WAUGH Technical Services GRADE 3/2 COURSE NOTES Paint / Painting Inspection Course Relating To B. Gas Syllabus BGC PS /Q4 ©Copyright ‘Waugh Technical Services 2001 These notes and associated course material are copyright and may not be reproduced in whole or part by any means without the approval in writing of Waugh Technical ServicesTWI [LM PAINT/PAINTING INSPECTION COURSE RELATING TO BGAS SYLLABUS BGC PS/Q4 ™I Training & Examination Services Granta park, Great Abington, Cambridge GB1 GAL, UK In Association with Waugh Technical & Education Services © Copyright Waugh Technical & Education Services, 1999WAUGH TECHNICAL AND EDUCATIO’ SERVICES ‘Course contents for B.Gas Syllabus B.G.C. PS/Q4 Grades 3/2. PAGES HEADING CORROSION THEORY MILLSCALE THE GALVANIC SERIES METHODS OF ARRESTING CORROSION SURFACE PREPARATION DRY ABRASIVE BLAST CLEANING CABINET AND VACUUM RECLAIM SYSTEMS HAND AND POWER TOOL CLEANING B.S. 7079 AND S.18, 05-59-00 : TESTING FOR SURFACE CONTAMINATION WET BLAST CLEANING NEEDLE GUNNING FLAME CLEANING CHEMICAL CLEANING PAINTS ee en ee & PAINTS— ADDED INGREDIENTS SOLVENT CHARACTERISTICS PIGMENTS PAINT DRYING AND CURING MAINTENANCE PAINTING 123, GLOSSARY OF TERMS ~ METAL PREPARATION AND PAINTS PAINT MANUFACTURE PAINT AND PAINT FILM TESTING ARTIFICIAL WEATHERING BSS. 2015 ~ PAINT FAULTS FINENESS OF PIGMENT GRIND VISCOSITY DENSITY OPACITY DRYING AND CURING TESTS WET FILM THICKNESS DRY FILM THICKNESS CALCULATION OF VS%, WF.T. AND DFT. ADHESION TESTING WEATHER CONDITIONS ere ww & t_ es 8 ey LL fea APPLICATION OF PAINTS PAINT COLOURS HEALTH AND SAFETY SPECIFICATIONS as gy S eaaiiiceed ‘Waugh Technical & Education Services 1999to Hob toa. to. wo 4 10. (AUGUST 1995) PAGES SP] (CATH HEADING GUIDELINES ABRIDGED DEFINITIONS SAFETY ON SITE ENVIRONMENTAL REQUIREMENTS ABRASIVE BLAST CLEANING METHODS MANUAL AND MECHANICAL METHODS OF PREPARATION CONDITIONS FOR FINAL SURFACE PREPARATION SURFACE PREPARATION OF WELD AREAS CLEANING DOWN SELECTION OF PAINT SYSTEMS APPLICATION OF PAINT SYSTEMS ‘OF PAINT THICKNESS SPECIFIC PAINTING APPLICATIONS NUMBERS 1 — 6 STATUTORY. REGULATIONS BRITISH STANDARDS INSTITUTE OF GAS ENGINEERS RECOMMENDATIONS B.GAS PUBLICATIONS ‘Waugh Technical & Education Services 1999CORROSION THEORY Ferrous metals (i.e, those which contain iron) corrode for the following reason. The iron content which goes into the steelmaking process starts its life as an ore beneath the ground, where it is in harmony with its surroundings and is chemically inactive. When we mine this ore and heat it to very high temperatures during steelmaking, its chemical nature changes and ever after attempts to revert back to its former natural inert state. This is what we see as rusting, The rusting of steel is an electrochemical process called Electrolysis, When metal is immersed in an electrolyte an electrical current will flow between certain areas of the metal known as Anodes and Cathodes. The current flows from the Cathode through the metal to the Anode and returns through the electrolyte which is capable of conducting electricity. This is called the Electrolytic Cell and the result is the destructive corrosion of the Anode area whilst the Cathode remains protected. The air itself is an electrolyte and contains sufficient moisture and impurities ‘for the promotion of corrosion to occur in the steel. The speed and severity at which corrosion can occur depends on how strong the electrolyte can become. The factors which influence this are as follows. ‘Variations in oxygen content on the steels surface (Wet/Dry) RH.% (above 60% is critical) Presence of impurities in the air (Acids, Alkalis, Salts etc) Higher nobility metals in contact with the steel (e.g, Millscale) ‘The above conditions represent the reasons why corrosion is particularly severe in industrial and marine environments. Here moisture, salts and other impurities in the air are to be found in much higher quantities. ‘Waugh Technical & Education Services 1999wa MILLSCALE Millscale is a thin black flaky layer of oxidised iron formed on the steel during its manufacture. It occurs because when the steel is being forged into various components it is worked at temperatures around 1000 °C. Whilst the steel is at these high temperatures it is also in contact with the cool air which causes the Millscale to be formed. Ir is essential for Millscale to be removed from the steel surface during blast cleaning for the following two reasons. 1. Millscale is more noble than steel and when parts of the Millscale break away the exposed areas of steel (Anode) will sacrifice themselves to preserve the more noble surrounding Millscale (Cathode). 2. If painted over, the Millscale which is loosely adhering and flaky will leave the steel, bringing the paint away from the substrate thus causing early breakdown of the system due to the lack of adhesion. Waugh Technical & Education Services 1999“bt Lie tu = THE GALVANIC SERIES Metals and metal compounds carry an order of nobility which determines their ability to corrode or not, Gold Noble (stable) Silver Copper Millscale Steel Aluminium Zine Ignoble (Unstable) This nobility is found by testing in sea water at ambient temperature. ‘We can use the galvanic series to bring about cathodic protection to steel. There are two ways in which this can be achieved, 1._BI-MET, c SION ‘When two differing metals are attached closely together the less nobie one will act as an Anode to the more noble one (Cathode) and will sacrifice itself SA COA! When a coating whose metallic pigment particles are Jess noble than steel (e.g. Zinc ot Aluminium) are coated onto steel they will sacrifice themselves in order to preserve the more noble steel. When coatings are used for this purpose they must contain around 90% of metallic pigment. ‘Waugh Technical & Education Services 1999~bs te TE GALVANIC SERIES Meals and metal compounds cary an order of nobility which determines their ability to corrode or not. Gold Noble (stable) Silver Copper Millscale Steel Aluminium: Zine Ignoble (Unstable) This nobility is found by testing in sea water at ambient temperature. ‘We can use the galvanic series to bring about cathodic Protection to steel. There are two ‘ways in which this can be achieved, 1, BIMETALLIC Ct ION When two differing metals are attached Closely together the less noble one will act as an Anode to the more noble one (Cathode) and will sacrifice itself. 2. SACRIFICAL COATING When a coating whose metallic pigment particles are less noble than steel (e.g. Zinc or Aluminium) are costed onto steel they will sacrifice themselves in order to preserve the more noble steel. When coatings are used for this purpose they must comtain around 90% of metallic pigment. ‘Waugh Technical & Education Services 1999ME B R PRINCIP] SACRIFI DS OF STING CORROSION This isolates the substrate from the environment by means of a low permeability coating system. This type of system is usually made up from around four coats and contains an MLO. coat which helps give the paint system its low permeability, This involves making a paint whose pigment particles (Zinc or Aluminium) are less noble than the steel onto which it is coated. The result is that the less noble coating (Anode) sacrifices itself to the more noble steel (Cathode). Involves the dipping of steel components into a bath of molten zinc (Anode) at around 450 °C this leaves a zine coating on the steel component of between 8Sum - 130um and is directed under BS.429 - Hot Dip Galvansing, 729 The tumbling of small steel fittings etc, in a hot zinc dust which leaves a coating of between 15pm - 30um. Chemical reactions which are achieved between rust inhibitive pigments in the primer and the substrate. ‘The spraying of molten zinc or aluminium onto steel. Often used for components which operate at high temperatures and which are usually sealed to improve appearance and extend the life of the coating. Blocks of metal ignoble to steel which are attached to steel structures as a sacrificial anode. ‘Waugh Technical & Education Services 1999‘There are many methods used to prepare metals prior to painting, Dry abrasive blast cleaning Flame cleaning Water blasting. Needle gunning. + Pressure washing. (Cleaning only) Abrasive dises. Chemical cleaning. Scraping. Wire brushing. Weathering. J ~atore any typeof surtace Preparation takes place it is essential that all oil, grease, and other » surface contamination is removed completely due to the fact that they may sll be present | after preparation has taken place, In addition the preparation process needs to be carried out with a high degree of safety in | _ mind 2s this process can require the use of pneumatic equipment and the incidence of dust | which can on occasions be toxic. Norzle 2 Coes Spee eg) o Hose i: Air hose : ‘Waugh Technical & Education Services 1999on DRY SIVE B! CLEANING OPEN SITE BLA: Al ‘The equipment required including safety features are as follows: Compressor (Max 100psi) Pressurised pot Carbon impregnated hoses (Reduces static shock possibility) Reinforced hoses External couplings (Helps prevent blowout) Dead mans handle Personal equipment (Air fed helmet, ear defenders, boots, gloves, leather apron) In addition warning signs, tapes or barriers and safety sheeting or an encapsulated area should be present in order to protect other site workers and or surrounding buildings or equipment ‘The abrasives used in open site blast cleaning should be expendable which means they are used only once. In essence when they hit the steel at high speed they shatter on impact and fall harmlessly to the floor. ‘Types of expendable abrasive are: Copper slag Crushed glass Ic € Walnut shells Plus others Note Free sand must not be used in dry blasting operations due to the risk of Silicosis. Nozzle types There are two types of nozzles in common use, both are usually lined with tungsten carbide to give longer life. VENTURI Which can generate the speed of abrasive at up to 450 mph. and which gives an even blast pattem over a relatively large area. STRAIGHT BORE Which can generate the speed of abrasive at up to 220 m.p.h. and is used for small or repair areas and softer metals. ‘The pressure at which the abrasive is delivered to the blast nozzle can be measured by using a hyperdermic needle gauge. ‘When site blast cleaning the cleanliness of the steel surface and its amplitude are governed by the abrasive characteristics and human factors as follows. ABRASIVE HUMAN FACTORS Size Speed Hardness Angle Density Distance Shape Time ‘Waugh Technical & Education Services 1999c T AND VAC DRY B. CLEANING SYSTEMS These are found in factory situations and are usually in a fixed position although they can be obtained in a portable form for blasting flat areas. Often items such as large quantities of pipes are cleaned by this method which is both effective and easily controlled. The abrasive used is usually iron or steel shot and grit which can be reclaimed, cleaned, monitored for size and reused up to 20 times. To obtain the required grade of cleanliness and to keep the amplitude to within the specification requirements the shot and grit are mixed together. For instance, if the amplitude was min 30m and max 75m the mix of shot and grit might be around 75% shot to 25% grit It is essential that steel or iron shot/grit are used in a closed cleaning system as they do not shatter on first impact. They would bounce back from the steel surface creating a danger to nearby people and equipment. Also, they are very expensive and must be reclaimed to ‘warrant the cost of using them. ‘The British Standard which deals with this type of abrasive is B.S. 2451 ‘Waugh Technical & Education Services 1999HAND AND POWER TOOL CLEANING This method of cleaning refers to methods of cleaning by hand such as grinding, abrasive discing, scraping etc. but is usually concluded by wire brushing in order that a visual standard to compare with the Swedish Standard $IS-05-59-00 contained in B.S._7079 has been achieved. Wire brushing standards are achieved by both manual and mechanical wire brushing. Care must be taken when carrying out the wire brushing process that a polishing of the steels surface does not occur as this can lead to poor adhesion of the subsequent paint system. For safety reasons it is often specified that the brushes used are of the non sparking type, in these cases the brushes would be made from Phospher Bronze or Berylium Bronze, in Phosphes Bronze or Berylium Bronze. Wire brushing is only carried out on rust grades B, C and D. eT- 2 sT-3 ‘Waugh Technical & Education Services 1999BS. 7079 AND S.LS. 05-59-00 The Swedish Pictorial Standard 05-59-00 is contained within B.S. 7079 PREPARATION OF RT »PLICATION OF P, REL, PRODUCTS. ‘The Swedish Standard gives visual information on the following RUST GRADES which depict the condition of the steel before preparation. A. Covered in Millscale with little or no rust. B. Ammixture of Millscale and rust, C. _Milllscale gone, rusted with slight surface pitting. D. Heavily rusted and pitted. BLAST CL] S SAI. Light Blast Cleaning. SA2. Thorough Blast Cleaning. SA2M. Very Thorough Blast Cleaning. SA3. Blast Cleaning to Visually Clean Steel GRA) OF IS} sT2 Thorough Hand and Power Tool Cleaning (Manual) ST3 ‘Very thorough Hand and Power Tool ‘Cleaning (Mechanical) Waugh Technical & Education Services 1999STING FOR CE IN Various tests exist to determine contamination left on a surface after blast cleaning. The contamination usually consists of either Hygroscopic Salts or Millscale and the tests are as follows. HYGROSCOPIC SALTS Soluble Iron Salts - Potassium Ferricyanide Test. Soluble Chlorides - Silver Nitrate Test. MILLSCALE Copper Sulphate Test Hygroscopic Salts are Water Loving Salts, and if left on a blast cleaned surface and painted over, will react and cause extensive blistering in the paint film. (Osmotic Blistering) ‘Waugh Technical & Education Services 1999u WET BLAST CLEANING The use of wet blast cleaning is becoming more popular due mainly to the following two reasons. 1. Itis more environmentally friendly than dry blast cleaning, 2. The equipment used is becoming increasingly effective as it develops. The equipment used can be with or without an abrasive injection and can operate from 100 Psi to up to 60,000 psi which represents the latest developments in water blasting equipment, At these very high pressures all contamination is removed and a profile can be cut on the steel, In addition wet blast cleaning is useful in removing toxic coatings as it does so without dust. . PRESSURE WASHING Whereas wet blast cleaning is designed to remove scale, rust and paint from steel, pressure washing is a low pressure (typically 100 psi) process mainly used for cleaning painted surfaces. This can be with or without detergent and is useful for removing salt and chloride contamination from surfeces particularly when maintenance painting. ‘Waugh Technical & Education Services 1999ty eH eo ey rae es es 1 EDL A Needle Gun is air operated the head of which consists of many small cross section Tungsten Needles. These bounce in and out rapidly and independently thereby making for effective cleaning around bolt and rivet heads. Usually permission is required for their use as they can create amplitudes above 100 um, can leave rogue peaks and can impress impurities into the surface. ‘Waugh Technical & Education Services 1999ELAME CLEANING Is where @ high temperature flame of around 3000 degrees C is passed over a corroded surface. This causes the metal and rust to expand at different rates and loosens them from each other. The intense heat also causes the rust to dehydrate and become a powder, and frees the surface from moisture, oil and grease. DISADVANTAGES ARE Dealing safely with high temperature naked flames. Damage and warping to thin materials. Heat causing loss of strength to steel fastenings. ADVANTA‘ ‘Metal is perfectly dry for painting. ‘Waugh Technical & Education Services 1999a (ACID PICKLING} Is a factory process for cleaning small steel components which can go on to be painted but which are often galvanised as part of the factory operation. J SEQUENCE OF OPERATIONS : Degreasing - using a suitable solvent. 1 Pickling - immersion in a tank of dilute Sulphuric Acid at a given temperature. Neutralising - spray washing to remove acid and remaining contamination. Phosphating - if specified. } . DISADVANTAGES 7 The size of the metal to be cleaned is governed by the size of the acid tank. Associated dangers with handling acids. ‘Waugh Technical & Education Services 1999. PAINTS Itis commonly believed that the definition of paint is a liquid which is capable of drving to 2 continuous film. In this day and age 2 great deal of technology is being applied to the development of new paints and coatings. Apart from the paints performance the need for solvent reduction or even elimination in paints is of the utmost importance, this because solvents are very harmful to both the environment and the individual, To this end powder based coatings, water based coatings and compliant solvent based (low solvent content) coatings have been developed. Still however the vast majority of paints in use today are "raditional solvent carrying paints soit is those and their constituenis which we need to study, A traditional solvent carrying paint consists of three basic constituents these are, BINDER _Binds the particles together and holds them in suspension. 7. Gives the paint its finish. Makes the coating adhere to the surface, . Gives flexibility to the paint film : Converts the coating to a solid dry film. Gives resistance to water chemicals and - abrasion. J . SOLVENT Forms the evaporative part of the drying process. e Thins the paint so it can be applied easily. ‘Washes out brushes and equipment, Acts as a degreasing agent if approved. Gives colour to the paint. Gives opacity to the paint. Gives resistance to acids, alkali and light. NOTE A binder and solvent are both liquid, they must be compatible and fully : dissolve with each other, whereas a pigment is a powder and can be mixed into any binder/solvent combination. Many paints take their name from the : binder they possess. ‘Waugh Technical & Education Services 1999ADDED INGREDIENTS Other items which can be added to paint in order to improve its performance. DRIER OR CATALYST Some binders such as oils or resins need added driers to speed up the drying process. ‘Two pack paints rely on a chemical action to bring about drying and the catalyst provides this. EXTENDERS ‘Are cheap mineral powders which can be added to paint To Poseurs &midtactt in order to make it flow more easily, increase opacity ut most of ali lower the cost of the paint. PLASTICISER ‘Added to the paint to prevent a brittle film, ‘THIXOTROPIC AGENT Gives 2 jelly like structure which gives the paint high build and anti sag properties. ANTI SKINNING AGENT Helps prevent oil based paints from skinning over. STABILISER Holds modem synthetic film formers intact and helps to prevent flocculation occurring in the tin. ‘Waugh Technical & Education Services 1999wit ILVENT. ICS As stated previously the binder and solvent in a paint must be entirely compatible with each other, with the solvent evaporating from the wet paint film as the first and sometimes only part of the drying process. List of binder and solvent compatibility. Strongest binder Epoxy Acetone Solvent = Chlor Rubber Xylene 5 Alkyd Resin White Spirit J Weakest binder Emulsion Paint Water Solvent Stronger solvents are required for powerful binders as their drying process is more complicated. This is known as solvent power. Where the power of the solvent matches the i strength of the binder. If the solvents rate of evaporation is too rapid problems can be caused with the paint film, usually dry spray occurs, J FLASHPOINT Each solvent has a flash point, that is the temperature at which the vapours of a liquid will ignite if an external source of ignition is introduced. This is determined in a closed cup of the Abel ype. fe TOXxIcrry As stated previously solvents are toxic. The amount of toxic solvent content in the air can be measured by something like a breathalyser a called a Draeger tube, and which gives results in P.P.M. (Parts Per Million) all solvent exposure limits are published in the C.0.S. H. Regulations of 1988, ' 2 2 ‘Waugh Technical & Education Services 1999[sr eo) ts B32 Ss Pigments are powders which can be obtained from the earth, or which can be organic or inorganic. In many modem coatings the pigments used are inorganic as man can now make pigments on @ laboratory bench much more successfully than natures products which were previously used, Each pigment has certain information catalogued about its characteristice and qualities. These are as follows. Origin - Earth, organic, inorganic. Specific Gravity ~ i ~ Ability to cover over a previous coating or surface. Tinting Strength- Ability to colour a paint. ‘ Resistance to - Acids, alkalis and light. The opacity, tinting strength and resistance to acids, alkalis and light ofa pigment are graded one scale of 1~5. 1 being good and 5 being bad. There are many pigments but so far as the painting of metals is concerned itis important that the primer used has a rust inhibitive pigment. Examples are. Calcium Plumbate Red Lead Coal Tar Zine Chromate Red Iron Oxide Zinc Phosphate Certain of these pigments are toxic and their use is restricted. LAMINAR PIGMENTS Pigments such as M.L.O., Graphite, Mica, Aluminium Flakes and Glass Flakes have a particle shape like small leaves or hands and upon drying of their paint film, overlap and interweave with each other to give a coating which is highly resistant to the passage of water CRITICAL PIGMENT VOLUME CONCENTRATION - refers to the amount of pigment contained in @ paint and how this affects it characteristics. Le. e paint containing lot of Pigment and litle binder will be a primer or midcoat, will have good opacity and a flat Anish Whereas a paint containing very litte pigment and a lot of binder will have poor opacity but will carry a high gloss finish. ‘Waugh Technical & Education Services 1999te ou. = . 