ATC 88

BGAS Painting Grade 2/3

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Cathodic Protection: Sacrificial

System

Zinc block
(anode)

Steel pipe
(cathode)

Must be in direct contact or joined by a conductive cable

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 Cathodic Protection: Sacrificial
System

Sacrificial zinc
anodes

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Cathodic Protection:
Impressed Current

Transformer /
rectifier
(negative) Positive
connected
t d connection
to pipe to ground
There is no
bed (anode)
(Cathode) current/
electron flow if
the coating is in
good condition

When barrier coating of buried pipe is damaged,

corrosion circuit commences. (Electrons travel from
cathode to anode via the electrolyte)

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 Impressed Current Transformer
Rectifier Unit

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Cathodic Protection:
Monitoring Potentials

Copper/copper
C /
sulphate half-cell
reference electrode

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 Cathodic Disbondment Test

Test in progress Inspection on completion

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Pinhole/Holiday Detection:
Sponge Detector

Voltage Range
9 to 90v. (Some have
only 2 settings)
intermediate 67.5v.
Sponge is wetted in
water with a drop of
detergent.
out
Excess squeezed out,
then passed over the
substrate.

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 Holiday/Pinhole
Detection

Typical high voltage set for

pinhole detection. Operates Holiday Detection on
up to 15kv too high for cross-country pipeline.
normal paint systems.

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High Voltage Holiday Tester

Test springs now not allowed on BGAS projects

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 Holiday Detection of
Coated Pipe

Contoured Brush

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Paint Application

Application methods

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Conventional spray

Suction feed Gravity feed

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 Paint application: Conventional Spray

Advantages Disadvantages

 Inexpensive nozzles.  Heavy hose lines.

 Good atomisation.  Operator fatigue.
 More Accuracy.  Specialised
 Less cleaning after containers.
use.  Slow application
 Better finish achieved. rates.
 Lower working
pressure.
 Concentrated spray
pattern.

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Paint Application: Airless Spray

Airless Spray
Gun

Portable Pump

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 Copyright © TWI Ltd

Paint Application: Airless

Spray

Air Circuit: Blue

Paint Circuit: Red

One Way Ball Valve

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 Paint Application: Airless Spray

Advantages Disadvantages
 High deposition rates.  Poor atomisation.
 Can apply high viscosity  Expensive nozzles.
fluids.  Coatings limitations.
 Versatile (no air hose).  Increased maintenance.
 High transfer efficiency.  High skill required.
 Lower waste.  Increased safety risk
g area coverage.
 Large g  ((+ or - 3500 p
psi).
)
 Uses manufacturers paint  Lower quality finish.
 containers.

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Paint Application: Electrostatic

Spraying

Negatively charged
Spray gun component

Positively charged particles

Ionised air volume

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 Paint A

Advantages Disadvantages

 High transfer efficiency.  Bulky, delicate guns.

 Good edge cover.  Requires extra
 Good wraparound. cleanliness.
 Uniform film thickness.  Fire/Safety hazard.
 Low wastage.  Component must be
conductive.
 High maintenance
costs.

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0
Hot duty surfaces (> 340 C)
(BGC/PS/PA10 PAGE 29 Table SPA 3c)

Requires the highest grade of cleanliness:

Profile 75um/Grade sa 3 (check for mill scale)

1 Thermally sprayed aluminium.

2 Inorganic zinc silicate.

3 Polysiloxane inorganic coating.

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 TSA: Thermally
Sprayed Aluminium

 The preferred system, giving longest life.

 Wire and pistol type (most common).
 High purity wire.
 Butane/propane and oxygen fuel gas.
 Propelled by compressed air onto substrate.
 Thickness approx 100 - 125 um.

For high temperature service silicone sealer must

be applied.

