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TSTI QUALITY

ASSURANCE TRAINING
Blast Competency Training, July 12th
2016
Instructor: Olumide Aluko

TRINITY Reference Only


STRUCTURAL TOWERS, INC.
TSTI Build Processes and 5 Quality Tollgates
Quality Quality
QA Tollgate # 1 Tollgate # 2
Measure
Hold BEFORE T-Flange Taper BEFORE
on Base Ring 1
Steel Plates Areas Production Fit-Up !
and Parts
Receiving Blast Plates, then Roll Plates and VT, then UT Weld Flanges to Rings VT, then MT and Sand Ring # 27
Inspection Cut and Bevel Weld Long Seams Long Seam Welds 1, 8, 9, 17, 18 and 27 UT Flange Welds Flange Weld

Critical to Quality Critical to Quality Quality


Wiki-SCAN the CTQ CTQ Tollgate # 3
Training Rings sent to Girth Seam Welds Data Data
the Fit-up Line Source Source BEFORE
and Ring Off-sets
Reference Only Blast !!!
Defect % Flanges
QA-17 MQAR
Fit-Up, Weld VT, then UT Base Section: Cut Weld Bosses MT and/or PT Bosses Measure Flanges
TSTI - Towers Girth Seams and Girth Seam Door Hole, Fit and and Personnel and Tie Offs; UT and Waviness and Taper;
Measure Off-Sets Welds Weld Door Frame Tie Offs PT Door Frame Welds Complete Repairs + NDEs
Process Flow

20 Feb. 2015 Quality Quality


Post Blast Weld Measure Measure Tollgate # 4 Tollgate # 5
Source: TSTI Quality Section sent to VT Inspections; Zinc Coating each Coating BEFORE BEFORE
the Blast Area Check Profile Thickness Thickness
Assembly Green Tag Storage
Yard
Blast Metallize Flange Paint Install Section Verify AC Circuits and Final Assembly
Section Areas with Zinc Section Internals (Assy.) Bus Bar Torques + Stripes Inspection
Pre-Loading and
Shipping MQAR

Completions are tracked via “signed” MQAR (Manufacturing and Quality Assurance Record) documents.
Blast and Coating Specification Job

 The owner is normally responsible for the


preparation of a specification of a blast &
coating job
Safety in Blast and Paint Application

Bend Hose

Abrasive Blast: Personnel Protection from Hazards

6
Commonly Used Abrasive Blast Material

 Steel grit

 Steel shot
Safety in Blast and Paint Application (Cont.…)

Abrasive Blast: Personnel Protection from Hazards


8
Operators Safety Gear and Deadman Valve

Blast Operator Safety Gear

Deadman Valve in off “Position”


Hazard information: Abrasive Blast Cleaning

 Abrasive blasting uses compressed air or water to


direct a high velocity stream of an abrasive
material to clean an object or surfaces

 Never get in the path of an abrasive blast.

 Abrasive particle can travel as fast as 450 mph


(724 kph)

10
Safety Concern Around the Deadman Valve

Damaged Coupling

11
Hazard information: Abrasive Blast Cleaning

 Abrasive Blast cleaning at high pressure is a


dangerous operation.

 It is essential to follow steps that would protect


both the operators and other site or plant
personnel.

12
Hazard information: Blast Hose Couplings

Steel Safety Cotter Pins

13
Hazard information: Abrasive Blast Equipment

 The Blast hose ID should be 3 times (preferably 4


times) the size of the Nozzle orifice

 Choose the appropriate couplings and holders


based on the job suitability not on the price

14
Abrasive Blast Equipment

Types of Blast Hoses used with Deadman-Valve


15
Hazard information: Abrasive Blast Equipment

 Protect workers from exposure to Carbon


monoxide

 A colorless, odorless, and deadly gas

 Installation of CO monitor/alarm helps protect


workers from exposure

16
Different Kinds of Hazards

 Electric Shock

 Suffocation

 Explosion

17
Hazard information: Blast Motor

Exposure of Electrical Wires on a Blast Air wash Motor

18
Different Kinds of Hazards

 Falling Objects

 Inhalation of Solvent or other Chemical & Fire

 Health Problems from Toxic Materials.