19 PAINT. IG AN) Paints employ differing methods of drying and curing according to type. Examples are Emulsion - Coalesence. Alkyd - Solvent evaporation followed by Oxidation. Chlorinated Rubber + Solvent evaporation only. 2 Pack Epoxy - Solvent evaporation followed by chemical curing Fusion Bonded Epoxy- Heat cured. CONVERTIBLE COATINGS Are those which undergo a chemical change upon drying and afterwards cannot be softened or damaged if they come into contact with their own solvent. NON CONVERTIBLE COATINGS Are those which dry by solvent evaporation only. ‘No chemical change takes place and after drying the paint would be softened or damaged if it came into contact with its own solvent. IN PERIOD Is the length of time a 2 Pack Paint has to stand after mixing and before application. This time allows air bubbles to escape and/or chemical reactions to take place and is stated by the Paint Manufacturer. POT LIFE Is the length of time following induction that a 2 Pack Paint remains in an applyable condition according to the Manufacturers instructions. Waugh Technical & Education Services 199920 MAINTENANCE PAINTING Once 2 metal bas been painted when new it must be treated periodically to maintain its resistance to corrosion attack and maintain its appearance Before maintenance painting can take place the nature of the existing system must be established in order to make informed decisions about what preparation needs to be carried out prior to recoating 1 It needs to be established whether the existing system contains any toxic coatings as this will dictate the method of preparation used. 2. Are the existing coatings compatible to the new system in terms of — ee eee eee ee oe Adhesion ie Possibility of solvent stripping ] Possibility of bleeding ‘3, Further information required ~ extent of surface contamination > extent of paint breakdown. extent of corrosion. 7 Where adhesion problems, solvent stripping or bleeding might occur, a tie coat would be J employed to prevent these particular problems arising. Pi] EG : New Coeds Bleceius, To Puxert lading enigking Cooling New Cong ect Sdveck p Totverent Biert 2 existing Caeding Aliya ee ‘Waugh Technical & Education Services 1999Ee i] GL tY OF TERMS TAL TIO! PAINT TECHNOLOGY J FERROUS METALS : Those which have an iron content. J NON FERROUS METALS - Those which do not have an iron content. a GALVANIC SERIES . A table of named metals given in their ability to resist 7 ae d MULLSCALE - A thin black flaky layer of oxidised iron formed on the J steel during its manufacture ABRASIVE ~ Ametalic or mineral material hurled atthe steel to vans. ] bring about its cleaning. Bs 2es1 (stent f Teen ot COSA, - Regulations which govern the use of solvents and sand J in the Industrial Painting Industry, ( a BAS.W.A. - Health and Safety at Work Act 1974. 4 CONTROL OF LEAD AT WORK ACT 1984 - Methods of dealing with coatings which > hhave a lead content, - RUST GRADE > An A~D grade given to the condition of unprepared | steel. DE OF SS- A grade given to blast cleaned steel following = Preparation. . AMPLITUDE + The given measurement of the peak to trough height of 7 a blast cleaned surface. o ROGUE PEAKS + Peaks which rise above the permitted amplitude. = BS. 7079 + British Standard document which relates to metal preparation and which contains the Swedish Visual 7 Standard 05-59-00. i ENCLOSED BLAST CLEANING - That which is carried out under factory controlled - conditions and which often uses steel or iron shov/grit as = an abrasive. = SUITE BLAST CLEANING - That which is carried out on site or in an open situation = and which employs an expendable abrasive for its operation. . ‘Waugh Technical & Education Services 19992 HYPERDERMIC NEEDLE GAUGE - An instrument to determine the pressure being delivered at the blast nozzle. WET BLAST CLEANING - A method of blast cleaning of up to 60,000 p.s.i. which employs water or water plus abrasive which is environmentally friendly and which is particularly useful for the removal of toxic coatings. io WASHINt . A low pressure method of removing contamination from a surface. STEAMCLEANING —-_—_A low pressure method for removing contaminstion from a surface, particularly oil and grease. HAND & POWER TOOL CLEANING - Methods of surface preparation by hand. BURNISHING + Anundesirable polishing up of surface leading to possible adhesion problems caused by the wire brushing Process. CHEMICAL CLEANING - The cleaning of metals by dipping into an acid solution. SOLVENT B, “AINT - WATER BORNE PAINTS - PAINT DRYING : RATE OF Ev, [ON - One whose solvent is entirely compatible and will fully dissolve in its binder. One whose solvent is water. A powder which is surrounded and wetted by a binder and which represents the VS% of a paint. The transition of a wet paint film to a solid dry state. The ability of a solvent to allow the molecules in'the paint to move easily during the drying process. The rate at which the solvent evaporates during the drying of a paint film. Too rapid drying can cause dry spray. The minimum temperature at which the vapours of a liquid will ignite if an external source of ignition was introduced. ‘Waugh Technical & Education Services 1999L ee eee 4 INDUCTION PERIOD POT LIFE TIE COAT STRIPE COAT DATA SHEET ‘The poison value of a solvent measured in P.P.M. A pigment which gives a coating low permeability, One which is used to produce finish coatings or coatings which will provide cathodie protection. ‘The relationship between the pigment and binder in a paint, and its effects on the paints characteristics. The length of time a 2 Pack Paint needs to stand after mixing and before application. ‘The length of time after induction that a 2 Pack Paint can be applied. ‘A coat of paint which can tie two normally incompatible systems together. ‘An extra coat of paint applied by brush to welds and ‘edges which guarantees min. D-F.T. of the system in ‘these areas. Information on a particular product regarding all aspects of that product and supplied by the Paint Manufacturer.ee be L se aaa gal we 24 PAINT MANUFACTURE Manufacturing paint isa relatively simple process. ‘The skill in making paint is how the paint saker utilises the vast array of various ingredients at his disposal. Paint is manufactured in paint mills whose main job is to grind down the pigment to the finest possible degree whilst at the same time mixing the ingredients to smooth high quality paint. TYPES OF PAINT MILLS Cons operator) DIRECT CHARGE MILLS. Which take and mix all the raw ingredients together. ‘Types are - Ball Mill. Attritor Mill. High Speed Disperser. Jo Sige opsnSin) PREMIX MILLS Take the ingredients which have G been pre-mixed to a rough consistency and refine this mixture to a high quality paint. This system is used for large production runs. ' Sand, Pearlon Bees mil i CeNoid mill, Single Roll mal ov Cople Rell il TYP! At 1G PI Select and assemble raw materials, Mill the paint Carry out any quality testing required. Can the paint. Warehouse and distribute the paint.eaiaee Cees eseeca gee eee ee 25 P AND P, M. IG The testing of paints and paint films is a wide ranging affair. These tests have been built up over many years and often involve somewhat strange and unlikely methods for achieving results. The British Standard for dealing with testing is B.S. 3900 METHOD OF TEST FOR PAINTS. This document is divided into eight separate parts each one dealing with a separate aspect of testing procedures. They are. Group A. - Test on Liquid Paint (Excluding Chemical tests) Group B. - Tests involving chemical examination of Liquid paints and Dried Paint Films. Group C. - Tests associated with Paint Film formulation. Group D. - Optical tests on paints. Group. - Mechanical tests on Paint Films. Group F. - Durability tests on Paint Films. Group G. - Environmental tests on Paint Films. Group H. - Designation of intensity, quality and size of common types of defect. General principles and rating scheme. ‘The eight separate groups of tests can be obtained individually as required for any particular testing need, ‘Waugh Technical & Education Services 1999- oy L ee Cee 26 AR WEA’ iG Formerly natural weathering of painted samples provided information on how well paints performed when subjected to various environmental conditions. This however was 2 slow process which sometimes took years to bring back results. In order to speed up this process a number of accelerated weathering devices were devised which brought back test results in a much shorter time. COMMON TESTS IN USE SALT SPRAY BOX ‘Simulates how paints behave under marine conditions. WATERSOAKTEST Tests for Paint Film permeability. BOX ‘Simulates how paints behave in a high humidity environment TEMPERATURE CYCLING __Tests for Paint Film flexibility by subjecting samples to alternate high and low teraperatures. COLD CHECK TESTING Tests for low temperature contraction cracking. ‘Waugh Technical & Education Services 1999‘ey : a PAINT FAULTS Faults which occur with paints are described in 1015, +6 ‘These faults are due to three main causes. EXAMPLES. BLEEDING sLISTERING CBALKING CISSING Faults “In the can” (Manufacturing faults) . Problems which occur due to poor preparation. Problems which occur due to incorrect or poor application or interference by ‘weather. ‘The action of a material in penetrating and discolouring a coating applied on top of it. In particular, Bitumin, Red Pigments and Creosote cause problems. ‘The formation of dome shaped blisters in a Paint Film. They can be BI which are usually caused by the expansion and contraction of the Paint Film against the substrate or OSMOTIC BLISTERS which can be caused by water entrapment, solvent entrapment or hygroscopic salts left on a blast cleaned surface. The breaking down of a Paint Film to become chalky or powdery ‘usually due to disintigration of the binder caused by attack from U.V. light or severe weather conditions. AA failure of the paint to form a continuous film usually due to oil sgzease being present on the surface. ELOCCULATION The separating out of a paints constituents in the tin and their refusal to ‘GRINNING be stirred back together again. ‘Seeing the underlying surface through the finish coating. Usually due to poor application technique, too great a difference in colour between the mid coat and finish coat or too few coats being specified to bring about good opacity. Missed or poorly coated areas on a painted surface. ‘Small defects down through a paint coating caused by escaping air bubbles. Waugh Technical & Education Services 1999wil 28 FINENESS OF PIGMENT GRIND During the paint milling process the pigment content of the paint is ground down to a very fine degree. This is required in order to give the finished Paint Film smoothness, but more importantly enables the paint to camry a high degree of gloss where this is required. If 2 pigment has only been coarsely ground the surface finish will be relatively rough and when subjected to a light box test will appear somewhat dull due to the reflected light being scattered rather than reflected. ‘The fineness of grind gauge which is also sometimes called a Hegman Grind Gauge is a block of stainless steel around 175mm long by 65mm wide, It has a channel running along its length going from Oym to 100m, the depth is identified along its length. Paint is applied to the channel and then a flat edged scraper is pulled from the 100ym deep end towards the shallow end. At some point along the way as the paint in the channel becomes shallower pigment particles will break the surface. Where between 5 ~ 10 particles break the surface this is said to be the pigments fineness of grind. Z, ae mid Cooks owe qr Qo Hote Gorm. ¥ Finish Coats oe ty piclly a aetna ‘Waugh Technical & Education Services 1999 J bpetoteer>| Le 29 viscosiTy “The term viscosity means THE MEASURE OF A FLUIDS RESISTANCE TO FLOW. We test for viscosity to find out how much solvent has been added to 2 paint. In order to provide a level playing field all paint is tested at 20 °C+ - 0.5 °C. “There are two types of paint and they are tested using different equipment. Thixctropic Paint - Rotation viscometer. Free Flowing Paint - Ford Flow Cup No. 4 ‘Waugh Techaical & Education Services 199930 DENSITY Density is termed as weight per unit volume and so is found out by using the following formulae. Weight the unit used is g/om’®, Volume We test for the density of a paint in order to find either how much solvent has been added to the paint or to find out if a two pack paint has been mixed to the exact correct ratio, A Density Cup is a small black cup made from Aircraft Alloy, usually it holds 100cc and the lid has a hole in the top. CALCULATING DENSITY The density of a paint is calculated by Weight, Volume Therefore if 5 Ltr tin of paint weighed 7.5 Kg its density would be 7.5 = 1.50 g/cm, 5 CALCULATING THE DENSITY OF A TWO PACK PAINT WHEN MIXED, This involves find the average density of all the parts when mixed together. Therefore if the density of Part A (paint) was 2.64 g/cm’ and the density of Pare B (Catalyst) was 1.86 g/om (assuming 1 to 1 mix) the density of the paint when mixed would be 2.64 + 186 2 450 = 2.25¢em ‘Waugh Technical & Education Services 1999ta T 3 opaciry Describes how well a paint will cover over the undemeath surface and is the opposite to transparency. The opacity of a paint is determined mostly by the amount of pigment in the paint. The greater the pigment quantity the better covering power the paint will possess Any piece of equipment which measures opacity is called a CRYPTOMETER, ‘Two types are in common use. HIDING POWER CHARTS ‘SIZE OVERALL: 280 x 180mm Ree se gee Gece eer Lea ee Geiger eed tea oc ‘Waugh Technical & Education Services 199932. DRYING AND CURING TESTS BALLOTINI TE! Ballotini which are tiny glass balls are dropped on to a wet painted panel. The time in hours is given at the side of the panel and where the Ballotini fails to stick to the painted pane! drying bas occurred. STYLUS TEST Similar to the Ballotini test, the Stylus test employs a series of trailing needles which pass over the wet painted panel, because the needles are set at different tensions it can be established when the paint is tack dry, hard dry and fully cured. pallotini Terk & a l ‘Waugh Technical & Education Services 1999' L Le ous L 3 WET FILM THICKNESS Wet Film Thickness readings are taken with each coat as an indication of what the D.F.T. will be, except in the case of coatings which contains M.LO. when the W.F-T. is taken and used to make a calculation for the D.F-T. reading. ‘Two methods are used to take W.F.T. readings. 1, ECCENTRIC WHEEL 2. W.E.T. COMB GAUGES When a comb is selected for use the range for the thickness will be obtained from the specification. This thickness should fall in the centre of the range of teeth as this should eliminate the possibility of an error in reading. ‘The readings are taken immediately after the paint has been applied for the following two reasons. 1, The sprayer will stil be on standby so that the thickness can immediately be rectified if necessary. 2. A lapse in time would mean that the wet paint film would already be starting to shrink therefore a true W-F.T. reading would not be obtained. ‘Waugh Technical & Education Services 1999ee eee nee ee a mo DRY SS There are four methods of determining the D.F.T. of a paint film. 1 a 3 4, NON DESTRUCTIVE TEST GAUGES eg. Electronic Gauge and Banana Gauge DESTRUCTIVE TEST GAUGES P.1.G. (Paint Inspectors Gauge) TESIPANELS Panels which are prepared in advance of the job commencing ‘These panels which are exactly the same as the substrate to be painted are prepared and coated with the same materials and by the same application method. This proves in advance that the specification requirements can be met. CALCULATION — by using the Formula VS x WFT : 100 ‘Waugh Technical & Education Services 1999ALS TION ILUME SO) The following formulae are used to calculate the above. VS% = x 10( is WFT WET = 100xDET fe VS J, DFT = VSxwer 100 : ‘Waugh Technical & Education Services 1999ION. iG Adhesion of a paint system is of the utmost importance as if good adhesion is lacking very early breakdown will occur. CROSS CUTEST anes ROSS BATCH TEST DOLLYTEST = METHOD Apply pull off force. ‘Waugh Technical & Education Services 1999 363900 Pash E V Peck EG Clean, degrease and roughen surface. Stick down Dolly with regular araldite. Leave for 24 hours at 25 °C. Cut round Dolly to isolate paint underneath ‘Check — at what P.S.I. failure occurred. - whether failure was adhesive or cohesive.J ee ae eee ee ee (ened ee jeeeyeee (eaiyee (ian Lo 37 WEATHER CONDITIONS It is of the utmost importance that weather conditions can be correctly established by the inspector. He should take readings each day before work commences, and several more times both in the moming and afternoon. Also, if there is an apparent change in the weather. As well as needing to cary this out in order to give permission for work to commence the readings obtained are entered on the inspection records. Under B.Gas specifications paint may be applied when. we ‘The air Sr'metal temperarure is at least 3 °C above the dew point temperature, The relative humidity is ess than 90%. ‘The temperatures for application are within the manufactures given limits. DEWPOINT Is the temperature at which condensation would form on a surface and which is obtained by a calculation made from the wet and dry bulb temperatures. RELATI Is the amount of water vapour in the air expressed as a percentage and which is obtained by a calculation made from the dry bulb and dew point temperatures. METAL TEMPERATURES It is most important that the metal temperature is established prior to painting, this is obtained by using a ‘magnetic steel thermometer or a digital thermometer. NOTE - Ifthe DB. temperanure is the same as the W.B. temperature the DP. temperature would be the same as the D.B. and W.B. temperatures and the RH. would be 100%. ‘Waugh Technical & Education Services 1999INSPE! DURES ‘The job of a Paint Inspector is to INSPECT AND REPORT. He must act with integrity at all times and be true to the specification requirements. A list of his duties are. ‘Leam the specification. (He cannot deviate without written permission) Attend site meetings as necessary Become familiar with the Plant and Equipment being used. Strike working relationship with colleagues, Agree work programme with contractor. PRACTICAL DUTIES. Assess condition of substrate, Check that correct materials have been obtained for use. Check dew point, relative humidity and steel temperatures daily as required. Inspect surfaces after blast cleaning. (Grade of cleanliness and amplitude) Wet Film Thickness checks. Dry Film Thickness checks, ‘Witness all preparation and painting procedures. Make reports as required (Daily, Weekly, Summary etc.) ‘Waugh Technical & Education Services 199939 201 ‘OR [CEs The inspector should be aware of malpractices which the contractor might attempt. These could be intended or accidental, ‘Using unqualified personnel, 2 Using unsafe plant and scaffolding. ~ Usiag equipment which is in a poor condition. ‘4 Carrying out further work before inspection has taken place. = Attempting to skip a coat. « Apply a coating system in the wrong sequence, + Preparing and painting when weather conditions are unsuitable. ¢ Using incorrect paint Using a paint which is out of date. to Applying too much solvent to a paint ur Incorrect storage of paint. ‘2 Applying low thickness coatings. 13 Using incorrect solvent for degreasing. 14, Using cotton cloths for cleaning. +5 Not observing induction and pot life times. ‘6 Using a compressor at above 100 psi 1 Attempting to re-use expendable abrasives. 1s Insufficient attention paid to awkward areas, “ ‘Waugh Technical & Education Services 1999IN OF P. There are several ways in which paint can applied. Each method has advantages and disadvantages for quality and cost effectiveness when in comparison with each other The principal methods are. BRUSH ROLLER SPRAY - CONVENTIONAL, AIRLESS, ELECTROSTATIC ‘BRUSH The quality of a brush is determined by its filling. The best types have a pure bristle (Hoghair) which allows for the maximum amount of paint to be held by the brush. The brush is very effective for applying primer as it works paint well into a substrate and in the right hands can produce an excellent finish. It is however very slow to use so is suitable only for ‘small areas. A hance 8 stoce C sering 0 fling Ponwase ations Sanctions Quer Rest bron, Cusack Bain of & Pigs nel fea batsen one ‘Waugh Technical & Education Services 199941 ROLLERS Rollers are produced in several versions: Single arm Double arm Curved ~ pipes, cormugates, ete. Pressure fed ~ constant application The heads or filament of rollers can be either natural (lambswool, mohair) or synthetic (nylon, dyne! sponge). The synthetic heads are designed to simulate the performance of natural filaments. A roller applies paint more quickly than a brush but does not work paint into a surface as well. In addition an uneven thickness costing is a disadvantage. In their favour is the fact that they can be used in conjunction with extension poles which improve access to working areas. dd - ot peat Aiess-tesroter ‘Waugh Technical & Education Services 1999a NAL SPRAY. Conventional spray set ups are as follows. GRAVITY CUP > PRESSURE FEED Conventional spray set ups operate at relatively low pressure so are only suitable for applying relatively thin materials. In addition, they hold only small quantities of paint so if applying paint to large areas constant re-filling of the container would be required. Also the gravity and suction versions can only be used with the gun in an upright position. ‘Waugh Technical & Education Services 1999AIRLESS SPRAY Up to 30 times faster than application by brush, this method is suitable for applying paint to very large areas, it produces very little overspray, has a large spray pattern and applies a thick coating at one application. Its disadvantages are that it is costly to purchase, the very high velocity of fluid can present a hazard, the guns have a tendency to block up and as with conventional spray the cleaning time is significant, The airless spray is in common use in the painting of steel structures and it is important to give further information on how the system ‘works and its safety features. ‘A-non pressurised container is held remote from the gun. The paint from the container is sucked in using 2 fluid pump and fed to the gun by means ofa high pressure reinforced fluid line. The pressure is supplied by a compressor which produces approximately 100 p.s.i. to the fluid pump. This air inlet pressure is adjustable. The fluid pump multiples the pressure by a ratio govemed by the pump, ¢.g. a 35 to 1 ratio pump which was supplied with an air pressure of 100 p.s.i. would produce a fluid pressure of 3500 p. : Spray tips on airless spray units are usually lined with Tungsten Carbide. They can usually be reversed by turning a lever 180 degrees which clears tip blockages. A Titan Tip exists which has an adjustable hole size. ‘The size of the orifice governs the amount of paint delivered and the angle