Surface preparation

► What is surface preparation?

Surface preparation is the process in which
the surface of work piece is been cleaned for
next process like painting,
coating etc.

Why it required?
With proper surface preparation we can make the
work piece corrosion free.
With this process we can providing more efficiency
to next processes.
 Types of surface preparation

Blasting

Water jet cleaning Surface preparation Acid-cleaning

Hand & power

tool cleaning
 BLASTING
Blasting is a one kind of surface preparation
activity in which surface is cleaned by
Impacting of abrasives
 Blasting
• Blasting is a process in which abrasives are blasted
on the surface of work-piece.

• Types of blasting
1) Wheelabrators
2) Air blasting

• Blasting is most common & applicable method in

industry so blasting is most preferable in a heavy
engineering industry, shipping & fabrication
industry
 Wheelabrators
► Wheelabrators are centrifugal blasts units Which is
mobile & fixed m/c types

► Qualityis maintained by conveyer in fixed m/c. In

mobile unit traveling speed maintain good quality

► Generally recycled type abrasive used in this

blasting e.g. steel shots, grits
 Wheelabrators
► Maintaina shot speed of 220mile/hour by rotor
speed of 2500 to 3500 rpm

► Very effective in a batch or mass production

► This types of process is most commonly used in

flat steels & long products in plate yard & ship-
yard
 Equipments
► Hopper ( blasting storage ):To store the abrasive
► Blasting wheel with elect. Motor : Give kinetic
energy to abrasive
► Screw conveyors & elevator: To movement of
abrasives for recycling
► Blowing or suction unit: To clean dust & abrasives
from the w/p after blasting
► Separator: To refine & separate abrasives
► Dust collector : To separate dust particle & air
collect from unit.
Blasting m/c
Portable wheelabrater
 Wheelabrator

► Generally this types of blasting is better result on

flat types of steel
► This blasting is more preferably in long products &
piping also.
► This blasting is generally done in ship yard.
► Abrasives used in this blasting is always recyclable
e.g. steel shots, steel grits
► This blasting is very effective in batch & mass
production
 Does
► Blasting m/c should be proper sealed
► Blasting operator, rigger & other work men should
wear safety goggles
► While doing maintenance, proper safety device
should be operated while going inside the m/c
► Leakage in m/c should be attended as early as
possible
► Rotor blade, blasting chamber liner ,bolts
&conveyor sleeves should be replaced by periodic
time as per manual
 Don'ts
► Don’t bypass any safety limit switch while entering
in m/c
► Don’t mix wet abrasive in m/c for increasing the
m/c efficiency
► Don’t bypass the limit switch while doing operation
or maintenance .
 Air blasting
-This types of blasting is also known as a manual
blasting. Abrasive is blasted with compressed air

- If Blasting done on 100 psi (7kg/sq.cm) it gives 100%

efficiency then reducing 1 psi we get 1.5% less
efficiency .

-We can do this blasting on any type of surface but

very effective for a pressure vessel It is

-very effective in a job production

 Equipments
► Compressor is used for giving the high
compress air 7 kg/sq.cm

► Blasting pot store abrasive & mix compressed

air with abrasives

► For
removing vapor & oil Vapor traps is used
between the compressor & blasting pot
 Equipments
► Hose convey the compressed air & abrasive
mixture as well as compressed air also

► Nozzle is the outlet of total unit from where

abrasive blasted on w/p

► For
safety every unit should have a dead mans
handle.
 Nozzle types
► 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.

► VENTURI : Which can generate the speed of

abrasive at up to 450 m.p.h and which gives an
even blast pattern over a relatively large area.

► Thepressure at which the abrasive is delivered to

the blast nozzle can be measured by using a
hypodermic needle gauge.
Nozzle types
Air blasting
 Air blasting
► This Blasting is called a manual blasting

► blastermoves & points nozzle to the direction of

w/p. So in this blasting more safety should be
provided.

► Generally this blasting is done for final painting.

