DAY ONE HOMEWORKS

PLEASE ANSWER ALL QUESTION

1) - What is Corrosion?
Degradation of a material by chemical and electro-chemical means.
2) - What is an Electrolyte?
A substance which will conduct a current and be broken down by it, dissociate into
ions.
3) - Were Electrolyte come from?
From a surrounding area, or ambient condition which contains a water, salt and
alkalis.
4) - In a corrosion triangle, anode, cathode and electrolyte, which one will corrode?
Why?
Anodes always corrode this because the combination of elements or oxidation takes
place at the anode.
5) - What is a Mill scale? And where it’s come from?
A dark blue color on a steel surface with thickness of 25µm to 100µm, these causes
by a combination of oxide during milling process from very high temperature to a
cold temperature.
6) - During corrosion reaction, what is a gas evolved at cathodes?
Hydrogen gas.

7) - Please explain on what your know about Anodes, Cathode and Electrolyte?
Anodes positively charge and always corrode, Cathodes are negatively charge areas
and protected, and Electrolyte are a substance which will conduct a current a be
broken down by it.

8) - Why the Degree of cleanliness very important to our coating life?

Degree of cleanliness will provide a surface to which the paint will readily adhere
and this wills effectively a longer service life from the coating.

9) - Prior to Blasting activities, what is a material used for removal oil and grease on the
substrate?
Solvent, detergent and degreaser.

10) - Name an abrasives used on open yard, and explain why?

Copper Slag and a Garnet, both are expendable.
11) - What is an Expendable abrasives means? List down an Expendable abrasives?
Used once only and than discharge. Copper Slag and Garnet.

12) - What is a Recyclable abrasives means, and why must recycle?

Abrasives which can used up to three times if cleansing units used to recollect, re-
clean and re-size before used. Because this type of abrasive have a very high density
and not easy to wear and also very expensive.
13) - What will happen to the abrasives during impinge upon blasting?
The abrasives will chip out the contamination, and at the same times roughening the
surface and increasing the surface area to increase adhesion properties.

14) - List down the names of equipment used to measure blasting profile or surface
profile?
Dial Micrometer with a Replica Tape or Testex Tape and a Surface Profile needle
Gauge.

15) - Please explains; a) SA 1 b) SA 2 c) SA 2 ½ and d) SA 3?

SA 1 Light Blast cleaning, SA2 Thorough Blast cleaning, SA2½ Very Thorough
Blast cleaning and SA3 Blast to visually clean steel.

16) - What is the optimum pressure at nozzle during blasting, and names of equipment
used to measure?
100psi pressure which measure using Hypodermic Needle Gauge.

17) - Please explain; a) ST 2 b) ST 3? And what is the different on each surface

appearance?
ST2 Thorough Hand and Power Tool cleaning, ST3 Very Thorough Hand and
Power Tool cleaning. The appearance of ST3 is much gloss, smooth and clean
compare to ST2.

18) - What is the test name to detect the presence of Soluble Salt and Soluble Chlorides?
For Soluble salt a test name are Potassium Hexa-cyanoferrate and for soluble
chloride the test name are Silver Nitrate test.

19)- Why there is no photo of Degree Cleanliness of SA 1 and SA 2 for Rust Grade A in
SS 055900 ISO 8501 BS7079ptA?
Because SA1 and SA2 cannot totally remove the Mill scale from the substrate.
20) - In a Footner Duplex System, what is a suitable pH value use?
pH4.5 to pH7 which less acidics.

DAY TWO HOMEWORK

PLEASE ANSWER ALL QUESTION

1) - Names a three basic ingredient of paints?

Binder, Solvent (where applicable) and Pigment and other additives.

2) - What is a Binder and it’s function in a paint formula?

A films former, vehicle and non volatile, its function for ease of application,
adhesion to substrate, resistance to abrasion and chemical attack, change a liquid
into solids, dielectric strength and cohesive strength.

3) - List down a Pigment use in paint formula?

Rust Inhibitive Pigment, Metallic Pigment, Opaque Pigment, Extender Pigment and
Laminar Pigment.

4) - What is a Pigment use on a Primer coat?

Rust Inhibitive Pigment and Metallic Pigment.

5) - What is the names of Additives Pigment use for Opacity?

Opaque Pigment.

6) - What is a means of Opacity, please explain?

Opposite of a transparency or hiding power, these a capability of a paint to hide an
underlying surface.

7) - What is a Laminar Pigment, explain their function and list down a paint names which
containing with Laminar Pigment?
Plate like pigment with excellent barrier with high resistance to water permeation.
Paint containing Laminar pigment is Micaceous Iron Oxide, Aluminum Flake,
Glass Flake, Mica and Graphite.