of the orifice governs the size of the pattern. IMPORTANT SAFETY REQUIREMENTS Use correct tips. Fluid lines in good condition. ‘No kinks in fluid lines. Ensure safety catch on when not in use. ‘Never point gun at anyone or yourself. ‘Never attempt to clean or adjust nozzles when pressure is on. Ensure equipment is earthed to prevent static shock, Wear an air fed helmet. PAINT FEED FLUID PUMP ’ FLUID HOSE RATIO ADJUSTER Waugh Technical & Education Services 1999ELE ATIC SI This method of application requires a special spray gun which applies a charge to the paint particles. “The substrate is positively earthed and the paint particles are given a negative charge at the tip as they Jeave the gun. The result is that the paint particles which are drawn to the earth can wrap themselves completely around small tubular components, an even thickness coating is obtained and there is very little wastage through overspray. This equipment is however very expensive to purchase. ‘Waugh Technical & Education Services 199945 PAINT COLOURS BS5252_- Framework for Colour Co-ordination for Building Purposes establishes 2 framework within which 237 colours have been selected as the source for all building colour standards and the means of co-ordinating them. It is not in itself ¢ range of colours for any particular product and is not used to specify British Standard Colours. A colour is only Standardised when it is included in another British Standard, such as those that have been derived for paints BS4800, Vitreous Enamel BS4900, Plastics BS4901 and Sheet and Tile Flooring BS4092. Such standards contain only a portion of the total colours contained in S525? and are selected to meet design requirements within relevant technical and economic constraints. ‘BS4800 BS4800_- Paint Colours for Building Purposes specifies 100 colours which have been selected from the framework of the 237 colours contained in BS5252. Each colour in BS4800 is identified by three parts as follows: wo? HUE ‘The first part signifies hue or colour and consists of an even number of two numerals (¢.g. 04), twelve main hues are used and are numbered: 02 Red purples 04 Reds 06 Yellow reds 08 Yellow reds 10 Yellows 12 ‘Yellow greens 14 Greens 16 Green blues 18 Blues 20 Purple blues 22 Violets 4 Purples GREYNESS The second part signifies greyness, ie. the apparent amount of difference in greyness between one colour with another. Five grades are used, each defined by a single letter. There are four steps of diminishing greyness from A (maximum) to D (minimum). Beyond this, colours ere pure or free from greyness and graded as E, e.g. pure yellows are prefixed 10-E.WEIGHT When coded only on the two above grades it was found that the yellow hues (yellow-red and yellow-green) at minimum greyness looked heavy in comparison with the other colours. This vas overcome by raising the value of the yellowish colours. The result was more uniform in weight. The weight is given in pairs of numbers from 01 to 56. Groups of colours within each of the five greyness ranges are graduated from high to low value, Each of these graduations is numbered: A greyness - 01 to 13 B greyness - 15 to 29 C greyness - 31 to 40 D greyness - 43 to 45 E greyness - 49 to 56 EG. 18 E 33 Hue (Colour) Greyness Weight 02-24 in A-E Colour saturation Even Numbers Ais neutral 01-56 Eis pure colour The above example signifies a Deep, Bright Blue. Black, White or any Grey made up from only Black and White are not colours but are called neutrals and are always pre-fixed by 00-. Black is 00-E-53. White is 00-E-55. B.5.4800 can be used to identify existing colours when maintenance painting and is a method by which all manufacturers can make exactly the same colour. ‘Waugh Technical & Education Services 1999SAFETY REG! IONS 1988 SCOPE ‘The Control of Substances Hazardous to Health Regulations 1988 came into force 1* October 1989. These regulations, referred to as the COSHH Regulations, define a substance hazardous to health as: 4 A substance listed in part 1A of the approved list of dangerous for supply, see Classification, Packaging and Labelling Regulations 1984(b) — nature of risk classified as very toxic, harmful, corrosive or irritant. 4 One which has an MEL in Schedule 1 of COSHH or if the H & S Commission bas approved an OES. 4 Armicro-organism which creates a hazard to health. + Dust in air—_when substantial. 4 A substance comparable with the above. ‘The COSHH regulations are not applicable to the control of lead, radioactivity, explosive or flammable properties of materials, high or low temperatures, high pressures, medical weatment or below ground working (mining). RESPONSIBILITIES ‘The exposure of an employee to substances hazardous to health is under the control of the employer. A training organisation is responsible for exposure by trainees. Employers must prevent exposure to substances hazardous to health, or control exposure when total prevention is not reasonably practicable. Personal protective equipment, e.g. masks, are a second choice for control. » Employees have a duty to report any problems in exposure control procedures or any defects found in protective equipment. Employers must keep records of examinations/monitoring tests carried out. These are kept for 5 years; 30 years for identifiable employees. HAS.W.A, Health and Safety at Work Act 1974. ‘Waugh Technical & Education Services 1999BS. 410 BS. 2451 B.S. 3900 BS.3900, BS. 5252 BS. 4800 BS. 7079 1so ssel—1 ‘SIS 05-59-00 BG.PAD SPECIFICATIONS SPECIFICATION FOR TEST SIEVES GLOSSARY OF PAINTTERMS — Yaint Faults ‘SPECIFICATION FOR CHILLED IRON SHOT AND GRIT METHODS OF TEST FOR PAINTS FRAME WORK FOR COLOUR CO-ORDINATION FOR BUILDINGS PURPOSES SPECIFICATION FOR PAINT COLOURS FOR BUILDING PURPOSES PREPARATION OF STEEL SUBSTRATES BEFORE APPLICATION OF PAINT AND RELATED PRODUCTS PICTORIAL SURFACE PREPARATION STANDARDS FOR PAINTING STEEL SURFACES. PAINT PROPERTIES AND PERFORMANCE REQUIREMENTS NEW AND MAINTENANCE PAINTING AT WORKS AND SITE FOR ABOVE GROUND PIPELINE AND PLANT INSTALLATIONS BLAST CLEANING OPERATIONS 1990 = (Selety @ BATE! ‘Waugh Technical & Education Services 1999WAUGH TECHNICAL & EDUCATION SERVICES ABRIDGED VERSION OF THE NEW BRITISH GAS TRANSCO DOCUMENT P.A.10 (AUGUST 1995) NEW AND MAINTENANCE PAINTING AT WORKS AND SITE FOR ABOVE GROUND PIPELINE AND PLANT INSTALLATIONS WTES Waugh Technical & Education Services 1995WwW AL & EDI TI SERVICES F RABRIDS I F B. Page No. 1. P.A9 General Information. _P.A.10. General Information. 2-4 Abridged Definitions 5-6 Safety on Site 7. Environmental Requirements, 8. Abrasive Blast Cleaning Methods 9. Manual and Mechanical Methods of Preparation 10. Conditions for Final Surface Preparation 11. Surface Preparation of Weld Areas 12, Cleaning Down 13. The Selection of Paint Systems 14, Application of Paint 15. Measurement of Paint Thicknesses 16. _S.P.A.1. New and Maintenance Painting for Long Term Protection 17. S.A. 1. Operation Chart for New and Maintenance Painting for Long Term Protection. 18. S.P.A.1. Operation Chart for Maintenance Painting and for Coatings with Limited Damage. 19. _S.P.A2. New and Maintenance Painting for Indoor Use or Short Term Protection. 20. §.P.A.2. Operation Chart for New and Maintenance Painting for Indoor ‘Use or Short Term Protection. 21. S.P.A.3. Painting of New Installations and Maintenance of Surfaces Likely to Operate at, 100°C - 149°C 150°C - 340°C Above ~ 340°C 22. S.P.A.3.A. Operation Chart for Surfaces 100°C - 149°C. 23. —S.P.A.3.B. Operation Chart for Surfaces 149°C - 340°C 24. S.P.A.3.C. Operation Chart for Surfaces above - 340°C. 25, S.P.A.4, Painting of Damp Ferrous Surfaces 26. S.P-A4, Operation Chart for Damp Ferrous Surfaces 27. S.P.A.S. Maintenance Painting for Low Pressure Gasholders 28. _S.P.A.S. Surface Preparation for Low Pressure Gasholders 29. S.P.A.5. Application of Paint to Low Pressure Gasholders 30. S.P_A.5. Operation Chart for Maintenance Painting of Low Pressure Gasholders. 31. _S.P.A.S, Operation Chart for Maintenance Painting of Low Pressure Gasholders (Cups, Grips, Steel Tank Wind and Water Lines). ‘Waugh Technical & Education Services 1995Contents Page Continued Page No. 32. §.P.A.6. Painting of Non Ferrous Surfaces 33. S.P.A.6.A. Preparation of Non Ferrous Surfaces 34, S.P.A.6.B and 6C. Paint Systems for Non Ferrous Metals with Initial Coat. 35. Statutory Regulations Ref to P.A.10. 36. British Standards Ref to P.A.10. 37. Institute of Gas Engineers (1.G.E.) Recommendation Documents Ref to P.A.10. B. Gas Specifications Ref to P.A.10. Other B. Gas Publications Ref to P.A.10. Waugh Technical & Education Services 19951 B. TRANSC! PALO B.GASP.A.9, Refers to the ordering of paints and performance of paint systems. Any paint used on B. GAS work must comply with P.A9 Whose title is; PAINT SYSTEMS - PROPERTIES AND PERFORMANCE REQUIREMENTS. B.GASP.A.10, Is the technical specification for; NEW AND SITE. OVE. Pi iONS. This current P.A.10 came into force in August 1995 and superseded the previous one which into force in June 1987. It is arranged into three sections. 1 Preliminary Information. 2. General Painting Information. 3 Information for Specific Painting Applications. (S.P.A.) ‘The Specification covers all types of Ferrous and non Ferrous engineering components but is not suitable for use with the following; 1 Below Ground ( Buried.) 2. Offshore Installations. 3. Internal Coating of Pipes. 4. Stove Enamel Coatings. ‘Waugh Technical & Education Services 1995ABRIDGED COMPLIANT COATING INS FRI 0 A coating which complies with the Environmental Protection Act of 1990 PA). CONTRACTOR A person, firm or company which enters into a contract with TransCo and to which the PA 10 specification applies. “LONG TERM PROTECTION Typically 10 years. MEDIUM TERM PROTECTION Typically 5 years. ~SHORT TERM PROTECTION Typically 2 - 3 years. DAMP SURFACES ‘Temperature below Dewpoint but on which water is not readily detectable. MOIST SURFACES ‘Where standing water and droplets bave been removed but which still displays a noticeable film of water. WET SURFACES Surfaces on which standing water or droplets are present. (When these may be in evidence final surface preparation is not normally carried out). ~NEW GALVANISING A galvanised steel surface upon which a cohesive oxide layer has not yet formed (bright and shiney, less than 3 months old). A galvanised steel surface upon which a cohesive oxide layer has formed by natural weathering (dull and lacking in sheen). The temperature at which condensation ‘would form on a substrate. The amount of water vapour in the air expressed as a percentage. ‘Waugh Technical & Education Services. 1995.AINDUCTION PERIOD POT LIFE ‘The length of time a paint is required to stand after mixing and before application. This time allows air bubbles to escape and or chemical reactions to take place and is specified by the paint manufacturer. The length of time (following induction) that a paint remains in an applyable condition according to the manufacturers instructions. MULTI COMPONENT PAINT A paint supplied as separate components WASH HOT DUTY SURFACES INSPECTION TEST AREAS (Two pack). (Multi component liquid. ) An etch primer for zinc metal surfaces. Blue in colour it tums black upon drying if ithas been applied successfully. Metal surfaces that will reach a temperature in excess of 99 deg. C when in use. No deviation from the PA 10 specification ‘will be permitted ualess in writing from the engineer. May be requested in order to demonstrate that the selected system is capable of meeting its requirements. This refers to the method and standard or preparation, equipment to be used, paint specified, correct number of coats and on the same substrate. Safe scaffolding is identified by a green tag. ‘Unsafe scaffolding by red tag.” ~ Scaffolding is inspected by a competent person at least every seven days and always after bad weather. SHEETING FOR PROTECTION Sheeting of a non flammable nature must be employed to protect areas not being prepared or painted from contamination, (in particular tarpaulins must not be used). ‘Waugh Technical & Education Services. 1995.AVAS. TE PRODUCTS ‘The contractor is responsible for removing all waste materials from site (corrosion products, empty containers, brushes, tissues etc) and must dispose of hazardous waste in accordance with the appropriate statutory requirements. In all cases the operation must comply with current environmental requirements. The contractor must mask out items to be protected during preparation and painting in particular to prevent malfunction of the plant. Such areas typically are (fire protection equipment, weld end preparations, ‘atmosphere sensing heads, spray heads, ‘vents on control equipment, flame traps, lubrication points, name plates). The contractor is responsible for removing all masking materials. Special care must be taken not to allow zinc rich paints to contaminate stainless steel nor to be applied within 75 mm of weld end preparations. High pressure jetting is useful in removing paint scale and corrosion products. Care must be taken to ensure safety measures are observed and that the equipment being prepared is not damaged. Similar to dry blasting cleaning but with a water injection which damps down dust, therefore making it a suitable method to remove toxic coatings from substrates. ‘Waugh Technical & Education Services. 1995,SAFETY SITE Personnel shall comply with all relevant regulations when cleaning, painting and disposal procedures are being carried out. All site swork is normally subject to a permit to work system. This shall be 2 complied with at all times and no work shall take place until a permit to work or form of authority has been issued. The engineer shall interpret any doubt over hazardous areas, working areas, permits to work or forms of authority. The contractor shall aquaint himself with safety and security restrictions on site. Any accident on site shall be notified to the engineer and entered in the installations accident record book This does not relieve the contractor of responsibilities in this respect. The method of work and equipment used by the contractor may be inspected at any time without prior notice. No inspection shall relieve the contractor of any responsibility under the Factories Act 196 A representative shall be nominated by the contractor to act on his behalf. His duties shall include. Obtaining permits to work or forms of authority (appropriate). Extent of work undertaken (usually daily). Precautions required. Keeping to the agreed programme. eee Ideally two days notice shall be given in obtaining permits to work or forms of authority. This to allow proper arrangements to be made. If the contract is to last for more than six weeks the contractor must notify the factory inspector. af All equipment whether electrically or pneumatically operated shall be earthed. No smoking regulations shall be observed, any person disregarding this may be removed from site. x Fire or flames shall not be used to dispose of rubbish or to clean out paint kettles. Waugh Technical & Education Services. 1995.6 The contractor shall not operate any valves or plant on site belonging to TransCo. ag Where areas are termed hazardous, non-spak tools and flameproof equipment shall be compulsory. Where sheeting is used for protection this must be non flammable. In particular tarpaulin sheets must not be used. The site shall be kept in an orderly manner so as no materials or plant can endanger persons passing by on their normal duties. Vehicles shall only be allowed on site at the discretion of the engineer. They shall keep to roadways and act under the direction of TransCo staff. ‘Waugh Technical & Education Services. 1995.ENVIRONMENTAL REQUIREMENTS ENVIRONMENTAL PROTECTION All waste materials resulting from surface preparation and painting operations shall be properly disposed of in accordance with the Environmental Protection Act-E.P.A, - (Duty of Care). When surface preparation and painting operations are carried out in the vicinity of rivers, lakes or other water courses, special precautions may be necessary to prevent the possibility of pollution. Care should be taken to ensure operations are carried out in accordance with the requirements of the Water Resources Act. ‘Waugh Technical & Education Services. 1995.BLAS: iG Safety requirements for abrasive blast cleaning shall comply with Document IGE/SR/21__Blast Cleaning Operations 1990. The standard for surfaces prepared by blast cleaning shall comply with BS 7079 (SIS-05-59-00), The type of abrasive used shall provide a blast cleaned profile of 30 pm min and 75 pum max unless otherwise required by an S.P.A. The profile shall be measured by means of testex tape and dial micrometer or an alternative method approved by the engineer. ‘Non metallic abrasives shall be silica free. Other media for blast cleaning may be used with the agreement of the engineer. Air for blast cleaning shall be clean, dry and oil free. Abrasives used in an open blast system shall be of the expendable type. They should not be re-used. For closed blast cleaning systems abrasives can be re-cycled for use providing they are monitored for cleanliness and size. Wet blast systems or enclosed recovery blast systems shall be used for removing lead based paint. Following wet blasting, dry blasting shall be carried out to remove any subsequent flash rusting. All traces of corrosion, chemical contamination, existing paints etc shall be removed from the surface. All surface defects such as laminations or inclusions shall be referred to the engineer. Where dressing is undertaken those areas must be reblasted to remove all rust and to provide an adequate key. ‘Wangh Technical & Education Services. 1995,JAL AND. (CAL. IDS OF PREPARATION ‘These methods are used when blast cleaning is considered unsuitable, and are undertaken with the approval of the engineer. They represent a lower standard of preparation, therefore care must be taken to ensure that, the agreed standard is reached (ST2, ST3). The danger always exists of a reduced life expectancy of the paint system where inferior preparation has taken place. Ferrous impact tools shall not normally be used, where scrapers are used wire brushing to an agreed standard will follow, and the scrapers must be of the type having a carbide tip. NEEDLE GUNNING The guns shall have needles of a small cross section, the profile created must not exceed 100 pm, no sharp edged craters must be left and all rogue peaks must be removed. ABRASIVE DISCS May be permitted in certain circumstances. Approval for their use must be sought and particular care must be taken on pressure containing parts not to create notches. GRINDING Shall only be carried out under the direct supervision of the engineer. ‘Wangh Technical & Education Services. 1995,10 CONDITIONS FOR FIN. ACE TION When conditions in the working area are such that metal surfaces are moist, damp or wet, final preparation shall not be carried out. ‘Any surface preparation, procedure or method of cleaning shall not be allowed to contaminate wet paint films. Equipment used shall be of the non sparking type. Electrically operated tools are not normally permitted. x Power tools operated by compressed air shall have oil and vapour traps fitted to t the compressed air lines. _z All contaminants shall be removed by means of an approved solvent. wAlgae and mould growth when in evidence, shall be treated with a biocidal agent and left for 24 hours at least in order that the biocide can kill the spores. It shall then be removed by scrubbing with stiff bristle brushes and clean water or by use of a high pressure water wash. All surfaces shall normally be dry before painting commences. ‘Waugh Technical & Education Services. 1995.i SURFACE PREPARATION OF WELD AREAS All weld areas including primed surfaces damaged by heat shall be blast cleaned to the required standard immediately prior to painting. All weld flux and spatter shall be removed prior to preparation and painting. Amy painted areas next to the weld area shall be suitably protected from any other operation. ‘Waugh Technical & Education Services. 1995.Immediately prior to painting all surfaces shall be free from contamination. (dust, chemical contaminants, oil and moisture). All grease and oil ete found on an existing paint surface shall be removed with an approved solvent. Where large areas are involved consideration can be given to low pressure detergent washing, which must be followed by rinsing with clean water and thorough drying. All surfaces immediately before painting commences, must be cleaned down with clean, dry oil free air, vacuum cleaned or brushed down. Ifoil or grease is found on a surface after it has been prepared that area must be swabbed with an approved solvent followed by a 2% detergent wash, further followed by washing with clean water, thorough drying and reblasting, ‘Where cleaning and swabbing of steel and painted surfaces takes place disposable lint free swabs must be used and once only. Cloth rags shall not be used. ‘Waugh Technical & Education Services. 1995.13 JECTION OF Each painting job is unique, therefore paint systems must be carefully chosen for each individual job, and a correct and manageable specification drawn up to meet its requirements. For new painting work the specification for any particular system chosen should consider cost as important. For maintenance painting special treatments may be required in order to produce compatibility between existing and new systems. (Tie coat, abrading . etc) Considerations for the above as follows, 1) Appropriate and cost effective methods of surface preparation. 2) Appropriate cost effective paint system to meet the required service life. ‘When repainting or maintaining present systems, it should be determined, 1) What the existing paint system is. 2) The extent of breakdown and corrosion. 3) The in service environmental conditions. 4) The nature and extent of any surface contamination. VARIANTS A contractor may propose variants to PA 10 only where the text states that TransCo would consider these. ‘Waugh Technical & Education Services. 1995.4 APPLICATION OF PAINT Paint shall normally be applied when, 1) The RH%is less than 90% 2) The air & metal temp is at least 3°C above the D.P. These measured figures are obtained by use of a whirling hygrometer and dew point calculator. end Maxarrr> y Ambient and substrate temperatures should not be below the minimum set out by the paint manufacturer for any particular paint or coating producf or, as stipulated by TransCo. Paint shall not normally be applied when conditions in the working zone are such that the working surface becomes moist or damp during the painting operation, When this condition prevails reference should be made to PA 10. S'P.A. 4, (Painting of damp ferrous surfaces). 