19
Different Kinds of Hazards: (Fall Protection)

Safety Harness

Harness tied to Man lift


20
(Fall Protection) Hazards

ABRASIVE UNIT GRIT HOPPER EXPOSED WITHOUT COVER PLATE


21
Hazards From Blast Cleaning Equipment's

22
Hazards from Blast Cleaning Equipment Cont...

ENSURE CO MONITOR IS CALIBRATED & FUNCTIONING AS DESIGNED

23
Hazards from Blast Equipment: Carbon Monoxide

VALIDATE CO MONITOR LIGHTNING INDICATOR IS GREEN


24
Hazards from Blast Cleaning Equipment Cont.…

VALIDATE CO MONITOR CALIBRATION STICKER IS UPDATED

25
Hazards From Blast Cleaning Equipment's (cont…)

 Cleaning Solvents

 Paint Materials

 Spray Equipment

 Support Equipment

 Environment

27
Safety Measures: Ventilation (Cont.…)

 Use exhaust ventilation systems in


containment structures to capture dust.

28
Use HEPA Filtered Vacuum (cont.…)

 Do not use compressed air to clean as this


will create dust in the air

 Clean and decontaminate tarps and other


equipment on the worksite

29
Safety Measures: Personal Hygiene (cont.…)

 Prohibit eating,

 No drinking, or tobacco products in blasting areas

 Provide wash stations

 So workers can wash their hands & face and before


eating, drinking, or smoking

30
Safety Measures (cont.…)

 Vacuum or remove contaminated work


clothes before eating, drinking, or smoking

 Provide accommodations for end-of-shift


showers

31
Safety Respirators (Niosh-Certified) cont.…

 Abrasive blasting respirator must cover the


wearer’s head

 Including the neck and shoulders

 This would help protect the wearer from rebounding


abrasives

 No dust is safe to breathe!

32
NIOSH Approved Respirators (cont.…)

33
Safety Respirators (Cont.…)

 Use respirators approved by Niosh

 This helps provide protection from dusts


produced during abrasive-blasting
operations.

34
NIOSH Approved Respirators

35
Safety Respirators (Cont.…)

 Personnel involved in cleaning may also need


respiratory protection

 Use type CE-Niosh- certified blasting airline


respirator with +VE pressure blast helmet

36
NIOSH Approved Respirators (cont.…)

Nava 2000 Blast Hood & Suit

37
Safety Measures (Cont.…)

 Employers must establish a comprehensive


respiratory protection program as required by
OSHA

 Follow the rules for equipment setup &


component compatibility

38
Personal Protective Equipment

 Hearing Protection

 Eye and face protection

 Helmet

 Safety shoes or boots

39
Safety Measures (Cont.…)

 Leather gloves that protect to full


forearm and aprons (or coveralls)

 Operator may be required to ground


equipment

40
Safety Measures: Worker Training (cont.…)

 Provide training to abrasive blast operators

 Support personnel on blasting health and safety


hazards.

41
Safety Measures: Educate on Use of Controls Cont.

 Personal hygiene practices

 Safe work practices and the use of PPE and


respirators

42
Safety Measures (cont.…)

 Blasting materials on (SDS) per OSHA’s


requirement

 Manufacturers are required to include appropriate


health hazard information on the MSDS

43
Ambient Conditions per ISO 8502-4

 Surface Temperature >5°F above air Dew point

 Relative Humidity <75% for Blast & TSC

 Relative Humidity <85% for Prime Coat (Epoxy Primer)

 Relative Humidity <70% for Topcoat (Polyurethane)

