons, replica tape, digital surface profile gauge Types of soluble salt contamination include: - anschlorides, sulfates, nitrates If inspection is to be effective with regards to soluble salts, the specification should very clearly state: - anslimits to be accepted, specific salts to be limited, test method to be used, frequency of testing, locations in which tests should be administered Test for soluble salts include: - ansbresle patch, sleeve test, soluble salt meters, conductivity meters Depth of surface profile can be evaluated by several methods: - ansISO Comparator, replica tape, digital profile gauge The ISO Comparator grades may be recorded: - ansFiner-than-fine grade, fine grade, medium grade, coarse grade, coarser than coarse grade The two types of replica tape are commonly used: - ansCoarse - for 20 to 64um (0. to 2.5 mils), X Coarse - for 38 to 115 um (1.5 to 4.5 mils) List the standards for using the Replica tape: - ansASTM D 4417 Method C, NACE SP 0287- When using Replica tape common errors include: - ansvariation in point-to-point profile over the surface being tested, the presence of particles of dirt on either the replica tape or gauge, gauge accuracy, the rubbing or burnishing technique Goals of a pre job conference include: - ansdiscuss health, safety and environment (HES) Requirements, address / clarify emergency procedures, review and discuss scope of work (SOW), review logistical support, discuss line communications between parties, review known critical hazards, establish list of critical point of contacts (POCS), discuss and clarify inspector (s) responsibilities and authority, clarify the chain of command (reporting system), discuss and clarify areas of concern
Coatings Product Data Sheets (Paint Specs) provide users with the following: - anssurface preparation, storage, mixing and thinning, application procedure, DFT requirements SDS contains the following: - ansProvides workers and emergency personnel with critical information on composition, handling or working with the substance. Includes information such as melting point, boiling point, flash point, toxicity, health effects, first aid, reactivity, storage, disposal, protective equipment, and spill handling procedures. Provides info regarding the safety issues associated with any hazardous (or potentially hazardous) material. Provides instructions for the correct action to take in the event of a spill, explosion, fire or hazardous exposure. Failure of coatings to cure may be caused by: - ansnot adding curing agent, wrong curing agent or incorrect amount of it. problem with material from the manufacturer. environmental issues (too cold, hot, or humid). wrong or contaminated thinner (solvent) Some of the problems that can be caused by amine blush are: - anssurface tackiness or greasiness, incomplete curing, poor adhesion, coating discoloration, poor gloss retention Runs, Sags, and wrinkles may be caused by: - ansapplying the coating too thick, too much or the wrong thinner used, surface too hot to apply the coating, application of coating at the end of its pot life, wrong thixotrope used in manufacturing ____ is a powdery, friable layer on the surface of a coating that is most common with epoxy coatings. - ansChalking Cratering may be caused by: - ansair trapped in the coating and forming a bubble which then bursts, air trapped in the coating during mixing if the proper procedures are not followed Vacules or voids are typically caused by: - ansrunning the mixer too fast Pinholes are: - ansVery small holes in a coating typically caused by air or solvent trapped in porous film and escaping. A common cause of blistering is: - ansSurface Contamination under the applied coating Cracking of coating is noted: - ansWhen the crack extends to the substrate Checking can be described as: - ansfine cracks in the surface of a coating that don't extend through to the substrate Adhesion failures may be caused by: - anscontamination on the surface, wrong surface preparation specified, failure to inspect surface preparation, insufficient surface profile, exceeding the topcoat window, application of incompatible coatings
General types of holiday detectors include: - ansLow-voltage DC, High-voltage DC, High-voltage AC Low-voltage (wet sponge) holiday detectors are powered by batteries with output voltages ranging from ______. - ans5 to 120 V DC Describe Low-voltage (wet-sponge) holiday dectectors: - ansground cable is attached directly to substrate, sponge saturate with a solution of tap water/wetting agent, maximum rate of 30 cm/s (1 linear ft/s) double stroke, used on coatings up to 500 uM (20 mils), may be used on concrete High Voltage DC Holiday detector types include: - ansDC - Pulsed, DC - Constant Current Describe High Voltage DC Holiday Detectors: - ansGroundconection must be made direct to metal substrate (preferred) or indirectly when necessary (e.g., to soil for pipeline measurement). Rule of thumb: 100V/mil (4V/um). Electrode rate of 0.3 m/s (1 ft/s) in a single pass (according to NACE Standard SPO 188). Voltage output range from 800 to 60,000 V The type of High Voltage Holiday dectector used for concrete is a: - ansHigh Voltage DC Constant Current What is a Standard? - ansAn established norm or requirement that is written by industry professionals. A formal document that establishes uniform engineering or technical criteria, methods, processes and practices What percentage of NACE Standards relate to coatings? - ans50%