3 Painting equipment shall be used in accordance with the paint manufacturers recommendations (type and operation) (spray or brush normally). ‘All paint shall be applied in order to produce a firmly adhering continuous film, free from misses, runs, tears, sags etc. x Stripe coating shall be carried out to welds, edges etc inorder to achieve a full paint film thickness as specified. All painted areas must be thoroughly dry before being overcoated and any contamination of the paint film should be removed before further coats are applied. O& The final coating shall be free from significant visible imperfections. ‘Waugh Technical & Education Services. 1995.15 NT OF THI SES The measurement of both wet and dry film thickness shall be carried out with each separate coat The DFT. is the reading which determines the final correctness of the application, except in the case of M.LO, and subsequent coats covering M.LO. where a W.E.T. comb gauge is used. Information for the W-F.T. required to achieve the D.F.T. as specified by the manufacturer, is to be found in the manufacturers literature. The WF.T/DFT. differential is governed by the VS% contained within a paint ‘Waugh Technical & Education Services. 1995.16 SPECIFIC PAINTING APPLICATION S.P.A. 1, NEW AND MAINTENANCE PAINTING FOR LONG TERM PROTECTION OF INSTALLATIONS AND COMPONENTS S.P.A. 1. applies to the painting at works or site of new installations and components, and to site maintenance painting of carbon steel surfaces operating below 100°C. Normally new components are prepared and part painted at works prior to subsequent completion on site. S.A. 1. applies to, 1) Part painting of new components at works 2) Completion of component painting on site 3) Site painting of uncoated or unsuitably coated surfaces 4) Site maintenance painting Each coat of paint shall be of a contrasting colour to the previous coat. ‘Waugh Technical & Education Services. 1993.17. P.A.1. OPERATION T FO! IF UNCO: OR UNSUIT: AT WO! ‘APPLICATION OF PAINT TO PREPARED SURFACES ‘MASK OUT REMOVE CONTAMINANTS OIL, GREASE ETC BLAST CLEAN SA2': MAX PROFILE 75pm Min. v Be 209 (CLEAN SURFACES (IMMEDIATELY PRIOR TO ON SITE SYSTEM PAINTING) WATER-BORNE ACRYLIC PRIMER 50 pm MIN HIGH BUILD EPOXY ‘ALUMINIUM HIGH SOLIDS 75 pm MIN SOLVENT BASED EPOXY PRIMER 75 wm MIN MLO. 75 um MIN EPOXY MLO. 75 um MIN UIC COMPLETION. -—— 50 pm MIN —|__ ONSITE a HIGH BUILD EPOXY U/C FINISH COAT 75 wm MIN 50 wm MIN TOTAL SYSTEM EPOXY OR DFT 225 wm MIN POLYESTER OR ACRYLIC FINISH DFT 250 um MIN 40 pm MIN IF PRIMER AND 1ST IMID APPLIED AT WORKS| TOTAL SYSTEM NB. Other compliant systems may be put forward as a variant DFT 265 ym MIN provided they comply with P.A. 9 and provide equivalent long term performance to the above systems. Primer in all cases to be applied within 4 hours of metal preparation. ‘Stripe coating to welds and edges before primer is applied in order to assist the achievement of DFT minimums. Wangh Technical & Education Services. 1995.SP. iG REF PREVIOUS PA‘ R COA’ WITH D MASK OUT REMOVE CONTAMINANTS OIL, GREASE ETC PREPARE EXISTING SYSTEM BY PROVIDING A KEY IF REQUIRED SURFACE PREPARATION OF EXPOSED SUBSTRATE OR WHERE PAINT IS TO BE REMOVED. eee (BLAST CLEANING OR WIRE BRUSHING AS SPECIFIED) CLEAN ALL SURFACES [IMMEDIATELY | PRIOR TO PAINTING SPOT PRIME OVERLAP Pena EXISTING COATING BY AT LEAST 100 mm SPOT WITH MLO. __—___ : -+—— OVERLAP PRIMER EDGE APPLY U/C oo APPLY FINISH NB, The engineer will normally specify the areas to be painted, the method of preparation and the paint system to be applied. The number of coats required will be dictated by the breakdown of the existing system and its required life. The minimum DFT will comply with the previous page. ‘Waugh Technical & Education Services. 1995.19 SPECIFIC PAINTING APPLICATION -P.A2. [ANCE FOR /R_US! OR SH TERM, ,CTION S.P.A2. Applies to new and maintenance painting for indoor use or short term protection of carbon steel surfaces operating below 100°C. WP. iG_FOR_ INDOOR SHORT TERM PROTEC! IN Compliant materials normally based on drying oil, or water bome acrylic paints shall be specified. If a decorative finish is required one coat of undercoat and one coat of finish shall be applied. The undercoat should be slightly complementary to the finish coat in colour. This complementation should allow the sprayer/painter to clearly see what parts he has completed and further should allow him to apply a sufficiency of material in order to eliminate grinning, MAINTENANCE OF THE ABOVE Damaged areas shall be prepared by wire brushing to BS 7079 05-59-00 standard ST3 as a minimum and spot primed, this followed by a coat of M.1.0. Depending on the required finish either one full coat of M.LO. or alternatively one full coat of undercoat and finish to the required colour shall be applied. ‘Waugh Technical & Education Services, 1995.20 .A.2 OPERA’ NANCE G FOR INDOO! ‘OR SHORT TERM PRO’ IN MASK OUT REMOVE ALL DEPOSITS CLEAN AREAS IMMEDIATELY PRIOR TO PAINTING APPLY PRIMER WITHIN 4 HOURS: 45 um DFT MIN MLO. 50 um DFT MIN DECORATIVE FINISH MLO. FINISH APPLY UNDERCOAT Lipari 45 um DFT MIN 20m DERM “APPLY FINISH 25 ym DFT MIN ‘Waugh Technical & Education Services. 1995.21 SPECIFIC PAINTING APPLICATION S.P.A3__APPI T -AINTING OF INST, Tit NANCE OF CES ARE Y TO OPERATE AT 100°C TO 149°C 150°C TO 340°C ABOVE 340°C 100°C TO 149°C Primer - Heat resistant aluminium pigmented epoxy or urethane primer to be used. Several coats to be applied until min D-F.T. has been achieved - 100 ym for urethane and 250 um for epoxy. NB. Heat resistant paints are normally pigmented with aluminium flake therefore a colour finish may not be possible. 150° TO 340°C Thermally Sprayed Aluminium (T.S.A.) shall be applied in accordance with BS EN 22063 and/or BS 2569 Part 2, Where this is not practical due to operational restraints or because it is considered too high a standard of coating, consideration may be given to inorganic zinc silicate or polysiloxane primers. NB, Care must be taken not to overthickness inorganic zine silicate as this can lead to mud cracking. ABOVE 340% ‘Thermally sprayed aluminium T.S.A. is the preferred choice. As above where not practical inorganic zinc silicate or polysiloxane primer can be considered. At these temperatures where T.S.A. or 1.Z.S. are used they should be sealed with a high temperamre sealer. These are applied and cured to the manufacturers recommendations. ‘Wangh Technical & Education Services. 1995.MASK OUT REMOVE CONTAMINATION. OIL, GREASE ETC. BLAST CLEAN SA2% 75 ym MAX foans Bone CLEAN AREAS IMMEDIATELY PRIOR TO PAINTING APPLY PRIMER WITHIN 4 HOURS. D.F.T. DEPENDS ON PRIMER USED FURTHER COATS TO BUILD 100 ym URETHANE 250 ym EPOXY ‘Waugh Technical & Education Services, 1995,23 OPE! IN CHAR’ °C TO 340° . LZ.S. OR 0: ‘STEM MASK OUT REMOVE CONTAMINATION. OIL, GREASE ETC. BLAST CLEAN SA3 75 ym MAX CLEAN AREAS IMMEDIATELY PRIOR TO PAINTING se TSA. (LONG SERVICE LIFE) TO INSTRUCTIONS | | MANUFACTURERS ar INSTRUCTIONS Boly “apphed ok wortes ‘Waugh Technical & Education Services. 1995,24 8 3 OP! TION CHART ABO’ 4 LS. /R POLYSILO: M MASK OUT REMOVE CONTAMINATION. OIL, GREASE ETC BLAST CLEAN SA3 75 wm MAX CLEAN SURFACES [IMMEDIATELY PRIOR} TO PAINTING PREFERRED SYSTEM IZS. PREFERRED SYSTEM POLYSILOXANE a SEALER. T.S.A. INORGANIC HEAT TO CURE. (LONG SERVICE LIFE) COATING |ALL TO MANUFACTURERS| RECOMMENDATIONS RighYeropeteab—— St a fae fe Het be Crt ‘Wangh Technical & Education Services. 1995.25 SPECIFIC PAINTING APPLICATION S.P.A.4 PAINTING OF DAMP FERROUS SURFACES S.P.A4, Applies to the painting of ferrous surfaces where condensation during painting-cannot be prevented. ‘A number of paint systems are available which are tolerant to damp surfaces but which are not usually used on wet surfaces. Further they shall not be used when ice is present or when the surface temperature is likely to be below 3°C. Types of material modified satisfactorily for use on damp metal surfaces include, 1. Moisture curing polyurethanes 2. High solids multi-component epoxy paints NB The above paints are specially modified by the manufacturer to be moisture tolerant, ‘Wangh Technical & Education Services. 1995.26 S.P.A. 4. OPERATIO! OUS CE! OLYURE- S OR HIGH SOL} i. COMPONENT EPOXY PAINTS REMOVE SURFACE CONTAMINATION. SWAB WITH GREASE REMOVING SOLVENTS. WASH VITH 2% DETERGENT} SOLUTION BLAST CLEAN SA 2% 75 wm MAX WASH WITH CLEAN WATER (TO REMOVE GRIT AND DUST) REMOVE DROPLETS AND . STANDING WATER. (SURFACE SHALL NOT BE WET) MOISTURE CURING HIGH SOLIDS MULTI- POLYURETHANES TO }COMPONENT EPOXY PAINT] MANUFACTURERS, TO MANUFACTURERS INSTRUCTIONS. INSTRUCTIONS. (BY BRUSH) (BY BRUSH) ‘Waugh Technical & Education Services. 1995.27 -CIFIC P, LICA’ IN S.P.A5. NANCE Pz LOW SURE GASHOLDERS S.P.A.5. Detailed procedures for the planning, surface preparation, cleaning and painting of the extemal surfaces of low pressure water sealed gasholder. Waterless gasholders of the Wiggins, Hammond, Klonne and M.A. types and the above ground frame work and water tank associated with water sealed gasholders shall be painted in accordance with S.P.A.1. Damp surfaces such as tank bottom plates and gas mains in pits which extend into the gasholder foundation are covered by S.P.A.4. TENDE} Shall clearly identify the following: Surfaces to be painted ‘The method of surface preparation Painting systems to be applied Finished colours to BS 4800 Surfaces and items not to be painted Areas which need to be protected during preparation and painting PAINT SYSTEMS SELECTION CRITERIA Environmental in-service conditions Existing paint system Extent of paint breakdown and corrosion ‘Method and extent of preparation Standard of cleanliness achievable Service life requirement NB Water-bome acrylics, compliant elkyds and moisure cured urethanes may be used satisfactorily in most cases. eee eee eee eee ‘Waugh Technical & Education Services. 1995,28 SURFACE PREPARATION FOR LOW PRESSURE GASHOLDERS A number of techniques may be used eg. blast cleaning, water jet cleaning, mechenical cleaning, manual cleaning etc. Precautions must be taken not to allow debris to enter the cups, the tank or any other vulnerable work area. Preparation methods for particular areas must be clearly defined. ‘Non drying paint can mask severe corrosion and should be removed prior to painting. Steam cleaning, hot water cleaning, detergent cleaning, heavy duty solvent wash and scraping are acceptable methods of paint removal. ‘Where blast cleaning takes place it shall be to S.A. 2%. Where other methods are used the surface should be to S.T.3. equivalent. In the event of the surface containing toxic materials (eg. lead) no dry blast cleaning or abrading shall take place. ‘The edges of remaining coatings will be feathered. ‘Waugh Technical & Education Services. 1995.29 TION OF PAINT. )W PRESSURE OLDE} ‘When the surface has not been totally blast cleaned, or where areas of the previous coating remain, the primer must be applied by brush. Succeeding coats can be applied by spray or brush. Application by roller is not recommended. ‘Where there is exposed prepared metal, the primer D.F.T. must meet the manufacturers recommendations. This could be spot or overall surface priming. Spot priming should overlap existing coating by at least 100 mm. Stripe coating may be necessary to achieve D-F.T. at edges, rivets and weld areas. ‘The manufacturers overcoating times shall be followed, although not more than seven days shall have elapsed before overcoating. The coating shall be allowed to dry for as long as possible and in any case at least two weeks prior to any operation of the gasholder. The finish coat on any one lift or on a single storey tank shall be of the same manufacturers batch number. Non slip paint made by mixing dry softwood coarse grade sawdust with the top coat paint should be applied as an extra coat to access areas such as walkways and stairs. A one metre band across the crown and around the inside of the crown perimeter shall also be applied. ‘Where non drying paint has been removed and some final traces still remain a white spirit based primer rather than a water based primer shall be applied. Water based paints require the movement of air to dry quickly, otherwise localised rust spotting will occur. This problem can be overcome by replacing the primer coat of the water based system with a quick drying solvent based primer. For surfaces which are predominantly immersed in water one coat of moisture tolerant epoxy shall be applied by brush to a minimum D.F.T. of 100 pm. (Measured by W-F.T. Gauge) ‘Waugh Technical & Education Services. 1995.30 S.B.A. 5 OPERATING CHART FOR MAINTENANCE PAINTING OF yw. SI ILD} PROTECT DEFINED AREAS AGAINST EFFECTS OF |PREPARATION AND PAINTING REMOVE CONTAMINATION |PARTICULARLY NON-DRYING| PAINTS AND OIL FILMS SURFACE PREPARATION. CLEAN ALL SURFACES IMMEDIATELY PRIOR TO PAINTING ee APPLY PRIMER WITHIN 4 HRS SPOT OR FULL COAT. STRIPE COAT WELDS AND EDGES, OVERLAP EXISTING COAT BY 100 mm MIN MILO. SPOT OR FULL COAT WITHIN 7 DAYS ADDITIONAL MLO. IF SPECIFIED. (TO EXTEND ‘APPLY FINISH (iF REQUIRED) SYSTEM LIFE) MIN 2 WEEKS BEFORE GASHOLDER CAN BE OPERATED NB. On the crown of the gasholder the number of coats of paint should be kept toa minimum. Where grit blasting has taken place only a two coat system of primer and M.LO. need be applied. This M10. finish coat should be of a light/silver grey colour in order to provide a reflective surface which minimises the crowns temperature. Reduced coating thickness will also improve flexibility and resist cracking. ‘Waugh Technical & Education Services. 1995,\ 31 Ww. S' SH ERS AND. T: WIND. POSITION GASHOLDER PROTECT DEFINED AREAS REMOVE SEDIMENT FROM CUPS LOWER WATER LEVELS SURFACE PREPARATION MIN ST3 CLEAN ALL SURFACES . (IMMEDIATELY PRIOR TO PAINTING) APPLY MOISTURE TOLERANT EPOXY PAINT FULL COAT 100 um DFT MIN RESTORE WATER LEVELS (BEFORE LEAVING SITE) ‘Waugh Technical & Education Services, 1995, WA’ i OF32 ‘SPECIFIC PAINTING APPLICATION S.P.4.6. PAINTING OF NON FERR¢ S$ S.P.A.6. Applies to the painting on site of the following non ferrous surfaces. nae ‘New galvanized surfaces. Weathered galvanized surfaces. Previously painted galvanized surfaces. Aluminium surfaces. Stainless Steel. Pre painted cladding (Plastisol cladding or equivalent). Glass Reinforced Plastics (G.R.P.). Fusion Bonded Epoxy (F.B.E.) Malti Component Liquids (M.C.L.) Concrete. wenn edeond Alll the above shall be thoroughly cleaned by removing all dust, salts, chemical contaminants, oil, grease and moisture from the surface prior to preparation and paint application (see page on cleaning down). ‘Waugh Technical & Education Services, 1995,33 CIFIC P, ICATION S.P.A.6a PREPARATI iON. CEs SURFACE PREFERRED | FIRST OPTION | COMMENTS OPTION _/| New Galvanizing | Sweep Blast | Hand Abrade ‘An etch primer (T.wash) used where the two options are impractical. ‘Weathered Stiff Bristle pak P, ‘Weathering ~| Galvanizing Brushing o4 | Wate aime oA | provides its own Wire Baie | epery key. Previously painted | Sweep Blast _ | Hand Abrade ee Galvanizing ‘Sweep Blast | Hand Abrade For thin gauge aluminium etch primer used prior to intermediate and finish coats. Not to be blast cleaned. Chlorinated hydrocarbon solvent shall not be used. ‘Stainless Steel | Sweep Blast ae Only aluminium used as blasting medium. Pre-painted ‘Sweep Blast | Hand Abrade ae cladding plastisol or equivalent Glass reinforced | Sweep Blast | Hand Abrade a | plastics Fusion bonded | Sweep Blast | Hand Abrade a | epoxy ‘Multi component | Sweep Blast | Hand Abrade oe Liguid To a Surface abrasion east Surfaces) | manufacturers may not be instructions Tequired for new concrete. Old paint, if required should be removed with scrabblers. ‘Waugh Technical & Education Services, 1995.34 SPECIFIC PAINTING APPLICATION S.P.A.61 6c P. RK 1OUS SURFA‘ SURFACE SYSTEM/ SYSTEM/ SYSTEM/ COMMENT PRIMER PRIMER PRIMER New galvanizing, | Water bome Epoxy high build | Alkyd or modified | Damaged Weathered acrylic__ oe alkyd galvanizing _| galvanizing, MLO. pigmented | Pigmented high | Alkyd or modified | repaired with Previously painted| water bome _| build epoxy alkyd zine rich galvanzing, acrylic 65 um DFT MIN | 40 pm DFT MIN | epoxy. Aluminium. 65 um DFT MIN Stainless Steel | Water borne Epoxy high build Zine rich anni eee paints must Chloride free not be used water borne epoxy high build on stainless acrylic 65 wm DET MIN steel. 45 ym DFT MIN Pre-painted ‘Water borne Moisture cured and or modified | Where steel cladding (plastisol | acrylic__ urethane__ substrate is orequivalent) —_| M.LO. pigmented | Compatible Cheam alkyd | exposed waterborne | moisture cured | or modified alkyd| repair as in acrylic urethane 40 pm DFT MIN | SPAI. 45 um DFT MIN | 25 wm DFT MIN Glass reinforced |Waterbome | Moisture cured _| Alkyd or modified plastic, acrylic__ urethane | alkyd_ Fusion bonded | M.LO. pigmented | Compatible Compatible alkyd epoxy, waterborne | moisture cured | or modified alkyd Multi component acrylic urethane 40 um DFT MIN qui 45 ym DFT MIN | 25 um DFT MIN ‘Water bore Moisture cured and ‘oF modified | For new (walls and floors) | acrylic__ urethane___ concrete @ Single pack water | Moisture cured Conile alkyd | sealer coat Dome acrylic | urethane sealer | or modified alkyd | may be z 40 um DFT MIN | required. primer 30 pm DFT MIN NB. Other compliant systems which meet the requirements of P.A.9. may be proposed to Trans Co as variants. ‘Waugh Technical & Education Services. 1995.STA’ cy TIONS All operations shall be subject to the Health and Safety at Work Act 1974 together with other relevant legislation. Hazardous substances shall be dealt with and handled according to the Control of 3 lous to Healt S.H.H. Regulations 1988), and Re tions other than the W. 1H. lis inP.Al0. No. 1145 1948. - The Building (Safety, Health and Welfare) Regulations No. 1580 1961 - The Construction (General Provisions) Regulations No. 1581 1961. - The Construction (Lifting Operations) Regulations 1989 - The Construction (Head Protection) Regulations No. 1248 1980 - Control of Lead at Work Regulations 1963 - The Contracts of Employment Act 1961 - The Factories Act 1947 - The Fire Services Act 1963. - The Offices, Shops and Railway Premises Act 1990 - Environmental Protection Act 1991 - Environmental Protection Act - EPA - (Duty of Care Regulations) 1974 - Control of Pollution Act (1974) & Amendment (1989) 1980 - Control of Pollution Special Waste Regulations (Amendment 1988). 1988 - Collection and Disposal of Waste Regulations 1989 - Noise at Work Regulations ~ Management of Health & Safety at Work Regulations ~ Manhandling Operations Regulations 1992 - Provision and Use of Work Equipment Regulations 1992 - Personal Protective Equipment at Work Regulations 1992 - Workplace (Health, Safety & Welfare) Regulations 1994. - Certification, Packaging and Labelling (CPL) Regulations (fr Cage of Dangerous Goods by Road Rail) 1993 ce Hazard Information and Packaging (CHIP) Regulations ~ Water Resources Act ‘Waugh Technical & Education Services. 1995.36 British Standards listed in P.A.10. BS 1129 ~ Specification for portable timber ladders, steps, trestles and lightweight stagings. BS 1139 ~ Metal scaffolding BS 2569 - Specification for sprayed metal coatings: Part 2 - Protection of iron and steel against corrosion and oxidation at elevated temperatures. BS 2830 - Specification for suspended safety chairs and cradles for ‘used in the construction industry. BS 2842 - Specification for whirling hygrometer. BS 3900 ~ Methods of test for paints: Part C5 - Determination of film thickness. BS 4800 = Schedule of paint colours for building purposes. BS 5493 = Code of practice for protective coating of iron and steel structures against corrosion. BS 5973 - Code of practice for access and working scaffolds and ‘special scaffold structures in steel. BS 7079 - Preparation of steel substrates before application of paints and related products: Part 0 + Introduction Part A + Visual assessment of surface cleanliness PartAl _—_- Specification for rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings. Part Al: Supplement 1 - Representative photographic examples of the change of appearance imparted to steel when blast-cleaned with different abrasives. ‘Waugh Technical & Education Services. 1995.37 Institute of eers LG.E. dat IGEISR/3 - Electrical equipment in gas production, transmission, storage and distribution. IGE/SR/4 ~ Low pressure gasholders storing lighter-than-air gases, IGESR/S - Opening of gas works plant and working in confined spaces. IGE/SR/12 - Handling of methanol. IGE/SR/21 - Blast cleaning operations. IGE/ID/6 - Handling, transport and storage of steel pipes, bends, tees, valves and fittings. British Gas Specifications BGPS/GII - Notes for guidance on the issue of Permits to Work BGESICWS ~ Code of Practice for the selection and application of field applied external pipework coatings. PAg ~ Technical specification for paint properties and performances requirements. GBEDIS 3.1 ~ Engineering Procedures - Safety - Health and Safety at Works. GBE/DIS/ 3.5 ~ Engineering Procedures - Health, Safety and Environmental Protection. Other British Gas Publications - Handbook on Safe Handling of Substances in Use within the Gas Industry. ~ Computerised Information System for Substances in Use in British Gas (CISSUB). ‘Waugh Technical & Education Services. 1995,PAINTING Surface and Surface Preparation Corrosion Corrosion is a chemical change brought by an electrochemical process called electrolysis. Steel is Anodic. Millscale is Cathodic, Anode corrodes faster than cathode. Millscale flakes of from. steel, the exposed steel is having contact with atmosphere, which contains moisture and oxygen. The exposed steel, which is anodic will sacrifice to protect ‘the millscale and corrodes. i i 1, Rapid change in oxygen content 2. Moisture content in the atmosphere is above 60% 3. Acid, Alkaly, Sulphide and Chloride content in the atmosphere Millscale ‘A thin black flaky lair of oxidised iron is called millscale. Steel is anodic to millscale. When millscale flakes of from the steel. the exposed steel scarifces it self to preserve the millscale. Surface Preparation Surface preparation is the most important factor in Painting & Coating, The success and failure of a coating depends on the correct surface preparation. Methods of surface preparation, 1. Degreasing 2. WireBrushing. 3. Grinding. 4. Needle Gunning. 5, Abrasive Blast Cleaning 6. Chemical Cleaning 7. Water Blasting. 