8) - Please List down the names of paint Additives that you know, function and
properties their have in a paint?
Anti Settling agent for Shelf Life of paint, Plasticizers for paint flexibility, Driers for
oxidizing oil and resins and Anti Skinning for retard the formation of a skin on the
surface of the paint.

9) - Please explain this:

a) Suspensions
Fine particulate solids dispersed within a liquid, no solubility. Example sand and
water.
b) Dispersions
A solids or liquids, within another liquid, where there is no solubility.
c) Solutions
The resultant liquid produced by dissolving a solute in a solvent.
10) - Epoxy is a Binder; please explain the properties have in Epoxy?
Provide good chemical, solvent and water resistance and also good exterior
durability(but prone to chalking).

11) - What you know about Thixothrophic Paint, please explain?

Jelly paints, non drip, and if stirred change to normal liquid consistency and when it
left, they slowly revert to thixothropic consistency.

12) - In Multi Component Liquid paint, what is a medium use for their curing process?
Chemical curing using a Part B, Curing Agent, Hardener or catalyst.

13) - What you understand a term of ‘Non-Reversible and Convertible ‘?

Thermosetting. Their chemical structure cannot change or remove after cure.
14) - In which document that you can find an Over coating time, induction periods and a
pot life?
Paint Manufacturer Product Data Sheet or Technical Data Sheet.

15) - What is means of Induction Periods? And what happen to the paints during
Induction Periods?
The length of time after mixing which the paint should stand before used. Chemical
reaction will commence and will be either an endothermic reaction or an exothermic
reaction happen.

16) - In a three coat paint system, what is a function of Rust Inhibitive Primer?
Added into primers to protect the steel substrate by passivation.

17) - Please explain the function of a Barrier in a paint system?

Applied over primers to prevent further water passing into the film and leaching
out the inhibitive pigmentation.

18) - What is a paint system use for service temperature above 340ºC in PA 10 SPA3?
First option thermally sprayed Aluminum, second option is Inorganic zinc silicate
with next layer was sealer and follow by heat to cure sealer and third option is
Polysiloxane inorganic coating.

19) - Please write the Operation Chart for Painting Damp Metal Surface in Table SPA4a?
Remove all surface contamination, blast clean to SA2½, wash by clean water,
remove droplets and standing water and lastly apply paint system by brush
application.

20) - Why we do a Galvanized in a steel substrate, please explain?

For longer protection up to 60 year using a zinc as a material which will sacrifice
itself to protect the substrate.
DAY THREE HOMEWORK

PLEASE ANSWER ALL QUESTION

1) - What you know about Water Bourne Coating?

A paint binder which can modified into a solvent free material or water based paint.

2) - What is a means of ‘Compliant’ in COSHH and EPA regulation?

Refer to material which complies with COSHH and EPA requirement and used for
Bgas Transco site.

3) - What is BS 3900 means?

Methods of test for paint.

4) - What is the equipment names for measuring Viscosity of paint?

Rothothinner, Kreb Stormer Viscometer and Ford Flow Cup.

5) - Explain this:

a) High Viscosity
Fluid with a high resistance to flow and will not run easily.
b) Low Viscosity
Fluid runs very easily.

6) - What is a means of Viscosity?

A fluids resistance to flow.

7) - Why a Wet Film Thickness must be checked immediately during paint application?
Paint will start their drying or curing process immediately after paint application
which will affect the accuracy of wet films thickness upon checking.

8) - List down all the equipment use for measuring wet films thickness?
Eccentric wheel/rims and Comb gauges.

9) - Please explains how to use Eccentric Wheel?

Place the gauge to a wet paint film with 0 reading at 6 o’clock position, roll the
gauge to left side with 180º angle until 0 reading now at 12 o’clock position and back
to it first position. Now continue roll to right side at a same angle and back to a first
position. The reading taken at both wet end of paint film which left at the eccentric
rim and total it, after that divide into two so there is the average reading for WFT.

10) - List down all the equipment use for measuring dry films thickness of paint?
Paint Inspector Gauge, Eddy Current, Electro Magnetic Induction, Horse Shoe
Gauge, Tinsley Pencil and “Banana Gauge” or Magnetic Coating Thickness gauge.
11) - Please explain how this equipment working:
a) - Rotothinner
Rotational viscometers relay on a paddle, disc or ball rotating in a liquid which
rotation driven by an electric motor which given Dynamic viscosity.
b) - Krebs Stormers Viscometer
Rotational viscometer relay on paddle, disc or ball rotating in a liquid which
rotation driven by falling a weight which given Kinematics viscosity.
c) - Ford Flow Cup
By fill up a cup with a paint and wait for a paint liquid run from an orifice nozzle at
the bottom of a cup.