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Wire and Pistol Type

TSA Applicator Gun

Wire feed
trigger

Fuel gas Oxygen Compressed air

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 TSA: Thermally
Sprayed Aluminium

Wire and Pistol Type

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Visual Inspection

Steel coated with TSA

Steel blast cleaned to Sa 21/2 Loss of adhesion (poor surface

preparation)

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IZS: Inorganic Zinc Silicate
 Alternative to TSA.
 Apply as per manufacturers recommendation.
 Apply silicone sealer.
 Apply heat to cure sealant (turn the system on).
Polysiloxane inorganic coating
 Alternative to TSA and IZS.
0
 Will withstand temperatures up to 1100 c.
 Apply as per manufacturers recommendation.
 This is not sealed.

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Paint, Faults and Bittiness

Inclusions, either
airborn or from the
paint itself.
Could also be caused
by partially cured paint,
which is out of shelf
life.

(Flocculation)
Coating Faults: Blistering

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 Coating Faults:
Bleeding

The solvent from the

top coat softens the
under lying material
and allows it to pass
into and through the
layer, causing
discolouration.
((Brown for bitumen,,
yellow for coal tar).

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Blisters can contain gas, liquid or crystals.

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 Coating Faults: Chalking

Degradation
D d ti off the
th
binder due to disruptive
factors in the
environment

Epoxies are especially

vulnerable.

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Coating Faults Cissing

Caused by
inadequate
q surface
preparation.
A difference in surface
energy causes local
lack of adhesion.

Larger spots known as

fish eyes and large
areas referred to as
crawling.

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 Coating Faults: Cissing

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Coating Faults: Cracking

Mud cracking
Differential expansion and
coating
ti age.

Crazing/hair cracking Crocodiling/alligatoring

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Coating Faults: Cratering

Bowl shaped depressions.

Caused by escaping solvent
or gases.
High viscosity paint will
not flow to fill the
d
depressions.
i R
Resulting
lti iin
small bowls and craters.

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Coating Faults: Curtains,

Sags, Runs and Tears

Caused by over
application.
application
To remedy: remove
excess material, lightly
abrade and recoat.

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Coating Faults: Flaking

As material ages, it
gets brittle
brittle, cracks
and starts to
detach.

Oxidising paints are

especially vulnerable.
(N t
(Natural l oils
il and
d
resins).

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Coating Faults: Holidays

Defined as :
A void, a miss, or an
uncoated area.

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 Coating Faults: Lifting

Caused by solvent strength and also lack of

observance of stated overcoating time.

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Algae and Mould Growth

Remedy: treat with biocidal agent for 24 hours, then

clean with detergent/stiff bristle brush/water washing.

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 Orange Peel

Similar appearance
to the skin of
a citrus fruit.

Caused by paint
viscosity problems
or by applicator
technique.

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Coating Faults: Ropiness

Brushmarks

Caused by brushing
when film is almost
dry, or when paint
viscosity is too high.

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 Coating Faults: Wrinkling and
Rivelling

Paint forms a skin, trapping solvent below the surface. As this

eventually dries, the skin contracts, causing the surface to wrinkle.

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Defect: Rash or Spot

Rusting

Cause: rogue peaks, or

possibly by contamination
of the paint film by
foreign matter, such as
grit or dirt etc.

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 Colour

Primary Colours: Red, Yellow and Blue

The human eye operates on only these three pigments. Plus,
other various colours can be created by combining to various
degrees.
degrees
Colour has 3 main attributes
Hue
Refers to the basic colour (red, green, yellow, blue etc.)

Brightness
The darkness or lightness of the colour.

Saturation
How vivid the colour appears (also known as chroma, intensity,
weight).

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BS 4800

Hue
From 00 (neutral) to 24 even numbers only.

Brightness
From A (max white) to E (max black).

Saturation
01 to 56 Higher number = stronger colour.
Lower number= greyer the colour.

Black and white, and all the grey colours in between, are
achromatic colours as they lack hue.

Anything having colour is said to be chromatic.