8, Weathering 9. Flame Cleaning 10, Steam Cleaning Dry Abrasive Blast Cleaning is the best method of surface preparation for long term protection coating systems. Blasting: The cleaning and roughening of a surface by the use of abrasive, which is projected on to the surface by compressed air. Speed = Approximately 450 mp.h., Recommended Pressure is 7 bar (100psi) Drop of 1 psi pressure will drop 1.5% efficiency Equipment for Hose pressure checking = Hypodermic Needle Gauge ‘Types of Nozzles: ale: The velocity of abrasive leaving a straight bore nozzle at 100psi is approximately 220 mp h, Straight bore nozzle provide an uneven surface prepration, this type is mainly using for small and repair areas and on softer metals. i ~The velocity of abrasive leaving a venturi nozzle at 100psi is approximately 450 m.p.h.. 12mm nozzle held 450mm from surface will gives approximately 150mm Dia area. Blasting angle 75 to 80° Short Nozzles (under 150mm) for easy clean surface. Long Nozzles (above 150mm) for hard to clean surface. Metallic and Mineral abrasives commonly used are: 1. Steel or Chilled Iron Grit 2. Steel or Chilled Iron Shot 3. Copper Slag 4,Gamet 5. Grit and Shot mixed (70% to 80% Shot, 20% to 30% Grit)Other expendable abrasives are: Sponge, Poly Styrene, Walnut Shells, Ceramic grits and Crushed Glass. ‘The use of Sand is not recommended. C.0.S.HH. 1988 Regulations Do not allow the use of ‘sand containing free Silica in dry blasting operations due to the health hazard of Silicosis. C.O.S.HH ( The Control of Substances Hazardous to Health Regulations 1988.) Came in to force at October 1989 and revised in 1994. ‘As per the regulation duty of : : Ist duty is to eliminate hazard and if this is not possible he must offer full protection against them, Employees for 30 years and casual visitors for 5 years. . Keep himself and others safe by his actions at all times. He has a statutary duty to report any accidents, incidents or spillages. ‘As far we concerned solvents and sands only covered in COSHH. Lead, Paint end Highly flamable liquids have their own separate legislations. 1. Specific Gravity 2. Hardness & Toughness 3. Size 4, Shape 5. Coast 1. Speed 2. Angle 3. Distance 4, Time ‘Surface Profile: The shape of cross-sectioned blast cleaned surface is known as Surface Profile or Anchor Pattern. The size of the profile as measured from the Peaks to Trough height termed as Amplitude, Peaks are produced above the permitted Amplitude are known es Sf 1. Surface Profile Needle Gauge 2. Micrometer with Testex Tape (com plaster method) 3, Surface Comparator. ( 1. Fine Profile, 2. Medium Profile, 3. Course Profile) Blasting grades The grade of a blast finish relates to the amount of surface contaminant remaining after blasting, BS 7079-(SS-05-59-00) Preparation of steel substrates before application of paints and related ‘products is & pictorial standard which shows the degree of surface cleanliness both before and after blasting. Rust grades: ‘A: Steel surface largely covered mill scale but little or no rust. B- Steel surface which has a mix of rust and millscale, C- Steel surface on which the millscale has rusted away or from which it can be scraped, but with little pitting visible to the naked eye. D- Steel surface on which heavly rusted and general pitting is visible to the naked eye.Blast cleaning preparation grades: 1, White metal Visually cleaned steel metal) -Sa3 _ -SSPC-SPS__NACE -Gradel 2, Near White metal (Very thoroughly blasting) - Sa 2 1/2 -SSPC-SP10 NACE -Grade2 3. Commercial finish (Thorough blasting) -Sa2 -SSPC-SP6 NACE -Grade3 4. Light blast & Brush off (Light blasting) © -Sal -SSPC-SP7 NACE -Grade4 Safety Use of carbon impregnated hose to reduce the chance of static shock Use of a dead-mans handle to stop the operation immediatly. Keep the hoses as straight as possible to prevent kinks which may lead a blow-out, Use external couplings if joining hoses together. Internal couplings reduce the bore and the eroding action of the abrasive could lead to a blow-out. Operators should wear protective clothing, including an air fed helmet, boots, leather apron and gloves. ‘Wet Blasting Wet blasting methods are good for removing Chlorides from surfaces and are good for the removel of toxic coatings. Ex. Red Lead Paint films. Disadvantages: ‘Availability and drainage of water. ‘The production and disposal of sludge. The extra coast of supplying and mixing of substrate inhibitor. The problems associated with drying large surface areas or the coast of water miscible primers. - Different Methods of Wet Blasting are: High pressure pure water blasting: Operates at 35000 psi. (Extremely dangerous) High pressure water plus abrasive injection: Operates at 20000 psi. also dangerous. ‘Low pressure water plus abrasive inection Operates at 100 psi, (High coast and low efficiency) : Operates at 100 psi . This method is good for mee contaminated with ol, ‘grease etc... High coast low efficiency) Air blasting with water injection: Water with or without an inhibitor is injected in to an air/abrasive stream. Operates at 100 psi St2- Manual Cleaning using Scrapers, wire brushes etc. 2. St 3-Power tool Cleaning using power tools like power wire brush needle guns etc. Power wire brushing may occur Burnishing on the surface, which will provide only poor adhesion wing: Jason’s hammer) Needle Gun consists of many air operated reciporating tungsten needles. Needles have a small cross section, useful for cleaning difficult areas like rivet heads and welds. After cleaning abrade the surface. Flame Cleaning The application of Oxy-acetylene or Oxy-propane flame to the steel surface. Differential expansion between the millscale and the metal, flakes off the rust scales. Rust is also De-hydrated and converted in to dry powder.eee 1. Degreasing 2, Pickling: Immersion in a tank of 5-10% sulphuric acid at 65-70°C remove millscale rust etc. 3. Clean water wash to remove acid 4. Phosphating ‘Tests to detect surface contamination ‘ing Millscale - m Spray a fine mist of copper sulphate solution to the test required surface. ‘The steel turn to a bright copper colour and any millscale particles show as black spots, Remove the copper from the surface by abrading or grinding, ae Sane : Spray a thin mist of distilled water to substrate. Wait for the droplets to evaporate. Press the Potassium Ferro-synide paper to the steel surface 2 to 5 seconds remove and examine the PF paper. If soluble iron salts are present a prussian blue spots can find. 1 oe Soak filter paper in the 2% silver nitrate solution . Press the wet filter paper on the surface. ‘After 20 seconds wash it in distilled water. Immerse the washed filter paper in photographic developer for 2 min. Chlorides will show up as brown-black spots. ti I ium ride Test: 6% Barium chloride and saturated solution of Potassium Permanganate. Soak the filter paper in barium chloride solution, drain and dry the filter paper. Press the filter paper on the surface backed by a peace of wet filter paper soaked in the potassium permanganate solution, Pink spots on the barium chloride treated filter paper show the presence of soluble sulphates. su ion of non-fe ‘A galvanised steel surface up on which, a cohesive oxide layer has not yet formed. Bright and Shiny, less than 3 months old If sweep blast or hand prepration is not possible an etch primer ‘ T-WASH” shall be used. T-Wash + Blue in colour it tums black up on if it has been applied sucessfully. w A Over 3 months old, dull, with cohesive oxide lair. Only stiff bristle brushing for surface prepration. No sweep blast or hand abrading. Thin gage Aluminium should not be blast cleaned. Treat with etch primer (PVB) Chlorinated hydrocarbon solvent shall not be used. 4 Sti ‘Only Aluminium oxide should be used as the abrasive for sweep blast.T int Basically three types of Paints exist 1. Solvent carrying Liquid Paint 2. Solvent free liquid paint 3. Powder paint Paint will consist of three principal components 1Binder (Film former) _2.Pigment — 3.Solvent (Thinner) Binder + Solvent = Vehicle 1Binder Binder converts the liquid to solid dry film. Binder binds the particles together. Tt provides finish tothe coating. Binder makes the coating adhere tothe surface Tt gives elasticity tothe film. Binder provides resistance to water chemical and abration ‘A Paint type is normally identified by its binder. eg, Acrylic, Alkyd, Epoxy, Emulsion, Silicone, Chlorinated rubber, Polyurethane etc ‘A paint binder forms Polymers when drying takes places. The name Polymer means “Many parts” and isa giant Molecule formed by the linking up of millions of small molecules calied Monomers, (Monomer means “Single part”) ‘The process by wich the monomer molecules are linked is called Polymerization (During the drying of paint film). ‘Three types of Polymers are: 1. Linear Polymer (single bond) - e.g. Vinyls 2. Branched Polymer - e.g. Chlorinated rubber 3. Complex Polymer (Cross linked) - e.g. Epoxy, Polyurethane etc.. Linear polymers and Branched polymers which have a ability to re-soften (Melt) by applying the solvent or heat. Complex polymers (Cross linked polymer) once fully cured cannot be re-softened. Paint binders may consist of resin, oil or resin and oil. Resin 1 Natural resins eg. Shellac, Copals, Demmars ete... ‘2.Synthetic resins. eg, Epoxy, Alkyd, Vinyl etc.. il Before synthetic resins un saturated drying oils were used as film formers. Ex. Linseed oil, Tung oil, Soya bean oil etc. Paints which contains more oil than resin is refered a Long Oil Paints. These paints are slow drying & elastic. Mainly using for decorative purposes. Paints which contain more resin than oil is refered as short oil Paints. These paints are fast drying Using for structural coating, Semi-drying and non drying oils are used in certain paints. e.g. Alkyd.Pigments Pigments are solids in powdered form, which provides colour and opacity. Pigments may be organic or inorganic, most pigments used in paints are inorganic. It improve the strength of the paint film, It protect the premeability of the paint film. It provides rust inhibitting properties. It add body (thiken the liquid paint). Also pigments improve adhesion. Also gives resistence to acid alkaly and light. e.g. Carbon-(Black), Cobolt-(Blue), Calcium-(Red, Yellow), Iron oxides-(Brown,Red, Yellow), Titanium dioxide -(White) Zinc Phosphate (White), Zinc Chromate (Yellow) Red lead and red oxide (Red) Coaltar (Black) Calcium Plumbate (White) etc.. These all are i ‘Anun pigmented paint is known as Varnish. Rust Inhibitive (Anti-corrosive) pigments used in Primers for corrosion prevention. e.g. Zinc chromate, Zinc phosphate, Red lead, Calcium plumbate, Coal tar etc... Metalic pigments for decoration and protective properties. eg, Zinc, Aluminium is for increasing viscosity, reducing gloss. Using extenders is lower coast e.g. Kaolin, Chalk, Tale, Siate dust etc... . i i - Pigment particles looks like leaf or hands, when drying takes place pigments “overlap and interwave and forms a solid film, which provides excellent coating to resist the passage of water. Ex. MIO, Mica,Glass flakes and Aluminium flakes etc... i Me i . Each paint hes a optimum ratio between the amount of binder and the amount of pigment it contains, this is known as the Critcal Pigment Volume Concentration (c.pv.c.) and controls the paints properties. eg Low pigments and high binder means high gloss paint with poor opacity High pigment and low binder means a flat paint with good opacity Too much pigments will give a porous film due to poor wetting. Too much binder gives a high gloss with low opacity, which has a tendency to chalk and blister. ‘Agregates: Pigments particles group together in small groups are known as Aggregates. el Solvents reduce the Viscosity until suitable for the intended application. Solvent must be volatile so that it evaporates from a coating of a paint to leave viscous film. e.g, Xylene, White spirit, Turpentine, Acetone, Alchohols, Water etc.. Important properties of a solvent are: 1, Solvent Pewer - Strong solvents, The molecules of the paint to move more easily. 2. Rate of evaporation - Method of application will affect evaporation if the rate of evaporation is ‘too quick. Problem may arise during application. e.g. Dry spray. 3, Flash point - The lowest temp at which the vapor of the flamable material will be ignited if an external source of ignition was introduced Measuring equipment is closed cup of the Abel type 4, Toxicity -(Poison content in the paint) The toxicity of a solvent can be determined from its ‘occupational exposure limit expressed in patrs per million. (p.p-m.) Other Constituents in the Paint a)Plasticizers: are adding flexibility to the paint film. eg. Castor wil, Coconut oil (Non drying oil)i - setrad the formation of sediment in the bottom of paint containers and help ‘maintain the paints uniform consistancy during the paints shelf life. e.g. Bentones and Waxes. ShDuiers: (Applicable to oil based paints) added to acelerate the drying process in oil based paints 2 Cobalt Napthenate- improves surface drying Calsium Napthenate- improves surface hardness Gv Ant-skinning agents: (Applicable to ol based psins) to reduce skin formation inthe container, eg, Thymol, Methy Ethyl Ketoxime. Paint Drying & Curing (BS 2015) Glossary of paint and related term Diving The change of a coating material from the liquid to the sold state, due to evaporation of solvent, physio-chemical reactions ofthe binding medium or a combination ofthese process, Air drying Drying process in normal temp. Forced drying ~ Heat above the ambient temp, but below that used for stoving. Stoving - Heat, using an oven or infrared energy. Me 1. Dust dry ‘Dust no longer adheres to the paint film 2. Surface dry Dry on the surface but soft and tacky underneath (oil based paints) 3. Touch dry Slight pressure with fingers does not leave a mark. 4, Tack free + Free fom tack, even under pressure. S.dryto handle —_: Can handle with out damage. ‘Drying Mechanisms 1 Solvent Evaporation: When the solvent evaporates the polymer reforms and become hard Solvent evaporation is Reversible-Non convertible e.g. Acrylic, Chlorinated rubber, Vinyls etc.. 2. Oxidation: Dry first by solvent evaporation then oxidation. The polymer then begin to cross link and form a dry film. Non reversible-Convertible eg. Alkyds, Oil modified phenolics, Epoxy esters etc. FChemical Curing: Dry intially by solvent evaporation, if solvent is present and then by polymerization due to chemical reaction ‘with the curing agent. Non reversible-Convertible e.g, Epoxy, Etch primers, Polyurethane etc... 4 Coalesgence: Dry intially by water evaporation. This allows the polymers which have already formed to join together. Reversible-Non convertible e.g. Acrylic Emulsions and Vinyl Emulsions. ‘Aconveriible coating is one which chemical changes up on drying. Therefore the dry paint cannot be softened or damaged if its own solvent is applied to it Non-Convertible Coating ~(Reversible film) saan convertible coating does not change chemically up on drying, but dries by evaporation only and can be damaged or softened if its own solvent is applied to it.a : : . Thermosetting is where heat is applied to cure and up on drying a chemical change accured. Apply of further heat will not re-soften the coating ‘Thermoplastic is non-convertible coating. Apply of heat can melt or damage the coating. Two pack paints are used taking into the consideration the Pot Life and in some cases the Induct 7 Pot Life -After mixing a two pack paint the maximum length of time after induction which the paint can remains in a applicable condition Induction Period - The Minimum period of time during which the mixed components are let to stand before use. This is to allow for certain chemical reactions to take place and /or time allowed for the air bubbles to escape. Induction periods are typically up to 30 minites. ‘There are several other curing mechanisum which only be employed where the curing agent may already present in the paint and activated by external means a) Heat (low-bake ovans) ) Uttra-violet radiation o) Infra-red radiation d) Electron beam ¢) Atmospheric moisture oatil te Corrosion Protection Methods: The paint system protects the substrate from corrosion by a combination of one or more of the following methods. 1. ‘The barrier principle : Using of a low permeability coating isolating the substrate from Environment, E.g. Polyurethane, epoxy 2. Passivation : Corrosion is retarded or arrested by chemical reaction between Rust inhibitive pigments in the primer and the substrate. E.g Zinc phosphate 2. Cathodic protection : Coating the substrate with a paint containing metallic pigments Like Zine or Aluminum, which are ignoble to the substrate. Layers of paint film & its functions 1. Primer : To provide maximum and lasting adhesion to a substrate. To provide a key for the next layer. To retard corrosion by means of an inhibitive pigment. 2. Mid coat: Mid coats to serve as barrier to prevent the passage of water. Primer and finish coats are thin coats, without a mid coat inhibitive pigmnts in the primer would be wash out or diluted which will lead to corrosion. Mid coats will build up the film thickness to provide more even surface by filling in slight surface irregularities 3. Finish coat _: Gives a surface its final appearence, colour and gloss etc. Each coat of paint shall be of a contrasting colour to the previos coat.i imers:- The zinc acts as a sacrificial anode when in contact with a steel surface at localised areas damage such as scratches. ‘Types of Coating system There are various ways to classify paint systems. A Function, B.Binder type, C. Pigment type, _D. Colour Barrier Coat: A low premeability coating which isolate the substrate from the enviornment. Tie Coat: A coat of a paint which acts as a intermediatry between two in-compatible systems. ficial Cast The pigments scrificed it self and protect the substrate to which the pigents is adhered e.g, Zine & Aluminium. Powder Coating: Basically powder coatings are solvent free, they may be thermosetting or thermoplastic. Epoxy powder gives a thermoset coating, which can be used on underground pipe lines. Each thermoset powder contain a base and curing agent, which are activated by means of heat source. Water Borne Coatings. Use water as a solvent in place of the hydrocarbon solvents normally associated with the coatings industry. ‘The binder types which are in comman use , using water as a solvent is: Alkyds, Epoxies, Acrylated rubber, Acrylics, Bitumens, Silicones, Polyurethane, Vinyls etc. Advantages: 1, V.0.C Complaint (Volatile Organic Componds ) No GWP or ODP GWP = Global Warning Potential ODP = Ozone Depletion Potential 2. No Toxic, 3.Non flammable 4, Water is cheap and readly available 5. Odourless, 6. Compatability 7. Low Viscosity Dis Advantages: 1. Requires high degree of surface preparation 2. Needs inhibitors and other additives 3. Slow evoporation rate 4, Needs non ferrous application 5, Less durable isture BS The surface that requires coating may be below the dew point temperature. a) Damp surface: Temperature below dew point but no water on surface. b) Moist surface: Moisture on the surface. ©) Wet surface + Free water are present on the surface Paint using are:1) One pack polyurethene, 2) Solvent free two pack epoxy, 3) Moisture tolerant chlorinated rubber Cathodic Protection ‘A coating system is the primery defence against corrosion, but when this caoting system is damagec corrosion may occur. Cathodic protection is a secondary line of defence against corrosion. There are two methods of applying cathodic protection6 ici Wv Sacrificial anodes may be used where the current required to achive cathodic protection is small. If steel is to be cathodically protected, magnesium, zinc or aluminium anodes may be used. 2. Impressed Current ‘Impressed current is second line for cathodic protection after sacrificial coating. ‘Voltage from an extemal power source called a transformer rectifier is impressed on the circuit between the pipline and buried earth connections known as ground beds resulting in a direct current being discharged. If too great current applied to the pipe line Hydrogen Gas forms and pushes off the sacrificial coating, this is known as cathodic disbondement. Paint Mills In Paint manufactering paint mills are for breakdown or disperse the groups of pigment partcls i ispersing mills: The liquid and solid ingrediants are added directly to the mill which are: 1) Bali Mill : Horizontlly mounted steel cylinder containing steel or procelain balls ‘which continually cascade down on to the ingredients when the cylinder is rotated. 2) Attritor Mill: Basically this is vertical ball mill. The cylinder is stationary and the balls are agitated by rotating shafts. This gives higher degree dispersion in _short time. 3). High speed disperser: Vertical shaft at the end of which is a disc shaped serrated edged impetter which rotates in a high speed. 4), Kady & Silverson Mills: Both are high speed mills (20 gls/ day) B) Pre-mix Mills: Pre-mix mills are for high quality requirements (Maximum disperson of the pigment). ill or 1 Mill: Most modem frequenly used mill for the large scale production, Rotating dicss attached to a shaft help to achive shear as the paint stury is forced through small abrassive particles present in the cylinder between discs. This mill gives. high degree dispersion. (1000 gal /day) ‘These mills are quite versatile, have a high output and are particularly suited to emulsion Paints. ti This mill consist of three parallel rollers , each runs at different speed and rotates different direction. Using for the production of paste meterials such as mastics. this is an expensive technic. 5ins fine Mainly using for refining purpose after milling operations. Small batch production and low efficiancy.Paint Testi ality Control & Performance) BS 3900 - Methods of test for_paints Group A - Tests on liquid paints (Excluding chemical tests) B - Test involving chemical examination of liquid paints and dried paint film CC - Tests asssosiated with paint film formation D - Optical tests on paints E - Mechanical tests on paint film F - Durability tests on paint film G -Enviornmental tests on paint films (Including tests for resistence, corrosion and chemical) H- Designation of intensity, quality and size of common types of defect, general Principles and rating schemes Different Paint Film Testing i Grind:- Degree of dispersion of a paint can be assesd with a fineness of grind gauge also known as HEGMAN GRIND GAUGE. ‘A quantity of paint poured in to the groove(s) and a flat edged scraper pulled along the ength towards the shallow end. This ensures that the groove is filled and surplus paint is removed. With in three seconds the scale should be observed to assess the point, where within a ‘3mm band across the grove 5 to 10 pigment particles break the paint surface. : ited i = 1. Weigh a throughly dry watch glass and stirrer 2. Add approximately 2 grams of paint and reweigh 3. Drive of volatile in an air oven at 105° C for 3 hours 4, Reweigh; determine volatile content and non-volatile content by simple calculation. 