12) - What is a benefits if we measuring WFT?

Gives a confidence that after a paint dry the dry films thickness is in a specification
acceptance range and control the consumption of a paint used.

13) - What is a Hegman Grind Gauge? Describe how to use this equipment?
Equipment use for measuring the degree of dispersion of paint. After paint milling,
put some paint inside the groove of this equipment and make it parallel by a
scrapper, immediately by visual, looking at a within 3mm band between a gloss and
matt.

14) - Opacity is very important for paint, what is a methods use for measuring of opacity?
Hiding power chart with applicator bar, Black and white fused plate and Pfund
Cryptometer trough type.

15) - What is a means of Adhesion?

A force required to spreads two surfaces in touch.

16) - What is suitable equipment use for Adhesion Test on a paint thickness of DFT
300µm?
Dolly test using Elcometer 106 or Hydraulic Adhesion Test Equipment (H.A.T.E).

17) - Please explain this:

a) - Relative Humidity
The amount of water vapor in the air expressed as a percentage of the amount of
water vapor which could be in the air at that same temperature.
b) - Dew Point
Temperature at which water vapor in the air will condense.

18) - What is maximum Relative humidity % in BS which not allow you to paint?
90% RH.

19) - What is the equipment name for measuring % Relative Humidity and a Dew Point
temperature?
Relative Humidity and Dew point calculator.

20) - What is a minimum Dew Point temperature which not allow you to paint and why
cannot Paint?
Must be always 3ºc below steel temperature reading, if the dew point is same or
higher than steel temperature reading, condensation will occur at a steel surface and
the relative humidity likely high relative humidity percentage.

DAY FOUR HOMEWORK

PLEASE ANSWER ALL QUESTION

01) - What is the function of Cathodic Protection?

As a secondary line of defence against corrosion by sacrificial anode system or
impressed current system.

02) - How Sacrificial Anodes system work?

Work on the principle of a bimetallic corrosion.

03) - Where is the correct location to install this Sacrificial Anodes?

Directly to the substrate where surrounded by an electrolyte.

04) - What is the equipment use to detect a Pin Hole or Holiday on a paint/coating with
DFT of 550µm?
High Voltage Pin Hole/Holiday detector.

05) - What is the equipment use to detect a Pin Hole or Holiday on a paint/coating with
DFT of 420µm?
Wet Sponge Pin Hole/Holiday detector.

06) - What is the correct current/voltage setting when use Wet Sponge Pin Hole Detector
on a paint/coating with of DFT 275µm?
9 volts current setting.

07) - Why BGAS Transco not allow to use Roller as a paint application?
Create a bubbles, uneven films thickness, roller marks, wool of roller stuck at the
peak of blasting profile and low production rate.

08) - What is the advantages when use a Paint Brush?

Wetted out the surface, can used on difficult accesses, low wastage and suitable for
small area.

09) - How is the Electro-static spray application working?

Small air driven turbine is mounted on the gun and supplies with current on the tip
and operates in the region of 85kv. The component to be coated is earth into the
same circuit and become negatively charged and the coating material is positively
charged and during application the coating material will be spray through an
ionised air and than attracted to the component or substrate.
10) - Please describe on a term of “wrap around effect” in an Electro-static spray
application?
The coating can stick all around the pipe or substrate easily without any miss spray
or holiday and gives sufficient thickness.

11) - What is the name of equipment use for applying a Thermally Spray Aluminum?
Wire and pistol system.

12) - What is a recommended of Degree of Cleanliness on a substrate before applying a

Thermally Spray Aluminum?
Blast clean to SA3 grade(must carried out mill scale test after blast).

13) - What are major causes of a Shagging, and how to avoid this paint fault?
Low viscosity of paint, to avoid a shagging paint viscosity shall be properly control
by following a paint manufacturer recommended solvent mixing.

14) - What is a BS 4800?

Paint color for building purposes.

15) - What is a BS 1710?

Pipe color coding.

16) - If we are working in confined spaces, what is a necessary action to be taken prior to
safety?
Enough lighting, good ventilation system, free from any gases or toxic and working
in a group.

17) - What is a document related to Safety on Blasting?

Safety to IGE SR 21.

18) - What is a Duty of a Paint Inspector?

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19) - As mention in a PA 10, please explain this: Short Terms protection, Medium Terms
Protection and Long Terms Protection?
Short Terms protection means typically two years to three years life, Medium
Terms protection means protection typically lasting five years and Long Terms
protection means protection typically lasting ten years.

20) - Please explain this: QA and QC?

QA means quality assurance as being a management tool, a method of maintaining
and improving quality whilst controlling cost. QC means a quality control which the
definition is operating techniques and activities that are used to fulfill requirements
for quality.