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 Colour: The Munsell System
(USA)
L= Luminance, chroma Yellow through green ,blue
a= From green to red Purple, red and back to
b= From blue to yellow yellow
ll

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Ral System

System uses cards

containing
t i i 210 colours.
l

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 Product Identification by Pipe Colour
Pipe Colour Coding to BS 1710 (Section 13)

Uses BS 4800 to identify product

Product Named Colour BS 4800 APP. REF

Air Light Blue 20 E 51

Acids and Alkalies Violet 22 C 37

Gases (except Air) Yellow Ochre 08 C 35

Fluids Black 00 E 53

Fresh Water Auxiliary Blue 18 E 53

Water Green 12 D 51

Electrical Services Orange 06 E 51

Min/Vegetable/Animal Brown 06 C 34
Oils, Combustible liquids

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Health and Safety

COSHH Regulations
(Control of substances hazardous to health )

 Harmful or Irritant Corrosive

Toxic or Very Toxic

Hazard warning symbols.

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 Hazard Warning Symbols

Explosive Oxidizing Extremely Highly

flammable flammable

Can be found on safety data

sheets and on the paint tin label.

Dangerous for
the environment

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Health And Safety: (COSHH

Regulations)
Abbreviations

EH 40 HSE guidance notes: list of all known harmful substances.

OEL Occupational exposure limit ( there are 2 types)

types).

MEL Maximum exposure limit must never be exceeded! The

maximum exposure to airborne substance over a reference
period.
OES Occupational exposure standard
The concentration level of an airborne substance (averaged over a
reference p
period)) which is considered safe to be exposed
p to,, day
y after
day (ppm).

RAQ Required air quantity

HASAWA Health and safety at work act (1974)

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 Protective Masks

Dust only! Solvents

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Health And Safety: Drager Tube and

Bellows

Each depression of the bellows draws 100 cc of air

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 Drager Tube and Bellows

To test the air quality when using solvents.

Varying crystal types for different solvents.

Example: Xylene (OEL: 100 ppm)

Raq: 500 cc (5 depressions).

Crystals will change colour, (white to red/brown).
Toxicity levels read from the scale on the tube
tube.

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Duties of a Painting Inspector

Ensure that all work is carried out in accordance

with the specification requirements.
requirements

No deviation from specification unless permission

given in writing from a higher authority, ie clients
engineer.

Report
p any
y deviation from specifications.
p
Especially malpractices.

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 Visual Inspection

Blast cleaned surfaces:

Slivers, hackles, laminations, cracks, pitting.

Wet paint films:

Runs, sags, cissing, uneven coverage.

Dry paint films:

Q lit off fi
Quality i h paint
finish, i t ffaults,
lt opacity
it ((grinning),
i i )
coverage, holidays.

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Report Writing

All information requested on a report sheet should be

completed.

The information provides traceability in the event of

any future breakdown.

Good reports and documentation are essential to

ensure efficient handover to another inspector in the
event of illness or other emergencies.

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 Day To Day Activities – Record

1. Environmental conditions.
2. Confirmation of materials used
(abrasives, paint, pipe data etc).
3. Confirmation of equipment (calibrations etc).
4. Adherence to specification application faults
5. Adverse weather conditions
(start and stop times etc).

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Daily Checks

Beginning of the day

Environment, equipment, materials, previous days
work.
work
During the day
Environment, equipment, materials, each
operators work, application faults, the standards.
At the end of the day
Th d
The days work,
k hhousekeeping,
k i all
ll d
daily
il reports.
t

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 Records - End of Contract

 All daily records signed off.

 A complete register of control documents.
documents
 A complete record of test results.
 All NCR’s should be closed out.
 Complete waste disposal records.
 A complete correspondance file.

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Purpose of a Quality
Plan

 To ensure stated paramenters are met.

 Establish the integrity of the system.
 To provide tracable records.
 To reduce the risk of error.

I i
Inspection I not quality
Is li assurance.
Inspection is not quality control.

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