3. Flash Point: - BS 3900 Part A9 ‘FlashPoint is the lowest temp. at which the vapour of the flammable materials will ignite Tfan external source of ignition was introduced. 1. Fix the Abel cup containing the substance for assessment in to water bath 2. Activate the source if ignition every 1/2° C rise in temp. 3. Apply a heat source to the water bath and monitor the air/vapour temp. In the Abel cup 4, Flash point temp. is identified when the blue flame flashes over the substance being assessed 4, Viscosity: ‘Viscosity is a measure of fluid resistance to flow A fluid with High viscosity means - Thick fluid ‘A fluid with Low viscosity means - Thin fluid Instruments using for measuring viscosity are known as viscometers. Unit of viscosity are- Poise, Newton, Dyne, Stoke, Centi Poise, Centi Stoke, and Seconds.Vise wy 3 i 1. Kerbs-stormer Viscometer 2. Cone and plate Viscometer 3. The Rota thinner ‘A simple method for measuring the viscosity of free flowing paints is Flow Cup (Ford flow cup No. 4) Thixotropic Paints Rotational type Viscometer. (Kerbs-stormer) ui in ire 1. Level the apparatus, then with the end of one finger over the orifice of the cup, rapidly fill it with paint. 2. Allow a moment for air bubbles to rise then draw a flat edge across the top of the cup ‘to wipe off the paint level with edges. 3. Remove the finger from the orifice and start the stopwatch simultaneously with the commencement of the paint stream, The watch is stopped when the first Distinctive break in the paint stream occurs. 4, The time in seconds is taken as the viscosity. Density is weight per unit volume. Formula:- Density Weight Volume Relative density or Specific Gravity is the density of any substance compared to the density of water. f 1, Weigh the cup 2. Remove cover and fill with paint to with in 2.5 m of the brim 3. Carefully replace the cover 4, Wipe off any surplus paint from the cover 5, Reweigh 6. Determine the weight of the paint by subtraction 7. Divide weight by 100 if the density in g/em3 ‘WET is taken immediately after a coating has been applied. Instruments: 1) Comb Gauge 2) Eccentric wheel VS% sw Film Thi ‘Four methods of determining the DFT a) Non-destructive test gauges b) Destructive test gauges c) Test panels d) Calculation 1. Eddy current/Electronic gauge 2. Magnetic film thickness gauge (Banana gauge)3, Pull-off gauge or Tinsley pencil 4, Magnetic horseshoe gauge Mainly using for ferromagnetic paint film (MIO) testing. ‘The paint inspectors gauge (P.1.G) “Metal plates of known thickness may be used to measure DFT indirectly, @) Calculation: DFT = VS%x WFT 100 Weathering and artificial weathering To determine how a coating will behave in natural weather conditions. Painted test plates are weathered for pre-determined time e.g. months or years. The test plates may be exposed to any environment, e.g. Marine or Industrial, to determine the coating systems behaviour in specific conditions a) Tropical box : High Humidity ») Salt spray box : Marine Environment ©) Water soak Resistance of water absorption d) Temperature cycling _: Expansion and contraction testing ©) Cold check testing : Low temperature contraction craking, Testing of mechanical pro} von resistence: Painted panels are abraded for a specified period of time by some particular instruments using falling sand, revolving rubber wheels, wire wool or by similar mean and then evaluated for the degree of abration 2. Hardness : Pendulam test - Koeing Albert apparatus 3._Flexibility: Bent test 4. Impact resistence: Falling weight impact test 5. Drying or curing test: 1, Ballotini test Tiny glass balls known as ballotini are allowed to fall in to a freshly painted slowly moving test panel. The amount of ballotini sticking to the surface will reduce as the surface dries. The drying time is recorded corresponding to the position where the last glass ball adheres. 2. Stylus test or Beck koller needle test Set-up is similar to the ballotini test. Number of needles of variable weight are allowed totrail across the freshly painted surface. When the paint is wet the needle touch the substrate, as drying occurs the needle score the film and eventually corrosponding to the interface at the position where the scratch is no longer visible 6. Gold leaf test: Residual touch ‘L_Mechanical Thump Test: Motor driven mechanical thump test 8,_ Pencil scratch test: using pencil to test hardnes of paint film ani ‘Needle with adjustable load applied to test panel. Minimum load to scratch, recorded. 10, Opacity: Opacity is the hiding power of paint film 1.Cryptometers. 2. Hiding power charts “The degree of gloss mainly depand on the degree of dispersion of pigment in the paint film, Also the amount and the type of binder used, other factors are method of application, skilled oprator and absorbency of the surface. Testing equipment :- Gloss meter a) Veecuttest: With sharp knife cut vee 12mm b) Cross cuttest: With sharp knife cut 6 line vertically and horizontly. Cover area with adhesive tape and snatch. ¢) Dolly Test : Pull of adhesion test 4) Hydrolic adhesion test: 13, Cathodic Disbondment test: w Conditi ‘The coating specification should always state the weather conditions in which a coating can and cannot be applied. BGAS d weather conditions are: For preparation The air or metal temperature must not be below the dew point. The air or metal temperature must be above 3°C of the dew point The RH.% must be below 90% Follow the manufactors minimum and maximum recomended temperature. Meesuring R.H% and dew point - Whirling Hygrometer + DP/RH Calculator ‘Measuring Metal temp. - Magnetic temp. gauge or Electronic temp. gaugeInspection ‘Specification - Specification is the governing document for coating work. It will define what the supplier or the sub-contractor is required to do. ties - It is the duty Of a painting inspector to ensure all painting and associated operations are carried out in accordance with the specification(s) for the contract. 2 a) Leam the specification(s) b) Get to know the plant @) Get to know the personnel @) Ensure all concerned understand the specification. ¢) Keep the Engineer in formed at all times of any departure from the specification. £) Make viritten reports at an agreed frequency. g) Conduct and/or attend site meetings. a) Check the environment 'b) Check the equipment ) Check the materials 4) Cheok the previous days work ) Agree the days work programme with the site contractors senior personnel 1a) Cheok the environment ) Check the equipment ©) Check the materials usage 4) Check each operators work €) Check the standard a) Ensure that system meets the specification by carrying out or witnessing tests. ) Check for any application faults t tH di 1a) Check the days work ) Check the housekeeping c) Complete reports. is ; 1a) Make the final check on integrity of the work ) Write the summary report. Prenty KA SaneAs per painting inspection procedure Painting inspector’s duties are: 1) Access the rust condition of substrate prior to treatment. 2) Access the prepared surface in accordance with SS-05-59-00. 3) Measure and record the amplitude 4) Ensure the materials used as per the client specification 5) R.H%, Dew point, Steel and Air temperature to be checked and recorded at frequent intervals 6) Wet & Dry film thickness to be checked and recorded 7), Witness & Inspect each coat of application, and inspect completed paint System in accordance with clients specification 7) To submit daily, weekly and job completion reports, recording all relevant information as required by the client. Copies to be retained by inspector. ‘The Inspector should be aware of the typical contractor malpractices, which are: ~ Use of unskilled operators and unsuitable equipments Painting or preparing surfaces during inclement weather conditions; rain, snow, fog, mist etc. Painting before inspection of substrate preparation or previous coat. ‘Applying two paint coats to the same area in one day assuming specification does not allow this Missing out a coat. ‘Use of wrong solvent or an excessive amount of solvent Using diesel in the paint (as a thinner or plasticiser) which will prevent proper drying Use of incorrect paint type or mixing different manufactures products Storing paint incorrectly 10. Use of date expired paints 11, Re-using of expendable abrasives 12. Insufficient blasting or painting in difficult access areas, under pipes etc. 13. Apply low thickness of paint 14, Cleaning surfaces with cotton waste or rags. Lint free paper tissues must be used Preranaeyen10- Technical Specification for BRITISH GAS TRANSCO. Ensure that adequate protection is given to surrounding areas and adjacent structure to avoid spotting, overspray and other condemnations. Ensure the masking of equipments, atmosphere sensing heads, spray heads vents on control equipments etc. Metallic Zinc is not allowed to touch with stainless steel. ‘Washing with solvent required Oil & Vapour traps (filter) fitted to compressed air for power tools. ‘All Algae and mould growth shall be treated with biocidal agent for a minimum 24 hours. It can be removed and clean by water. Surface profile - Not less than 30 jum and not grater than 75 pm Wet blasting system for lead based paint. Following wet blasting dry blasting to remove subsequent flash rusting. Ferrous impact tools not normally used. Needle gunning- Profile not exceeds 100 um, Remove rogue peaks. Abrasive disk - Special care required, danger of creating Notches ‘All weld flux and spatter shall be removed, Blast cleaning recommended on weld areas. Any oil or grease on the prepared surface - Solvent cleaning followed by 2% detergent solution then with clean water, then abrasive cleaning repeated. : Disposable lint - free swabs shall be used; cloth rags shall not be used. SPA - Specific Painting Application for r ‘components ‘Two Main Systems for BGAS 1. Compliant solvent-based Paint system Primer : High build epoxy aluminium primer minimum DFT 75 um 2ndCoat =: = MIO Minimum DFT 75 um 3rdCoat ‘High Build epoxy undercoat minimum DFT 75 pm Finish Coat : Epoxy or Polyester acrylic finish minimum DFT 40 pm Total DFT 265ym 2. Water - borne acrylic system Primer Minimum DFT 50 wm 2nd Coat =: = MIO. Minimum DFT 75 pm 3rd Coat Undercoat minimum DFT 50 pm Finish Coat Minimum DFT 50 pm TotlDFT : — 225pm PrqulyA SepMask out Degreasing with approved solvent Blast clean SA 2.5 Profile max. 75 jum Clean surface immediately prior to painting At works Primer — High solids Solvent based Epoxy primer DFT 75um Epoxy MIO DFT 75 yum L l On Site Compliant Solvent Based System Water Bore System Under coat ~ High Build Epoxy U/C Under coat — Water Bome U/C 50m DFT 75um Finish Coat ~ Water Bome Finish 50m Finish Coat - Poly Acrylic Finish DFT Total DFT - 250 wm 40m Water Borne System on site Total DFT - 265 um Total DFT 225 pm ion fo ns [All surfaces nt tobe waited hal be masked 2. Blast clean Bs 7079 Sa 2 1/2, Profile with in the range of 30 wm and 75um 3. Clean all surfaces immediately prior to primer application 4, Apply Primer as per the system recommended 5. 2nd coat MIO 6. Before applying 3rd and final coat clean all surfaces (Degreasing, Washing with a 2% Detergent) ‘SPA Ib - Preparation of Painted surfaces with Limited damages Surface prep: BS 7079 ST3 Mechanical wire brushing High solid solvent based epoxy primer and epoxy MIO One coat of High Build undercoat and One finish coat. For installations previously painted with drying oil or chlorinated nibber paint systems maintenance painting can generally carried out with any of the following systems 1. Compliant Solvent Base System Or ‘2. Water Borne System Pega RAS2- it inting for in IR’ rot : int for f 1 1. All surfaces not to be painted shall be masked 2. Washing 3. St 3 Mechanical cleaning 4. Edges of existing sound coating shall be feathered 5. One coat of primer by Brush. The paint shall overlap on to any existing coating by at least 100mm, DFT 45 pm 6. One coat of MIO by Brush DFT 45 ym 7. Ifa decorative appearance is required one coat of under coat 45 um and one Coat of finish 25m shall be applied. 1. Spot prime - DFT 45m 2. Spot MIO - DFT 45um 3. Apply Undercoat - DFT 45m 4. Apply Finish coat - DFT 254m Or Spot prime + Spot MIO + One fill coat of MIO DFT S0um /A.3 Painting of f : 1. Masking 2. Washing 3, Blast clean 2 1/2 Profile 754m 4, Primer - Heat Resistant Aluminium pigmented epoxy DFT 250m Or Urethane Primer - DFT 100m ‘Heat resistant paints are normally aluminium pigmented no finish coat required. 1. Masking 2. Washing 3. Blast clean Sa3 Profile 75m 4. Optional Systems a) Thermally sprayed Aluminium b) In-organie zinc silicate o) Poly siloxane inorganic coating SPA3c- Operating temp. above 340°C T. Masking, 2, Washing 3. Blast clean Sa 3 profile 75 jm 4. Apply thermally sprayed Aluminium Or Peg A Seena) In-organic zine silicate ) Apply silicone sealer ) Apply heat to cure sealer Or Polysiloxane in-organic Coating PA 4 Paint Fem Moisture tolerant system for Damp surfaces 1, Degreasing with solvent, The surface shall subsequently be washed with a 2% detergent. 2. Blast clean Sa 21/2 3. Washing with clean water, droplets and standing water shall be removed from the surface. Cloths and rags shall only be used if they are lint-free. 4, All paints shall be brush applied 5. Apply Moisture tolerant system in accordance with Manufactures Instructions. Corrosion protection required Non Ferrous surfaces are: 1. New galvanised Surfaces 2. Weathered galvanised surfaces 3. Previously painted galvanised surfaces 4, Aluminium surfaces Paint System - 1. Water borne acrylic 2. Epoxy high build 3. Alkyd or modified alkyd Total DFT is 1201m ‘New Galvanising - If sweep blast or hand abrading is not possible (impractical), an Etch Primer (T-Wash) shall be used. ising - Only stiff bristle brushing for surface preparation, no sweep blast or hand abrading Aluminium -Thin gauge Aluminium should not be blast cleaned. Treat with Etch primer. Chlorinated Hydrocarbon solvent shall not be used. The following Non Ferrous materials are painted for Cosmetic Purposes. 1. Stainless Steel Only Aluminium Oxide should be used as the abrasive for sweep blast Paint System - 1. Water borne acrylic, 2. Epoxy High build (Chloride free) 2. Pre-painted Cladding 3. Glass Reinforced Plastics (GRP) 4, Fusion Bonded Epoxy (FBE) 5. Multi Component Liquids (MCL) 6. Concrete Paint System for (2t06) 1. Water bone Acrylic 2. Moisture cured Urethane 3. Alkyd or Modified AlkydMethods of application ion a) Cheap to purchase b) Easy to maintain «) Slow job 4) Good job in right hands ) Poor access ) Works paint well in to the substrate 'g) Cannot apply all coating types bh) Sheeting up only is required (No masking required on surrounding) i) Personal protection is minimum ) Cheap to purchase b) Two to three times quicker than brush ¢) Easy to maintain 4) Washing out time is significant. Also washing out uses a lot of solvent €) Access is better (Extension poll) but cutting in needs to be done by brush. 4) Finish is poor (Orange peel) 12) Not so good adhesion to substrate 1h) Roller spray i) Gives an uneven costing {) Variety of shape roller heads available k) Suitable for large flat areas 3: Spray Application: a) Conventional Spray: 1. Gravity feed 2. Suction feed 3. Pressure feed or remote cup ‘a) More costly than brush but cheaper than airless spray b) 4 to 5 times faster than brush ©) Good job in right hands 4) Access is only good in pressure feed only ¢) Washing out time is significant £) Washing out uses lot of solvent g) Do not apply all-coating types h) Only good for some paints e.g. Cellulose i) Masking out time significant j) Personal protection clothing required h) Safety becomes a consideration PequelyKA SuphaeenCoating Faults Coating Faults BS 2015, 1. Bittiness - ‘The presence of particles of gel or foreign matter in the coating material or 2. Bleeding - 3. Blistering - (Bubbling) 4. Blooming ~ 5. Cissing - (Craving) 6.Cracking - 7.Chalking —- 8. Cratering - 9. Curtaining, - (Sagging, Runs) projecting from the surface of a film. Caused by lack of care and attention to cleanliness in surface preparation, materials and equipment. This appears as staining or discoloration of an applied paint by constituent of the surface or the pervious coating. The solvent(s) of the new paint can cause certain organic pigments, coal tar, or bitumen to dissolve. To prevent bleeding the surface can be sealed with an aluminium sealer before application of the new paint. Formation of blisters in the dry film by local loss of adhesion and lifting of the film from the underlying surface. Presence of Hygroscopic salts or soluble iron salts in the surface can create blisters. This is the formation of a surface dust on gloss type paints usually due to the moisture in the atmosphere. Loss of gloss and dulling of colour. Cissing describes the appearance of a wet paint film, which hes either been applied to a grease or oil contaminated substrate, or the application method has been contaminated. It appears as tiny ‘unwetted areas where the paint has contracted away from the contamination. Crawling is an extreme form of cissing and in the retraction of the wet paint from large areas of the surface. Both defects can be considered due to the lack of surface tension Crazing, Crocodiling, Mud Cracking etc... This is where breaks in the paint film occur and extend through to the substrate. It can be the result of inadequate elasticity of the paint system applied on to a substrate, which expands and contracts. Cracking is usually a precursor to flaking ‘The formation of friable, powdery coating on the surface of the paint film. Caused by the degradetive action of the weather and / or Ultra Violet radiation Formation of small bowl shaped dispersions in the film. ‘A downward movement of a paint film between the times of application and setting, resulting an uneven coating having a thick lower edge. Because of poor workman ship or excess amount of Thinner in the paint can increase the flow of the paint. ProwetyKASigbene,Airless spray is considered to be the main tool for Industrial Painting, Airless spray is a) Expensive to purchase b) 20 to 30 times quicker than brush ) Large areas can be covered 4) Only method for applying high builds materials ¢) Washing out time is significant and uses a lot of solvent £) Safety is major consideration (Trigger locking, static electricity, personal protecting clothing required) g) Parts are very expensive hh) Swivel tip (for blockage) i) Masking is required which The Conventional spray a mixture ofr and paint i fed othe gun at comparatively low pressure (typically 30 to 100 psi) at the gun. This mix is atomised and projected on to the surface with a relatively small fan pattern and relatively low thickness, In airless spray, paint is fed in to a fluid pump. This pump can be adjusted to multiply the 100 psi in let pressure up to 60:1 ratio. Therefore if the ratio adjusted to 35:1, the paint would be pressurised and delivered at 3500 psi. This pressurised paint is then fed to gun by means of high-pressure fluid line. The paint is only atomised when the trigger is pulled and the paint is released in to the air at high pressure because no air is involved in the delivery of the paint, it is called airless. High volume and high thickness of paint are achieved Electrostatic Spray: Method of painting of ferrous surfaces. Spraying in which electric charge attracts paint to surface. a) Very expensive to purchase +b) Specialist application for small and tubular components ¢) Paint particles are negatively charged 4) Substrate positively charged ¢) Coats all around component ) Gives an even coating 2) Very little wastage of material Other coating methods are: Dip coating, Flow coating, Curtain coating, Spin rotating ete. 1) Galvanising, 2) Sherardizing 3) Electro plating 4) Hot metal spraying etc. Peped oy KA Shear10. Flaking 11. Holidays - 12. Lifting - 13. Orange peel - 14, Wrinkling, - Rivelling) 15, Flocculation - 16. Grinning - 17. Dry Spray - 18, Efflorescence - Lifting of the coating material from the substrate in the form of flakes or scales. Inadequate surface and intercoat preparation, poor application, incorrect choice of primer, paint applied over chalking surface ete.. are the causes for the paint fault. Discontinuity, pinholes etc. Failure caused by the swelling of dry film of paint or varnish when another coat is applied over it and usually manifested by a wrinkled appearance. This is a defect with an appearance resembling the skin of an orange and is usually brought about by the rapid evaporation of the solvent before the paint has flowed out. The cause include too great a spraying distance, excessive air pressure, excessive environmental temperature, substrate temperature too high, or combination of these. The development of wrinkles in a paint film during drying, usually due to the initial formation of a surface slain Manufactering fault of paint, separated materials in the paint difficult to bind together. The underlying surface showing through due to the inadequate ‘opacity of the paint film applied to it. It can be caused by colour differences between successive coats, uneven application, over thinning of paint, or failure to adequately mix settled pigment in the can prior to application. This is partly dry paint particles which have failed to coalesce and thus presents a sandpaper effect. It can be caused by too great spraying distance, too wide a spray fan, or excessive air pressure in relation to nozzle size. ‘Not a paint defect. It is the development of crystalline deposit on the surface of brick, cement, etc., due to water containing soluble salts, ‘coming to the surface, and evaporating so that the salts are deposited. In some cases the deposit may be formed on the top of any paint film present, but usually the paint film is pushed up and broken by efflorescence under the coat. 19. Failure at burnt or backs of weld areas - The localised heat of burn and weld areas can severely damage the binder and leave unbonded carbonised residues. These residues have to be removed and the affected areas re-treated, otherwise there will be flaking due to the ingress of moisture under the paint Peguel by Asaph3 20. Failure at weld areas - 1 Failure at weld areas can be brought about from a number of reasons. Due to the chemical nature of weld flux, moisture can be absorbed thus creeting an Electro-chemical cell leading to corrosion. It is therefore essential that all weld flux (spatter) be removed prior to preparation and painting 21. Failure at edges and comers - ‘Any paint applied to edges and comers of structures will eventually suffer breakdown due to the surface tension of the film drawing it away from the edges. This can cut down the film thickness by factor of three. As a result all edges and comers should be radiused where possible, but an additional coat of paint applied as a ‘stripe-coat’ is suitable alternative. 