► This blasting is suitable or any kind of w/p

 Air blasting
► Inthis blasting, both type of abrasives recyclable
and non recyclable, are used

► Thisblasting is done in generally Heavy

engineering industry.

► Thisblasting is very much effective in job

production.
 Does
► Wear proper P.P.E. for the blasting process for
safety purpose.

► Alwaysuse carbon impregnated hoses for

compressed air & abrasive mixture.

► Blasting
area should be permanently or
temporarily covered while blasting.
 Does
► Keep standard distance from the work piece

► Proper ventilation should be available when

blasting

► Proper dust collection system should be available.

 Don'ts
► Don’t do blasting in open or crowdy area.

► Don’tstart blasting without checking the safety

equipment.

► Don’t work without fixed dead mans handle with

blasting nozzle

► Don’t use wet abrasives for blasting.

 Abrasive
Natural abrasive
Garnet,
Silica send

By product
Specialty abrasive Coal slag
Plastic shot Nickle slag
Glass bead Copper slag
Abrasive

Manufactured
Agriculture Al.oxide
Coconut shell Silicon carbide
Black walnut Steel grit/shot
 Selection
Cost

Application
Availability
method
selection
of Abrasives

Quality Material
required of W/P.
 BLASTING REQUIREMENTS
• Blasting Report with Temp. Log
• Contamination Level check
• Blasting Shot Size / Recycling requirements
Blasting Process Controls
… Humidity < 85 %
… Ambient Temp. < 60° C
… Surface Temp. < 50° C
… Surface temp 3°C above Dew Point

It may very for the different customer or

application
 Blasting grades
► Inblasting system different grades are
given below
BS 7079 PtA SSPC NACE
Sa3 Sp5 Grade1
Sa2.5 Sp10 Grade2
Sa2 Sp6 Grade3
Sa1 Sp7 Grade4
 Quality of blasting
Quality of blasting measured by two parameters
1)Degree of cleaning ness
2)Surface Profile
For measuring Degree of cleaning ness w/p is
compared with standard photographs.degree of
cleaning ness is depends on the surface rust grade
before blasting
For measuring profile following instrument used
-Profile needle gauge
- Micrometer dial gauge with replica tape
 Rust grade
Rust grade designated A,B,C & D respectively, are
specified As per SSPC std.,Described below.

A) steel surface largely covered with adhering mill

scale but little, if any rust.

B) Steel surface which has begun to rust & from

which the mill scale has begun to flake.
 Rust grade
C) Steel surface on which the mill scale has rusted
away or from which it can be scraped ,but with
slight pitting visible under normal vision

D) Steel surface on which the mill scale has rusted

away and on which general pitting is visible under
normal vision
Comparison
 Standards of blasting
► Cleaning ness is measured with grade
e.g.Sa1,Sa2,Sa2.5,Sa3 As per ISO 8501

► Profileis measured in a micron(µ)

e.g. 50µ,80µ As per ISO 8503.

NOTE : There is no relation between cleaning ness

& profile.
 FACTORS AFFECTING BLASTING

Factors

Abrasives Human Factors

Hard ness of Angle from the

Size of Abrasives Speed of blasting
abrasives surface to Nozzle

Density of Shape Distance from

Time
Abrasives of Abrasives W/P to Nozzle
 TESTING FOR SURFACE
CONTAMINATION
► Various tests exist to determine contamination left
on a surface after blast cleaning. The
contamination usually consist of either
Hygroscopic Salts or Mill scale and the tests are as
follows.

► 1) HYGROSCOPIC SALTS
Soluble Iron Salts -Potassium Ferricyanide Test
Soluble Chlorides - Silver Nitrate Test

► 2) MILL SCALE
Copper Sulphate test.
 CKECK POINT FOR BLASTING
OPERATION
► Air & oil filter shall be provided on compressor &
hopper.
► Oil/Grease shall be removed from the surface
before blasting.
► Abrasive shall be free from salt.
► Slag shall not be recycled, and grit can be recycled
after ascertaining its quality.
► Uniform pressure of 6-7 Kg/sq.cm shall be
maintained throughout blasting operation.
 CKECK POINT FOR BLASTING
OPERATION
► Abrasive size and shape selection based on
surface roughness I.e. profile requirement.