Per TSTI Plan A specifications/Product data sheet

44
Ambient Conditions per ISO 8502-4

45
Environmental Psychrometer + IR Thermometer
(EXTECH HD500)

46
(Extech HD500 Psychrometer): Values to TSTI

 Reduction in the time it takes to measure

 Increases accuracy

 Used as an environmental data logger

 Cost is cheap & equipment is rugged

 Infrared capability

 3-in-1 combination meter

 USB compatibility to the PC

47
Electronic Hygrometer (Positector DPM)

48
Ambient Condition: Surface Temperature

 This is the temperature of the surface


awaiting preparation

 The coating application, and the temperature


of the air near that surface

49
Ambient Conditions (Cont.…)

 That can have great effect on the coatings


application itself

50
Substrate Pre-Blast Conditions

 Visually Inspect the surface to be coated

 Ensure surface is free from grease, oil or any


form of contaminant

 Steel soluble salt such as sulfates/chlorides

51
Substrate Pre-Blast Conditions: Testing for Soluble Salt

52
Substrate Pre-Cleaning

 Treat any oil & grease with SSPC-SP 1,


Solvent Cleaning

 Treat any salt contamination with a low or


high pressure washing per SSPC-SP 1 &
SSPC-SP 12/NACE NO.5

 This also includes removing dirt, snow, ice &


water prior to mechanical cleaning

53
Substrate Pre-Blast Conditions: Oil and Grease Cont.…

Oil & Grease

54
Substrate Post-Blast Conditions: Contaminants

Contaminants on a Tower Section

55
Paint Marker Residue on a Section after Blast

Paint Marker Residue


56
Substrate Pre-Blast Conditions: Contaminants

Contaminants on a Tower Section

57
Substrate Pre-Blast Conditions: Contaminants

Contaminants on a Tower Section

58
Substrate Pre-Blast Conditions: Contaminants

Contaminants from an Internal Diameter of a Tower Section


59
Substrate Pre-Blast Conditions: Contaminants

Foot Print from Personnel


with No Booties

Contaminants from an Internal Diameter of a Tower Section


60
Substrate Pre-Blast Conditions

 Before grit blasting & after grit blasting

 Check for soluble salt on each piece to be


coated in 3 random locations

61
Condition of Steel Tower Surface Before Blast

62
Surface Imperfections

 Inspect prior to blast and after the blast cleaning


of steel surface.

 Ensure steel surface complies with preparation


grades of surface imperfections in ISO 8501-3.

63
Surface Imperfections Cont.…

 Weld Spatter

 Sharp Edges

 Slivers & Burrs

 Crevices & Porosities

64
Design Problem – Weld Defects (Cont.…)

Weld Spatter

65
Design Problem – Weld Spatter (Cont.…)

66
Fabrication Defect – Rough Weld (Cont.…)

67
Fabrication Defect – Weld Crack (Cont.…)

68
Fabrication Defect – Weld Crack (Cont.…)

Weld Crack

69
Fabrication Defect – Weld Burn Through (Cont.…)

Weld Burn Through

70
Fabrication Defect – Weld Porosity (Cont.…)

Weld Porosity
71
Weld Defect – Slag (Cont.…)

72
Weld Defect – Undercut (Cont.…)

73
Weld Defect – Wire Stub (Cont.…)

Wire Stub

74
Weld Defect – Arc Strike (Cont.…)

Arc Strike

75
Surface Preparation (cont.…)

 Surface preparation is the foundation of any


corrosion program.

76
Corrosion Product: Mil Scale

77
Corrosion Product

78
Abrasive Blasting Cleaning Unit/Blast Booth Cont.…

79
Surface Preparation (Cont.…)

 This is defined as the cleaning or treating of


metal or other types of surface

 To insure the best possible bond between the


surface to be coated and coating to be applied.

80
Surface Preparation (Cont.…)

 (60 – 80)% of all premature coatings failures are


attributable to inadequate or improper surface
preparation

81
Surface Preparation – Important Rule (Cont.…)

 The service and life expectancy of a given


coating system is directly dependent on the
degree of surface preparation prior to the paint
application.

82
Objectives of Surface Preparation (cont…)

 Eliminate contaminants

 Remove surface imperfections

 To provide an anchor Pattern/Surface Profile

83
Primary Elements of a Blasting System

84
Abrasive Blasting Cleaning Flow Diagram Part Cont.…

85
Pressure Blasting Cleaning Equipment Cont.…

Pressure Blast Equipment


86
Abrasive Air Blasting Cleaning

 It is a process of propelling abrasive particle from a blast


machine, using the power of compressed air

 Each component contributes to the overall performance of


the system

 Surfaces are cleaned using pressurized equipment that


meters abrasive particles into a stream of compressed air
via blast hose & a nozzle.