22. Mould growth - Fungi, algae and mould growth. Moisture is the essential prerequisite for their development and growth, consequently they can occur in conditions of high humidity or on surfaces which have high moisture content. Remedial action is ideally a reduction in humidity and moisture content, and the application biocidal agents to kill the growth. 23. Saponification - Saponification means the formation of soap, and it ocours when an alkali attacks the oil constituent of oleoresinous paints in the presence of ==” moisture. The paint film loses gloss, colour, and becomes soft and sticky. ‘The defect may be a result of external attack by alkaline substances, such as the cleaning down detergents not being completely washed off. 24, Ropiness - A finish in which the brush marks have not flowed out, this being the normal appearance of a paint or varnish having poor levelling properties. A similar appearance may also produced in a paint, which normally has good levelling properties, by continuing to brush the paint after the film has begun to set. Pepe RAS ee‘WAUGH TECHNICAL AND EDUCATION SERVICES QUESTION PAPER NO. 2. GRADE 3/2 1. What isan Osmotic Blister and what can cause it. C¥iae Plier Sy one Wick Contain = Liquiel, Usuoll, Conted toy Setnbde salty bei afr neol One rg Wakes and Cart osekenint Busroring oh Raink Ye - 2 Same mere ard to repere and pag, pans thee and deeb how you might prepare them. Fa 3. Where a pipeline leaves the ground what problems would you find at Ground level and how might you treat this. Constent ly Wwrend Dry So Tapid Getvosion . “Sail _ dame, dork Onamieshy ache anch doseakt Curt. citnes tapes o% poly ethablin shies. Dy wring Sleeve apple’) onete teve eal . Dent do Slaawe wher Shyinki By tent . Wake Sere ae Contd... .f2)3 and Ric Kole ba ‘What is a Holiday Detector, what does it detect, and how does it work. Hotidar— tssecl aver Rin Wle:- Tiny Wolew Troy feit Kin vsestly cauresl by ait babel feoro ubak int filno And Wee ning weak Vorot bles Galle Cloge out tee BR Retidoy of Pinkele datecks doled Ret aults Slee. Cag yk Gpenge eadanh UH Rae Goo Sek Volege owas SAREE SE Qin bot debesked an Audio Os Vigub) Waning UNI Ges. TLecarces muh et { Woleoe, Rapaivecl and Re— & ‘If you worked on a contract where frequent stoppages occurred for poor weather, what additional information would you record. Vines a) Reppin, and thedhng Pregpen a lo ty Stopege cx todate Damege\ ek Paiotesl amear 9. Wehave a pipeline in direct contact with Accoustic Cladding, what system would be applied if we wished to maintain it every 3 years. or not at all. WARS Ang her vst Bult Soh bo Ned. Fo Rue & Sow but poi’ Munlbhe opplics Bye Mack — Que JoW MWe prdmet obly, toad ae By ¥ eciies} Minws Ynish Cook. (Contd... — ld)B P IN MODEL QUESTION PAPER What kind of process is corrosion? Electrochemical process. Corrosion is a chemical change brought by an electrochemical process called electrolysis ‘What particular problems relate to the splash zone ? Splash zone is salt laden atmosphere, Rapid change in oxygen content. Always wet and dry changes. Access is difficult. Wave impact and erosion. Growth of marine life. Derby and Boat damage. ‘What factors influence the rate of corrosion? Rapid change in oxygen content. Moisture content in the atmosphere is above 60%. Sulphide, Chloride, Acid and Alkalis in the atmosphere. High nobility metals being in contact with the steel. ‘What is millscale and why is it a particular problem when attempting to protect steel? Miillscale is a thin black flaky lair of oxidized iron. Steel is anodic to millscale. Therefore when areas of millscale flakes off, the exposed steel sacrifices it selfto preserve the millscale. ‘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? ‘SS-05-59-00 Rust Grade Grade A — All millscale litle or no rust Grade B ~ Mix of rust and millscale Grade C — Rusted with very slight pitting Grade D — Heavily rusted and pitting Bi _SA-1 Light Blasting +SA-2 — Through Blasting -SA-2 1/2 Very Throughly Blasting % SA-3 Visually cleaned steel metal‘Name and describe three tests for locating soluble iron salts and millscale on a blasted substrate ? 1) Copper sulphate test = Millscale 2) Paralel Light test - Millscale 3) Silver Nitrate test = Soluble Iron Salts 4) Potassium Ferrocyanide test Soluble Iron Salts ‘With regard to abrasives name the four factors which influences how clean and = how rough the surface becomes after blasting ? Size, Hardness, Density and Shape Human Factors are - Speed, Angle, Distance and time. Regarding hand and power tool cleaning state what always concludes this process and to what standards ? Wire brushing - St 2 Manual Wire brushing - St 3 Mechanical “What three basic ingredients make up a traditional solvent carrying paint? 1)Binder 2) Pigment 3) Solvent ‘What are the functions of each in paint ? Binder Binder converts the liquid to solid dry film. Binder binds the particles together. It provides finish to the coating. Binder makes the coating adhere to the surface, It gives elasticity to the film, Binder provides resistance to water chemical and abration. Pigment ‘Pigment gives colour and opacity. It improves the strength of the paint film. Pigment gives resistance to Acid, Alkali and Light. ‘Solvent Solvent thins the paint for easy application by any method. It is the evaporative part for the drying process. Cleans the brushes and equipments, Acts as the degreasing agent. ‘Name five items that can be included in paint to improve its performance or stability for a certain use ? 1) Drier, Hardner or Catalyst 2) Plasticiser 3) Stabilizer 4) Anti skinning agents and Anti settling agents 5) Extenders 6) Thixotropic agents. Identify six paints by their binder names ? 1) Alkyd -2)Emulsion 3)Epoxy 4) Polyurethane ~—_5) Acrylic 6) Chlorinated Rubber 7) Silicone17. 18. 20. ‘Name 4 binder / solvent combinations ? 1)Epory - Acetone —-2) Chlorinated Rubber - Xylene 3) Alkyd === White Spirit 4) Emulsion - Water Name six opaque pigments together with their respective colours ? 1)Zine Chromate Yellow 2) Zine Phosphate ~ White 3) Titanium Oxide - White 4)Read Oxide - Red 5) Calcium Plumbate - White 6) Coaltar - Black Describe what a laminar pigment is ? ‘A pigment whose particle shape is like leaves or hands, when dry they overlap and interwave with each other to provide a coating with good resistance to the passage of water. ‘What is the difference between a convertible and non-convertible coating ? Acconvertible coating is one which chemical changes up on drying. Therefore the dry paint cannot be softened or damaged ifits own solvent is applied to it. ‘A.non convertible coating does not change chemically up on drying, but dries by evaporation only and can be damaged or softened ifits own solvent is applied to it. Define the time induction period ? Induction period is the length of time after mixing the paint, which required to stand before application. This time allows air bubbles to escape and or chemical reactions to take place. Time to be 30 minuets or less. (Specified differently by the manufacturer) Define the term “pot life” ? ‘The maximum length of time following induction that a two pack paint remains in an applicable condition according to the manufacturers instructions. Define a “barrier” coating ? It is a coating system of low permeability, which isolates the substrate from the environment. Define the term “tie coat” and give an example ofits use ? A tie coat is a coat of paint, which acts as an intermediate between two normally in- compatible systems. Example :- If you wish to coat an Alkyd system over Bitumastic, you would use an ‘Aluminum leafing primer as tie coat21. 23. 24. 25. 26. 27. What is the difference between thermosetting and thermoplastic ? ‘Thermosetting is where heat is applied to cure and upon drying a chemical change accured. Apply of further heat will not resoften the coating ‘Thermoplastic is opposite to the above ‘What is impressed current and what problem can arise from its incorrect use ? Impressed current is the second line of cathodic protection after the sacrificial coating . If too great of voltage is applied to the pipeline Hydrogen Gas bubbles can form on the steel surface and push off the sacrificial coating. This is known as Cathodic Disbondment. Name two types of paint mill and give two examples of each ? 1) Direct Charge Mill E.g, Ball Mill, Attritor Mill, High speed dispersor 2) Pre-mix or Slurry Mill E.g. Sand, Pearl or Bed Mill, Colloid Mill, Single or Triple roll Mill ‘What is the title of BS 3900 ? - Method of test for paints How many test sets are in BS 3900 ? - 8 (Eight) How are the tests Identified (name, number, letter) which ? By title and letter Ato H ‘What does a fineness of grind gauge measure ? It measures the degree of dispersion (Fineness of pigment particles) What is “flashpoint” and in what apparatus is it determined ? ‘The lowest temperature at which the vapors of aliquid will ignite ifan external source of ignition was introduced (Abel Cup) What is viscosity and what equipment is used to measure the viscosity of A) A free flowing paint. B) A thixotropic paint ? Viscosity is a measure of fluids resistance to flow. a) Ford Flow Cup No. 4 is for free flowing paints. b) Rotation Viscometer for thixotropic paints.28, 29. 30. 31. 32. 33. 34, 35. ‘What is a density cup and give an example of its use ? Density is weight per unit volume, Density Cup is a small black cup made from Aircraft Alloy. It is used to weigh materials exactly. This process determined the quantity of added thinner in a paint or determined if a two pack paint have been mixed to the correct proportions (Ratio) Calculate the density of a two pack material if part A weighs 1.5 and part B weighs 0.5? PartA=1.5 + PartB=0.5 Total 00. Density is 2.00 /2= 1 Calculate the volume solids of a paint if W.F.T. was 186 um and D.F.T.was 93 ym? 93 x 100/186 = 50% Calculate the W.F.T. of a paint if vs% was 66% and D-F.T. was 88 um ? 88 x 100 / 66 = 133.33 Calculate the D.F.T. of a paint if vs% was 44% and W.F.T. 234 pm? 44 x 234/ 100 = 102.96 Name an example of A) Non destructive DF.T. gauge? - Banana Gauge (Magnetic Film Thickness Gauge) B) Destructive D.F.T. gauge ? - Paint Inspectors Gauge (P.1.G) ‘Name three artificial weathering devices and say what they are designed to simulate ? 1) Tropical Box - High Humidity 2) Salt spray Box - Marine environment 3) Water soak — Paint film permeability 4) Temperature cycling — Flexibility 5) Cold check test - Low temperature cracking ‘Name two drying / curing tests ? 1) Ballotini test 2) Stylus test,36, 37. 38. 39. 40. 4l. What does a eryptometer measure and give two examples of a cryptometer ? Cryptometer measure the opacity (Hiding power) of the paint film. 1) Pfund cryptometer 2) Hiding power charts What determines the degree of gloss a paint may posess ? How finally the pigments is been grined, Amount and type of binder. Other factors:- Method of application, Skilled applicator, Absorbency of surface. ‘Name three adhesion tests and describe how two of them are carried out ? 1) Vee cut test 2) Cross cut test :- With sharp knif cut 6 line vertically and horizontally. Cover area with adhesive tape and snatch. 3) Dolly test :- Clean abrade surface, stick dolly with regular araldite, leave for 24 hours at 25% , cut around the dolly, apply pull of force. After brack down check if brack down was adhesed or cohesed and p.s.i. ‘State the weather conditions under BGAS allow. A) Preparation to take place ? Air or metal temperature must not be below dew point B) Painting to take place ? 1) Air or metal temperature must be at least 3°c above dew point temperature. 2) Relative Humidity must be below 90%. 3) Manufacturers recommended maximum and minimum temperature to be followed Name 8 duties of a paint inspector ? 1) Access the rust condition of substrate prior to treatment, 2) Access the prepared surface in accordance with SS-05-59-00. 3) Measure and record the amplitude 4) Ensure the materials used as per the olient specification 5) RH%, Dew point, Steel and Air temperature to be checked and recorded at freq: intervals 6) Wet & Dry film thickness to be checked and recorded. 7) Witness & Inspect each coat of application 8) To submit daily, weekly and job completion reports, recording all relevant information as required by the client. Copies to be retained by inspector. List 8-contractor malpractices? 1) Use of unskilled operators 2) Use of unsuitable equipments 3) Painting or preparing surfaces during inclement weather conditions. Rain, snow,f-2 and mist etc. 4) Painting before inspection of surface preparation or previous coat42. 43. 45, 5) Missing out a coat 6) Use of wrong solvent or an excessive amount of solvent 7) Re-using of expendable abrasives 8) Insufficient blasting and painting in difficult access areas 9) Apply low thickness of paint 10) Use of date expired paints. ‘Name three methods of epplying paint and compare the advantages and Disadvantages of each ? 1) Brush Application 2) Roller Application a) Cheap to purchase a) Cheap to purchase ) Easy to maintain b) Two to three times quicker than brush ©) Slow job ©) Access is better (Extension poll) 4) Works paint well in to the 4) Finish is poor (Orange peel) the surface €) Cannot apply all coating types _¢) Not so good adhesion to surface a) Expensive to purchase 'b) 20 to 30 times quicker than brush ¢) Large areas can be covered 4) Only method for applying high build materials, e) Washing out time is significant and uses a lot of solvent f) Safety is a major consideration g) Parts are very expensive nt ‘Masking is required What does BS 2015 “Glossary of paint terms” refer to and give three examples ? Paint & Painting faults 1)Bleeding 2) Blistering 3) Chalking 4) Cissing _5) Floceulation 6)Grinning 7)Holidays 8)Pinholing 9)Slaging 10) Flaking ‘What BS 4800 and how is it used in construction industry ? BS 4800 is a range of 100 standardized colours selected from the 237 colours found in BS 5252 for the use of construction industry and is titled “Paint colours for building purpose”. It is identified in numbertand letters. By making paint colours this set of mumbers and letters conform each manufacturer can guarantee to produce exactly the same colour. In that way the colours become standardized. How do British Gas define the following ? Long term protection - ‘10 Years Medium term protection- 5 Years46, 47. 48. 49, 50. Sl. 52, 53. 54. Short term protection- to 3 years New galvanizing ~ Less than 3 months old, shiny with no cohesive oxide lair Weathered galvanizing - Over three months old, dull, with a cohesive oxide lair What is the procedure for removing oil and grease from a surface before preparation commences ? Approved solvent wash (Xylene ~ Yes , White spirit -No ) What is the procedure for removing oil and grease ftom surface if found after preparation has taken place ? [Approved solvent wash , followed by 2% detergent wash followed by rinsing Drying and re-blasting. What is the procedure for removing algae and mould growth from pipework ? Apply a Biocidal wash then leave for 24 hours at least; remove with stiff brushes and clean water ‘Under what conditions must paint be stored ? Ina dry lockable well-ventilated building away from live gas areas, flames, heat, sparks and the rays of the sun and under manufacturer instructions. What is T. Wash? It is an etch primer (nipdatybaing) What is it used for? - To provide a key on new galvanizing What colour is it? - Blue How do we check for a correct reaction when using it ? — Colour turns to black What two coats of paint are applied “at works” ? High solids solvent based epoxy 75 um minimum followed by epoxy MIO 75pm min ‘What distance must be let at areas to be welded when painting? - 75 mm How much must new paint overlap old repairs? - 100 mm What is the maximum allowed time for priming to take place following preparation? ‘And by what method is primer applied? 4 hours , Brush or spray as appropriate55. 56. 51. 58. 59. What do British Gas class as a hot duty service ? ‘Asservice which attains a temp. in access of 99°C when in use. ‘What must all pneumatically and electrically operated power tool equipment be? Earthed ‘What type of sheeting may not be used for protection against spillage and spotting ? It must be non-flamable in particular, Tarpaulins must not be used. What must not be used to clean out paint kettles or to dispose of rubbish ? Fire and Flames Give the rules for the mixing of paints regarding sizes Up to 5 liters may be mixed by hand. Above 5 liters must be mechanically mixed.+44 01287 610006, FA eo. Buta “ob f- 4 WAUGH TECHNICL SERVICES, June 1999 (COURSE RESEARCH PAPER QL, What kind of process is corrosion.? ey eee Elesstrs Chamical poocss cal \{ Qe, What particular problems relate to the maintaining of an effective coating % System in the splash zone. Qn What factors inftuence the rete of corrosion.? Maisto Content abens, GS 7 a ode ped Bipnas Geokent ar Ohws el nee sae es mratabs on Cente WO Sted (04, Whats milscale and why is ita particular problem when atempting to protect steel? Millscabe is ablack Yaky bait eridased 4109 WAY senle cote Amedie te Stan 8o Sly wiliscaba Holker ok en} caasiper Be eth be pecsany He Se. Q5, 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? Rust! A- peer agar eee naiaennts Be Mae of Millseake amd arab e- Noe Milsade gol Seat Aiged piling, Biaiiog ok on af Weel 1 tron ly blab clearing Sh Veo, oe SRS 1 puabeleanig As clea Greek. SN Soe bebe ia aaa cae ange Bolla two sels — Poliacivm Femme,adt Teak: @ Soluble Chdends — Sivoo witents text @ Miliscala — Copper Siphete steak Q7, What factors influence how clean and how rough the surfuce becomes after blast a cleaning. @ Size, @ Shope dDencity and Yeodnnrss at home Ramin Packet). pend, |QarQe DUM |@ Didance 8. Regarding hand and power tool cleaning state what always concludes this Peer die OE nia ce nem) wirebrtny Sr- . - st- Vee ee Row ax oo ete © Binds © Pigmact @ Scher.+44 @1287 610006 Q10, What are the each ofthese three in a solvent carrying indus -- indus paint, we Liquid & Sold eee Hho, Binkes Moles | Vea fees os Th paovides geod adnarioe be Substeats , OF gins akaatidty bs he Glre. Gincs ginal te epadot. giver praxithena, & aol chemicals and olvmmtion Rigmink: Powida cele aod mpacity By gina aasiteme le acid end alkalis net Deak Tove! BAW ke Vola pest oh ey peccais, Dr Wars He paint be Sites eeaey APE Renta cay Mthed- wre QL, Name five items that can be included in paint to improve its performance or aye suitability for a certain use. ODwen Gna cakabyer @® Thine topic ee yet ape out extlerdiws BAnM deinmy Ages a3) i G@ Aah Selling Agents © Plosbicises s, O12, Identify six paints by their binder names. o pr ioe a Chlwinekad Rurter @ AKG 4 @ Policia @® emuision © Vinyls Cll Guw one Q13, Name four binder /solvent combinations. Oepery — A cerene @ chiow nockes) Rebber ~ xylene BE Aikyd~ wlhivemnt GE) Emulsion - Woded eee een ‘with their respective colours. oa @ Zive presphak @ Eire Srwemats — Yellen & Cat pas © Thaninn oxide, © Rad Lead -*4 Q1S, Describe whst « laminar pigment is. igre ee Strapas Lika Leak ex hoods. chen ° Qigmet particle oveslep and Unbewalole andl gia a Sel Cooking Ubith Seritteese We pastege afulete . is, ‘What is the difference between a convertible ands non convertbe coetng Se Cramer’ Shane oe ig: rot omaged on Ganek apply all fools. Bay bmi New, sooperm nt tobry Blow Be B Beces mn eotiet, |e) Pat ane expentire ee Cention Yes Gn we] a wate S Reae uit. Sato a Reales ey mesy |+44 01287 610005 (44, What does BS 2015 “GLOSSARY OF PAINT TERMS" refer to and give three Pago Fatty Boeds Disealo eng c Gabing beans of Herel eal | g Seine” SEAT SSL 7 ® otvlking - 045, What is BS 4800 and how is it used in the construction industry. BS 4800 ~ Paint Colown Jes Building Pus poses. Specifies Wo Glow ctlid. Kane bea Selected geo to framtotetle al) 233 Glows cocteinelin ®sSasz OH s Adanbiest GO namben ad kellen . 046, How do BGAS define the following. Long term protection. — (© year‘ ‘Medium term protection. — S ¥o>™* ‘Short term protection. eeeotes Speers ie lng cbel , Siwy New galvanising. Legs thas [Roce me ee ae feathered galvanising. eet ws UC, We ising Reve than three moniter old , Dull ee Coheyive omit Layer. Q47, What is the procedure for removing oil and grease from a surface before preparation commences. Kheanive Wee Safe ease whiny x +44 @1287 610006 069, Ifa pipeline was in direct contact with Accoustic Cladding, what paint system ‘might be applied if we wished to maintain it every three years, of not at all. Q70, What is important about selecting « paint system suitable for # certain environment. seloek He su cooks: Systens Fitelote des tee parbcrted eoniorimen® O71, What information do BGAS require to be on a paint tin and what BGAS document deals with the properties and performance of paints. PRT. Proeppak7 are pactemenet ye pe ap Paict Maen! rane, Colowt ag tea pairks 07 a a Segree een Se nshechiest, Stage uo yematom, Mar he Gamped gay Bans — era) 22, What i ual sos the preparation of fies wich ee da wih onder 4. ’ Ae Blast clessing , Waket Warr OB, ‘State the principles of being able to use a banana gauge for taking D.F.T. : Banang gan ds Fermons Safa wor femmes CORR Q74, Give one advantage of using Testex tape and plastic disposable W.F.T. combs. Regmactan- recand foo Meceltiiy, Q75, Describe what you know of H.A.S.W.A. and C.0.S.HH. " —\Ore Wtewe - Healte acd Sty ok Bote Act \or Tuas ack chasks onile fee A oglee employ ard employe vn He Wet place hd COSHH Contsel 4 Svbstte ees Rayer ee Zhehay ragerding Solvent, Sanzl ona) dakSELF ANALYSIS PAPER QL, Describe why and how eprrosion occurs. PN A itor Tame. alendenap bh go broek & ks Nakweet toed Boge. thats OS, GA Cansedsr _ Coresion Chamica® Clrange beer A ksy ae lech Chami calpareentt Called Cledmoly sis. Three «lomat Crnede, Calkoda & Clechrobyte) a saguived bs Complt< 02, Describe what is meant by Bi-Metallic corrosion. Ss] were «Lon checsto! ive UV ackely ace nal fegetdy ee ee noble DEW sacepen * ko topes re igh motte mukeh. Tred cctled Bi - mutate Corrosion Q3, Describe the following; {(@) The Galvanic series _ edad ef i. mols a Laked on 4s, inotalth Ty code ce called GeWwowe Sones, () Millscale Wt Weak a a Back a oxidiged deo. 