► Blasting shall be permitted only when relative

humidity is less than 85% & steel temperature is
at least 3 degree more than Dew point
temperature.

► Blasted surface shall be free of dirt, dust and

abrasive material. This can be achieved by blowing
air on blasted surface or vacuum cleaning.
Prepared by : VPP
Wheelabrator
Air blasting unit
 White metal blast cleaning

► This blasting called as a Sa3 or SSPC SP5 blasting

► When without magnifying glass surface should be

viewed clean & free from mill scale, rust, foreign
matter, oil, grease & dirt

► It should have a uniform metallic colour

 Very through blast cleaning
► Thistype of blasting called as a Sa2.5 or SSPC
SP10 blasting

► Some remaining traces of contamination shall

show only as slight stains in the form of spots &
strips but visible grease, mill scale, rusting, oil,
foreign matter should be not visible on surface.

► This blasting is known as a near white metal

blasting
 Commercial blasting
► This type of blasting called as a Sa2 or SSPC SP6
blasting.

► In this type of blasting without glasses oil,

grease,& dirt fully removed. most of the mill
scale ,rusting, paint coating should be removed.

► This blasting known as a through blast cleaning

 Brush of blasting
► This blasting called as a Sa1 or SSPC SP7 blasting

► When viewed without magnification surface shall be

free from visible oil, grease,& dirtbut poorly adhering
mill scale, rust, paint coating & foreign matter.

► This blasting known as a light blast cleaning

► This grade blasting is not used for rust grade-1

Rust grade
Dead mans handle
 LARSEN & TOUBRO LIMITED
HAZIRA WORKS
SURFACE PREPARATION & COATING REPORT
EQUIPMENT NO: MV-RDZ311-C05 L&T PROJECT REPORT DETAILS
EQUIPMENT NAME: CRUDE COLUMN NO. DATE NO.
COATING CONTRACTOR(NAME) : BLAST O PAINT 45366 05-Oct-07 5
CONDITION IN WORK AREA
ITEM DRY WET DEW STEEL
ITEM PREPARED OR COATED COND. TIME RH
NO. DATE BULB BULB POINT TEM P
REFS. HRS %
0
C 0
C 0
C 0
C
1 Externel surfaces of shell, A 25-Sep 20:00 33 27 62 25 34
B 23:00 31 26 67 24 31
nozzles & appartances from
th C 1:00 30 25 67 23 29
4 stiffner ring to bottom D 3:00 29 25 72 23 29
tanline E 6:00 29 26 79 26 30
F 8:00 31 25 67 26 31
G 10:00 33 26 60 23 34
H 01-Oct 10:00 32 24 52 21 33
I 12:00 34 26 53 23 35
J 14:00 35 26 49 23 36
PREP. COND. PREP. STD. SURFACE TIME
SURFACE PREPARATION METHOD
REF. REFS. SPECD. ACT. PROFILE MICR. START END
Abrasive Blasting X A-E SP-10 SP-10 70 20:00 6:00

ABRASIVE M ANFG.: Hindalco Industries TYPE: Copper Slag GRADE: N.A.

COATING M ANUFACTURER: Ak zo-Nobe l pvt.ltd.(INDIA)
PRODUCT DETAIL M ETHOD PREV.
ITEM COAT COND PREP TIME WFT DFT
OF COAT
NO. NAME BATCH NO. NO. REF REF ENDED M ICRON M ICRON
APPL. DATE
HD 4905 HA Airless
1 INTERZINC-12 1 F-G X 10:30 --- 85 ---
HE 5312 HA spray
HE 5071 HA Airless
2 INTERTHERM-181 2 H-J … 14:00 … 180 25-Sep
HE 5520 HA spray

1) Salt contamination test: Test carried out using SCM 400 meter and f ound contamination 3.5 µgm/sq.cm.

L & T INSPECTION AGENCY