87
Pressure Blasting Cleaning Equipment Cont.…

Metering Valve Uses Gravity to Feed Abrasive into Fast Flowing Stream of
Compressed Air 88
Abrasive Blasting Cleaning Air Compressor Cont.…

89
Air Compressor Moisture Separator Cont.…

90
Centrifugal Wheel Blasting

 This method is mostly used in shop environments

 Several portable type units are now available for onsite


use

 It uses motor driven bladed wheels that throw abrasive


particles by centrifugal force

91
Centrifugal Wheel Blasting Unit

92
Wheel Blasting Cleaning Critical Part Cont.…

Recommended for your Abrasive Recycle Unit Vent for high Efficiency
93
Centrifugal Wheel Blasting cont.…

 The material to be cleaned is passed through an


enclosed cabinet where the wheels are located using a
conveyor system

94
Centrifugal Wheel Blasting Unit cont.…

95
Centrifugal Wheel Blasting cont.…

Small Plate Unit

96
Centrifugal Wheel Blasting cont.…

97
Centrifugal Wheel Blasting cont.…

Abrasive System Air wash Separator


98
Abrasive Recycle Unit Air Wash Separator Cont.…

Abrasive System Air wash Separator Clogged


99
Abrasive Wheel Blasting cont.…

Abrasive System Air wash Separator Clogged


100
Centrifugal Wheel Blasting cont.…

Abrasive System Air wash Separator Clogged


101
Centrifugal Wheel Blasting cont.…

Abrasive Handling Machine Flow


10
2
Centrifugal Wheel Blasting cont.…

 This method offer considerable savings in time, labor,


energy and abrasive consumption versus abrasive air
blasting

 Anchor pattern would also stay constant due to the


automated system

103
Centrifugal Wheel Blasting cont.…

Large Plate Unit

104
Abrasive Blast Pneumatic Control & Remote Cont.…

OSHA Requires Remote Controls on all Abrasive Blast


Machines, “Deadman Switch”
105
Abrasive Blast Recycle Unit Cont.…

106
Dust Collector Cont.…

107
Dust Collector Cont.…

108
Dust Collector Maintenance Tips Cont.…

 Empty hopper regularly

 Inspect shaker mechanism

 Check drive for loose belts & correct direction

 Dust on cell plate floor indicates leakage between dirty & clean
side of the collector