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Brest Than Compl, wth porn mannlad Secommdarions .Austenitic stainless steels Austenitic stainless steels have high ductility, low yield stress and relatively high ultimate tensile strength, when compare to a typical carbon steel. ‘A carbon steel on cooling transforms from Austenite to a mixture of ferrite and cementite, With austenitic stainless steel, the high chrome and nickel content suppress this transformation keeping the material fully austenite on cooling (The Nickel maintains the austenite phase on cooling and the Chrome slows the transformation down so that a fully austenitic structure can be achieved with only 8% Nicke)). Heat treatment and the thermal cycle caused by welding, have little influence on mechanical properties. However strength and hardness can be increased by cold working, which will also reduce ductility. A full solution anneal (heating to around 1045°C followed by quenching or rapid cooling) will restore the material to its original condition, removing alloy segregation, sensitisation, sigma phase and restoring ductility after cold working. Unfortunately the rapid cooling will e-introduce residual stresses, which could be as high as the yield point. Distortion can also occur if the object is not properly supported during the annealing process. Austenitic steels are not susceptible to hydrogen cracking, therefore pre-heating is seldom required, except to reduce the risk of shrinkage stresses in thick sections. Post weld heat treatment is seldom required as this material as a high resistance to brittle fracture; ‘occasionally stress relief is carried out to reduce the risk of stress corrosion cracking, however this is likely to cause sensitisation unless a stabilised grade is used (limited stress relief can be achieved with a low temperature of around 450°C ). ‘Austenitic steels have « F.C.C atomic structure which provides more planes for the flow of dislocations, combined with the low level of interstitial elements (elements that lock the dislocation chain), gives this material its good ductility. This also explains why this ‘material has no clearly defined yield point, which is why its yield stress is always as a proof stress. Austenitic steels have excellent toughness down to true absolute (-273°C), with no steep ductile to brittle transition. ‘This material has good corrosion resistance, but quite severe corrosion can occur in certain environments, The right choice of welding consumable and welding technique can be crucial as the weld metal can corrode more than the parent material. Probably the biggest cause of failure in pressure plant made of stainless steel is stress corrosion cracking (S.C.C). This type of corrosion forms deep cracks in the material and is caused by the presence of chlorides in the process fluid or heating watet/steam (Good water treatment is essential ), at a temperature above 50°C, when the material is subjected toa tensile stress (this stress includes residual stress, which could be up to yield point in magnitude). Significant increases in Nickel and also Molybdenum will reduce the risk.Stainless steel has a very thin and stable oxide film rich in chrome. This flm reforms rapidly by reaction with the atmosphere if damaged. If stainless steel is not adequately protected from the atmosphere during welding or is subject to very heavy grinding operations, a very thick oxide layer will form. This thick oxide layer, distinguished by its blue tint, will have a chrome depleted layer under it, which will impair corrosion resistance, Both the oxide film and depleted layer must be removed, either mechanically (grinding with a fine grit is recommended, wire brushing and shot blasting will have less effect), or chemically (acid pickle with a mixture of nitric and hydrofluoric acid). Once cleaned, the surface can be chemically passivated to enhance corrosion resistance, (passivation reduces the anodic reaction involved in the corrosion process). Carbon steel tools, also supports or even sparks from grinding carbon steel, can embed ffagments into the surface ofthe stainless steel. These fragments can then rust if ‘moistened. Therefore itis recommended that stainless steel fabrication be carried out in a separate designated area and special stainless steel tools used where possible. If any part of stainless-steel is heated in the range 500 degrees to 800 degrees for any reasonable time there is a risk that the chrome will form chrome carbides (a compound formed with carbon) with any carbon present in the steel. This reduces the chrome available to provide the passive film and leads to preferential corrosion, which can be severe. This is often referred to as sensitisation. Therefore it is advisable when welding stainless steel to use low heat input and restrict the maximum interpass temperature to around 175°, although sensitisation of modem low carbon grades is unlikely unless heated for prolonged periods, Small quantities of either titanium (321) or niobium (347) added to stabilise the material will inhibit the formation of chrome carbides. ‘When heated to between 500°C to 850°C, carbides form at grain boundaries. Grains become depleted in chromium and lose their corrosion resistance drawn to site of carbides‘To resist oxidation and creep high carbon grades such as 304H or 316H are often used. ‘Their improved creep resistance relates to the presence of carbides and the slightly coarser grain size associated with higher annealing temperatures. Because the higher carbon content inevitably leads to sensitisation, there may be a risk of corrosion during plant shut downs, for this reason stabilised grades may be preferred such as 347H. ‘The solidification strength of austenitic stainless steel can be seriously impaired by small additions of impurities such as sulphur and phosphorous, this coupled with the materials high coefficient of expansion can cause serious solidification cracking problems. Most 304 type alloys are designed to solidify intially as delta ferrite, which has high ‘solubility for sulphur, transforming to austenite upon further cooling. This creates an austenitic material containing tiny patches of residual delta ferrite, therefore not a true austenitic in the strict sense of the word. Filler metal often contains further additions of delta ferrite to ensure crack free welds, ‘The detta ferrite can transform to a very brittle phase called sigma, if heated above 550°C for very prolonged periods (Could take several thousand hours, depending on chrome level. A duplex stainless steel can form sigma phase after only a few minutes at this temperature) ‘The very high coefficient of expansion associated with this material means that welding distortion can be quite savage. I have seen thick ring flanges on pressure vessel twist after welding to such an extent that a fluid seal is impossible. Thermal stress is another ‘major problem associated with stainless steel; premature failure can occur on pressure plant heated by a jacket or coils attached to a cold veesel. This material has poor thermal ‘conductivity, therefore lower welding current is required (typically 25% less than carbon steel) and narrower joint preparations can be tolerated. All common welding processes can be used successfully, however high deposition rates associated with SAW could cause solidification cracking and possibly sensitisation, unless adequate precautions are taken. To ensure good corrosion resistance of the weld root it must be protected from the ‘atmosphere by an inert gas shield during welding and subsequent cooling. The gas shield should be contained around the root of the weld by a suitable dam, which must permit a continuous gas flow through the area. Welding should not commence until sufficient time has elapsed to allow the volume of purging gas flowing through the dam to equal at least the 6 times the volume contained in the dam (EN1011 Part 3 Recommends 10). Once purging is complete the purge flow rate should be reduced so that it only exerts a small positive pressure, sufficient to exchude air. If good corrosion resistance of the root is required the oxygen level in the dam should not exceed 0.1%(1000 ppm); for extreme corrosion resistance this should be reduced to 0.015% (150 ppm). Backing gasses are typically argon or helium; Nitrogen Is often used as an economic alternative where corrosion resistance is not critical, Nitrogm + 10% Helium is better. A wide variety of proprietary pastes and backing materials are available than can be use to protect the root instead of a gas shield. In some applications where corrosion and oxide coking of the weld root is not important, such as large stainless steel ducting, no gas backing is used.A.pdf guide to weld purging Huntingdon Fusion Techniques Limited Carbon content: 304 L grade Low Carbon, typically 0.03% Max 304 grade Medium Carbon, typically 0.08% Max 304H grade High Carbon, typically Up to 0.1% ‘The higher the carbon content the greater the yield strength. (Hence the stength advantage in using stabilised grades) Typical Alloy Content 304 (18-20Cr, 8-12Ni) 316 (16-18Cr, 10-14Ni +2-3Mo) 304 + Molybdenum 316 Ti (316 with Titanium Added) 304 + Moly + Titanium 320 (Same as 316Ti) : 321 (17-19Cr, 9-12Ni+ Titanium) 304 + Titanium 347 (17-19Cr, 9-13Ni-+ Niobium) 304 + Niobium 308 (19-22Cr, 9-11Ni) 304 + Extra 2%Cr 309 (22-24Cr, 12-15Ni) 304 + Extra 4%Cr + 4% Ni All the above stainless steel grades are basic variations of a 304. All are readily weldable and all have matching consumables, except for a 304 which is welded with a 308 or 316, 321 is welded with a 347 (Titanium is not easily transferred across the arc) and a 316Ti is normally welded with a 318. Molybdenum has the same effect on the microstructure as chrome, except that it gives better resistance to pitting corrosion. Therefore a 316 needs less chrome than a 304, 310 (24-26Cr,19-22Ni) True Austenitic. This material does not transform to ferrite on cooling and therefore does not contain delta ferrite. It will not suffer sigma phase embrittlement but can be tricky to weld. 904L —(20Cr,25Ni,4.5Mo) Super Austenitic Or Nickel alloy. Superior corrosion resistance providing they are welded carefully with low heat input (less than 1 kI/mm recommended) and fast travel speeds with no weaving. Each run of weld should not be started until the metal temperature falls below 100°C. It is unlikely that a uniform distribution of alloy will be achieved throughout the weld (segregation), therefore this material should either be welded with anover-alloyed consumable such as a 625 or solution annealed after welding, if maximum corrosion resistance is required.Carbon Steel To Austenitic Steel ‘When a weld is made using a filer wire or consumable, there is a mixture in the weld consisting of approximately 20% parent metal and 80% filler metal alloy ( percentage depends on welding process, type of joint and welding parameters). Any reduction in alloy content of 304 / 316 type austenitics is likely to cause the formation ‘of matensite on cooling. This could lead to cracking problems and poor ductility. To avoid this problem an overalloyed filler metal is used, such as a 309, which should still form austenite on cooling providing dilution is not excessive. ‘The Shaeffler diagram can be used to determine the type of microstructure that can be ‘expected when a filler metal and parent metal of differing compositions are mixed together ina weld. ‘The Shaeffier Diagram 30 Austenite Nickel Equivalent 20 Chromium Equivalent The Nickel and other elements that form Austenite, are plotted against Chrome and other ‘elements that form ferrite, using the following formula:-Nickel Equivalent = %Ni + 30%C + 0.5%Mn Chrome Equivalent = %Cr + Mo + 1.5%Si + 0.5%Nb Example, a typical 304L = 18.2%Cr, 10.1%Ni, 1.2%Mn, 0.4%Si, 0.02%C Ni Equiv = 10.1 + 30x 0.02 +0.5x1.2= 11.3 Cr Equiv = 18.2+0+1.5x0.4+0=18.8 A typical 309L welding consumable Ni Equiv = 14.35, Cr Equiv = 24.9 ‘The main disadvantage with this diagram is that it does not represent Nitrogen, which is a very strong Austenite former. Ferrite Number ‘The ferrite number uses magnetic attraction as a means of measuring the proportion of deta ferrite present. The ferrite number is plotted on a modified Shaeffler diagram, the Delong, Diagram. The Chrome and Nickel equivalent is the same as that used for the Shaeffler diagram, except that the Nickel equivalent inchides the addition of 30 times the Nitrogen content. Nickel Equivelent ‘kel EquivalentNickel Equivalent Chrome Equivalent ‘The Shaefiler diagram above illustrates a carbon steel C.S , welded with 3041 filler. Point A represents the anticipated composition of the weld metal, if it consists of a mixture of filler metal and 25% parent metal, This diluted weld, according to the diagram, will contain martensite. This problem can be overcome if a higher alloyed filler is used, such as a 309L, which bas a higher nickel and chrome equivalent that will tend to pull point A into the austenite region. Ifthe welds molten pool spans two different metals the process becomes more complicated, First plot both parent metals on the shaefiler diagram and connect them with a line. If both parent metals are diluted by the same amount, plot a false point B on the diagram midway between them. (Point B represents the microstructure of the weld ifno filler metal was applied.)Nickel Equivalent Ferrite ° @ = = 0 Chrome Equivalent Next, plot the consumable on the diagram, which for this example is a 309L. Draw a line from this point to false point B and mark a point A along its length equivalent to the total weld dilution. This point will give the approximate microstructure of the weld metal. The diagram below illustrates 25% total weld dilution at point A, which predicts a good microstructure of Austenite with a litle ferrite, Nickel Equivalent Chrome Equivalent ‘The presence of martensite can be detected bv subiectine a macro section to a hardnesssurvey, high hardness levels indicate martensite, Alternatively the weld can be subjected to a bend test (a side bend is required by the ASME code for corrosion resistant overlays), any martensite present will tend to cause the test piece to break rather than bend. However the presence of martensite is unlikely to cause hydrogen cracking, as any hydrogen evolved during the welding process will be absorbed by the austenitic filler metal, Evaluating Dilution x 100 e+S 5 = Area Of Mohten Parent Plate Macro Section OF & (Shown hatched) Weld Bead On Plate ‘$= Total Area Of Motten Poo! (Area Enclosed by Red Line) S Root Run In A Typical Butt Weld, “Approx 25% Dilion Causes Of High Dilution Square Butt Showing Very High Dit ion + High Travel Speed. Too much heat applied to parent metal instead of on filler metal, + High welding Current, High current welding processes, such as Submerged Are ‘Welding can cause high dilution, ‘Thin Material. Thin sheet TIG welded can give rise to high dilution levels + Joint Preparation. Sauare vrevs generate verv hieh dilution. This can be reducedby carefully buttering the joint face with high alloy filler metal. http://www avestapolarit.convupload/steel_properties/Schaeffler_large.jpg ‘Large Schaefiler/Delong Diagram (Qutokumpu.com) Retum To Sub Menu Last Modified 19 Jan 2004Duplex stainless steels Typically twice the yield of austenitic stainless steels. Minimum Specified UTS typically 680 to 750N/mm2 (98.6 to 108ksi). Elongation typically > 25%. Superior corrosion resistance than a 316. Good Resistance to stress corrosion cracking in a chloride environment, Duplex materials have improved over the last decade; further additions of Nitrogen have been made improving weldability. Because of the complex nature of this material itis important that itis sourced from good. quality steel mills and is properly solution annealed. Castings and possibly thick sections ‘may not cool fast when annealed causing sigma and other deleterious phases to form, ‘The material work hardens if cold formed; even the strain produced from welding can work harden the material particularly in multi pass welding. Therefore a full solution anneal is advantageous, particularly if low service temperatures are foreseen. ‘The high strength of this material can make joint ft up difficult. ‘Usable temperature range restricted to, -50 to 280°C Used in Oil & Natural Gas production, chemical plants etc. ‘Standard Duplex '$31803 22Cr SNi 2.8Mo 0.15N PREn = 32-33 Stronger and more corrosion resistant than standard duplex. $32760(Zeron 100) 25Cr 7.5Ni3.5Mo 0.23N PREn = 40 Dark Areas:- Ferrite Light Areas:- Austeniteunless the correct welding technique is used. Too much Nitrogen will form a layer of Austenite on the weld surface. In my experience most duplex and super duplex are TIG welded using pure argon. Backing / purge gas should contain less than 25pm Oxygen for optimum corrosion resistance. Fast cooling from molten will promote the formation of ferrite, slow cooling will promote austenite, During welding fast cooling is most likely, therefore welding consumables usually contain up to 2 - 4% extra Nickel to promote austenite formation in the weld. Duplex should never be welded without filler metal, as this will promote excessive ferrite, unless the welded component is solution annealed. Acceptable phase balance is usually 30 — 70% Ferrite Duplex welding consumables are suitable for joining duplex to austenitic stainless stee! or carbon steel; they can also be used for corrosion resistant overlays. Nickel based welding consumables can be used but the weld strength will not be as good as the parent metal, particularly on super duplex. ‘+ Low levels of austenite: Poor toughness and general corrosion resistance. ‘+ High levels of austenite: - Some Reduction in strength and reduced resistance to stress corrosion cracking. Good impact test results are a good indication that the material has been successfully welded. The parent metal usually exceeds 200J. The ductile to brittle transition temperature is about -50°C. The transition is not as steep as that of carbon steel and depends on the welding process used. Flux protected processes, such as MMA; tend to have a steeper transition curve and lower toughness. Multi run welds tend to promote austenite and thus exhibit higher toughness Tight controls and the use of arc monitors are recommended during welding and automatic or mechanised welding is preferred. Repair welding can seriously affect corrosion resistance and toughness; therefore any repairs should follow specially developed procedures. See BS4515 Part 2 for details. Production control test plates are recommended for all critical poduction welds. Welding procedures should be supplemented by additional tests, depending on the application and the requirements of any application code:~ + A ferrite count using a Ferro scope is probably the most popular. For best accuracy the ferrite count should be performed manually and include a check for deleterious phases. ‘* Good impact test results are also a ood indication of a successful welding orocedureDuplex solidifies intially as ferrite, then transforms on further cooling to a matrix of ferrite and austenite. In modern raw material the balance should be 50/50 for optimum corrosion resistance, particularly resistance to stress corrosion cracking. However the materials strength is not significantly effected by the ferrite / austenite phase balance, Liquid Ho-CoNi Phase Diagram Dashed Line shows solidification of a typical Duplex ‘The Red region denotes a minture of Ferrite and Austenite ‘Temperature in °C ‘The main problem with Duplex is that it very easily forms brittle intermetalic phases, such as Sigma, Chi and Alpha Prime. These phases can form rapidly, typically 100 seconds at ‘900°C. However shorter exposure has been known to cause a drop in toughness, this has ‘been attribute to the formation of sigma on a microscopic scale. Prolonged heating in the range 350 to 550°C can cause 475°C temper embrittlement. For this reason the maximum recommended service temperature for duplex is about 280°C. ‘Sigma (55Fe 45Cr) can be a major problem when welding thin walled small bore pipe made of super duplex, although it can occur in thicker sections. It tends to be found in the bulk of the material rather than at the surface, therefore it probably has more effect on toughness than corrosion resistance. Sigma can also occur in thick sections, such as castings that have not ‘been properly solution annealed (Not cooled fast enough). However most standards accept that deleterious phases, such as sigma, chi and laves, may be tolerated if the strength and corrosion resistance are satisfactory. ‘Nitrogen is a strong austenite former and largely responsible for the balance between ferrite and austenite phases and the materials superior corrosion resistance. Nitrogen can’t be added to filler metal, as it does not transfer across the arc, It can also be lost from molten parent metal during welding. ‘Its loss can lead to high ferrite and reduced corrosion resistance. ‘Nitrogen can be added to the shielding gas and backing gas, Up to about 10%; however this ‘makes welding difficult as it can cause porositv and contamination of the Tungsten electrodeand are mandatory in BS4515 Part 2. ‘+ A corrosion test, such as the G48 test, is highly recommended. The test may not model the exact service corrosion environment, but gives a good qualative assessment of the welds general corrosion resistance; this gives a good indication that the welding method is satisfactory. G48 test temperature for standard duplex is typically 22°C, for super duplex 35°C ‘Root Run slightly heavier than second pass so that the HAZ of run 2 does not impinge upon the root face and spoil the corrosion resistance of the weld. ‘Typical Welding Procedure For Zeron 100 (Super Duplex) Pipe 60mm Od x 4mm Thick Position 6G Maximum Interpass 100°C Temperature at the end of welding < 250°C 16mm Filler Wire 85 amps 2 weld runs (Root and Cap) Arc energy 1 to 1,5KJ/mm Travel speed 0.75 to 1 mm/sec 1.5mm mf foe Recommended Testing 1. Ferric Chloride Pitting Test To ASTM G48 : Method A 2. Chemical analysis of root3. Ferrite count Retum To Sub Menu Last Modified 19 March 2002