 Inspect for worn vent piping

 Check manometer reading

109
Parameters Before Choosing An Abrasive

 Shape – angular or round

 Hardness – hard or soft

 Density – heavy or light

110
Conditions of An Abrasive: Abrasive Wear Cont.…

Abrasive Wear
111
Parameters Before Choosing An Abrasive cont.…

 Size – large or small

 Coating system to be used

 Profile required – light or heavy

112
Parameters Before Choosing An Abrasive cont.…

 Type of surface

 New, light, heavy rust, coated steel, or aluminum

 Degree of cleaning required

 Environment constraints
113
Types of Abrasives Available

 Cast steel, Shot and grit

 Naturally Occurring

 Mineral and silica sand

 Flint, garnet and zircon


114
Types of Abrasives Available

Steel Shot

115
Types of Abrasives Available

Steel Grit

116
Types of Abrasives Commonly Used

 Steel shot & grit

 Smaller size abrasives will clean faster

 They cost less than larger sizes

 Check for specifics in manufacturers PDS/Cert


117
Types of Abrasives Commonly Used

118
Types of Abrasives Commonly Used

Steel Grit
119
Abrasive Blast Machine

 Cleans best with use of a range of abrasives

 The largest particle size is the newly added


abrasive

 The smallest particle size is determined by filter


meshes in the recycling unit

120
Abrasive Blast Machine cont.…

 Large particles impact the surface to loosen


scale, sand

 Small particles clean small irregularities

 Small particles scour the surface, removing


loosened particles so work is thorough

121
Maintaining a Well-Balance Operating Mix: Advantages

 Provide consistency on work been cleaned

 Ensure uniform abrasive coverage of the work

122
Maintaining a Well-Balance Operating Mix Cont.…

 Ensure the conditioning of the abrasive for


optimum cleaning

 Minimum lowest abrasive & machine part-wear


to reduce downtown for maintenance

123
Maintaining a Well-Balance Operating Mix Cont.…

 Periodic sieve analysis on the abrasive assist


the operator/Inspector to maintain a proper
operating mix

124
Maintaining a Well-Balance Operating Mix Cont.…

Sieve Analysis Screen

125
Maintaining a Well-Balance Operating Mix Cont.…

Sieve Analysis Shaker & Screen


126
Abrasive Sieve Analysis of Grits Cont.…

CS-05 Sieve Analysis Acceptance Calculation


127
Surface Profile

Surface profile/anchor pattern is a measurement of


the roughness of a surface

 This are results from the abrasive blast cleaning

This is measured from the bottoms of the lowest


valley to the tops of the highest peaks

132
Surface Profile Cont.…

 The maximum allowable depth (height) will


depend on the coating system dry film thickness

133
Surface Profile/Anchor Pattern Cont.…

Abrasive Blast with Profile around the Flange Area of a Tower Section
134
Surface Profile/Anchor Pattern Cont.…

Blast MQAR
135
Rust Back Cont.…

 Rust back occurs when freshly abrasive blast


cleaned steel surfaces are exposed to high
humidity, rain or a corrosive atmosphere

136
Surface Preparation Summary Cont.…

 This is the most important part of an engineered


corrosion protection program

 Any compromise you make here will


compromise even the best coating system

137
Surface Preparation Summary Cont.…

 Recyclable abrasive, should test for cleanliness


before and during the project

 Perform a vial test on the abrasives & a blotter


test on the air source from the compressor

138
Surface Preparation Summary Cont.…

 Removed dust from the blasted surface by


vacuuming or blowing down

 Dust on the surface can interfere with the


coating’s ability to bond to the surface

139
Surface Preparation Summary Cont.…

 Be sure not to touch the steel with your bare


hand

 Oil, grease, salt or any form of contaminant


could be transferred to the surface

140
Surface/Anchor Profile (cont.…)

 Know exactly what anchor pattern tolerances


are allowed, e.g. Tower flanges (2.8 – 4.0) mils

 A well-written specifications requires a surface


profile range, e.g. Tower shell (2.4 – 4.0)mils

 Be sure to clarify for any variables.

141
Testex/Replica Tape (ASTM D4417 Method C) (cont.…)

142
Anvil Micrometer (cont.…)

143
Testex Tape and Swizzle Stick (cont.…)

144
Anvil Micrometer Procedure (cont.…)

145
Documenting Anvil Micrometer Reading on MQAR
(Cont.…)

TESTEX PRESS-O-FILM or TESTEX TAPE


146
Recording Surface Profile Reading in the MQAR
(cont.…)

147
Surface Profile Gauge (ASTM D4417 Method B) (cont.…)

Elcometer 224

148
Visual Comparator (cont.…)

Visual Comparators
149
SSPC VIS-1 Rust Grades (A-D)

150
Reference Standards: Abrasive Blast Cleaning

Standard Random Staining Cleanliness

NACE No. 1/SSPC-SP 5


White Metal Blast Cleaning None
Free of all visible oil, grease, dust, dirt,
NACE No. 2/SSPC-SP 10 mill scale, rust, coating, oxides,
Near-White Metal Blast Cleaning 5%
corrosion products, and other foreign
NACE No. 3/SSPC-SP 6 matter.
Commercial Blast Cleaning 33%

NACE No. 4/SSPC-SP 7


Brush-Off Blast Cleaning Tightly adherent mill scale, rust, and coating may remain.

NACE No. 8/SSPC-SP 14 Traces of tightly adherent mill scale, rust, and coating
Industrial Blast Cleaning residues are permitted to remain on 10 percent of each
unit area.

152
Post Blast: Surface Finish and Cleanliness

Surface cleanliness shall be verified in accordance


to:
 Visual standards in SSPC-VIS 1 or ISO 8501-1

immediately before any coating application.

153
SSPC-VIS1 Reference Photograph

SSPC-VIS1:
 Visual standard for abrasive blast cleaned steel

surfaces

 Guide and reference photographs for Steel


Surfaces prepared by Dry Abrasive blast
Cleaning

154
NACE/SSPC Standards for Surface
Preparation of Steel

 SSPC SP 1 - Solvent Cleaning

 SSPC SP 2 - Hand Tool Cleaning

 SSPC SP 3 - Power Tool Cleaning

155
Hand Tool Equipment for Surface Preparation
of Steel
Power Tool Equipment for Surface
Preparation of Steel

157
NACE/SSPC Standards for Surface
Preparation of Steel

 SSPC SP 11 – Power Tool to Bare Steel Cleaning (1 mils


Profile)

 SSPC SP 5 - White Metal Cleaning

 SSPC SP 6 - Commercial Cleaning

 SSPC SP 10 – Near White Metal

158
Overview of Blast Process in Trinity Towers

Outside of a Blast Booth


159
Overview of Blast Process in Trinity Towers

Outside of an Auto Blast Unit


160
Overview of Blast Process in Trinity Towers

Entrance of an Auto Blast Unit


161
Overview of Blast Process in Trinity Towers

Inside of a Blast Booth


162
Overview of Blast Process in Trinity Towers

Manual Abrasive Blast Unit with the Vent Outlet


163
Overview of Blast Process in Trinity Towers

Needle Pressure Gauge Used for Air Pressure Check at the Nozzle
164
Overview of Blast Process in Trinity Towers Con…

Fresh Tower Section #2

165
Overview of Blast Process in Trinity Towers Con…

Section with one pass ran with OD Blaster

166
Overview of Blast Process in Trinity Towers Con…

Tower Section with the OD Blasted

167
Overview of Blast Process in Trinity Towers Con…

Blasted ID Flanges

168
Overview of Blast Process in Trinity Towers Con…

Flanges OD Finish, ID in Process

169
Overview of Blast Process in Trinity Towers Con…

Blaster Holding the Deadman Valve on the Blast Nozzle


171
Overview of Blast Process in Trinity Towers Con…

Air Supply to the Grit Valve

172
Overview of Blast Process in Trinity Towers Con…

Air Coupler – Q4x Mated with Q3x , Main line to the Whip

173
Overview of Blast Process in Trinity Towers Con…

Air Coupler – Q4x Mated with Q3x , Main line to the Whip
174
Overview of Blast Process in Trinity Towers
Con…

#2

Blast Dust Collector


175
Objectives of Blast Equipment Maintenance

 Blast operation must achieve maximum productivity at the


highest level of workers safety

 Poor performance by one element would hamper the system’s


effectiveness

 Checking equipment upfront can ensure smooth operation during


the job while protecting workers & avoiding costly downtime

176
Maintenance of Blast Equipment Con…

Abrasive Blasting Set-up


177
Maintenance of Blast Equipment Con…

Breathing Air Filter


178
Maintenance of Blast Equipment Con…

Breathing Air Filter


179
Critical Factors in Blast Equipment Maintenance Con…

 Maintaining volume and pressure of compressed air is


critical

 Replacing component before they fail is wise

 Establish good maintenance habit

 Assuring operator safety & Properly trained

180
Critical Factors in Blast Equipment Maintenance Con…

Check Weekly for Wear to the Nozzle Liner

182
Critical Factors in Blast Equipment Maintenance Con…

Venturi Nozzle
184
Critical Factors in Blast Equipment Maintenance Con…

Nozzle wear should not exceed 1/16th of


an Inch, (1.6 mm).

Nozzle Aperture Test


185
Factors Required for Nozzle Choice

 Type of work to be done

 Volume of compressed air available

 Type of blast unit been used

 Velocity needed

186
Maximum Nozzle Size Relative to Compressor Size

187
Critical Factors in Blast Equipment Maintenance Con…

Cut away of ASME-Code Blast Machine with Key Component to


Check for Wear
188
Reporting & Documenting of Blast Process Correctly into
the MQAR Con…

Exceeded Hold times & Overcoat intervals with No CSP-0005-1 Log


193
CSP-0005-1 Log for Reporting Environmental Conditions &
Contaminants per SSPC VIS 1 Con…

Activate CSP-0005-1 Log If the Hold Times & Overcoat Intervals is Exceeded
194
Questions?

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