BRITISH GAS PLC NSP Interim Amendment to BGC/PS/Q4 and BGC/PS/Q7 APRIL 1990INTERIM AMENDMENT TO _BGC/PS/04 & O7 COATING INSPEC’ ORS This amendment details the requirements for two grades of inspecto mill coating inspector and site coating inspector, which replace the existing: shift Coat & Wrap Powder Coating Wrapping Coat ings Both will need the same ‘core' knowledge with different extra items, all summarised below: - MILL INSPECTOR = A + B SITE INSPECTOR = A + C A MILL AND SITE (CORE) AL Surface preparation a2 Internal coatings a3 Handling and storage Aa Removal of coatings AS Health and safety AG Cathodic protection AT Record keeping a8 Practical B MILL (EXTRA) BL Surface treatment B2 Coatings - types used and application in mill B3 Testing and inspections Ba Repairs c SITE (EXTRA) ca Coatings - types used and application on site cz Inspection c3 Repairs ca Backfilling, stringing, bending cs PearsonAl A2 Aa AG AS MILL AND SITE COATING INSPECTORS URFACE PREPARATION Standards BS7079 A, B, C and D. BG/PS/SSW4 and other B.G. specification’ Methods - blast cleaning, needle gunning, wire brushing, discing, chemical emulsion solvents. Materials - grit, shot, solvents, etc. Environmental conditions - temperature, RH, dewpoint Assessment of surfaces (before, during and after) for cleanliness, contamination, profile, etc. Standards required for various coating types (internal and external surfaces) Time allowed between operat ions/conditions/inspections cut-back preparation Grinding of defects Safety requirements - BG/PS/SSW4 INTERNAL COATINGS Standards - BG/PS/CM1, CM2, PAB Differences between systems and their uses Knowledge of different coating types Inspection techniques and constraints Repairs HANDLING TRANSPORT AND STORAGE Standards BG/PS/L3, IGE/TD/6 - legislation, liabilities Precautions necessary for handling, transporting, lifting, stacking, offloading, storage Safety aspects Inspection REMOVAL OF COATINGS Methods, materials, hazards Surface cleanliness, contamination and testing Metallurgical considerations HEALTH AND SAFETY Appreciation of HSE and COSHH regulations and mandatory requirements B.G. requirementsAG AT ag CATHODIC PROTECTION Appreciation of basics Methods of applying C.P. Relationship with coatings and combined role Interaction RECORD _KEEPING Appreciation of its importance Factors to record Retrieval of records PRACTICAL Identification of abrasives Assessments of surface quality, profile and temperature measurement Environmental tests Coating thickness measurement and holiday detection Identification of samples and faults©AB Ag. AB.2 AB.3 Ag.4 COATING INSPECTION PRACTICAL Environmental Tes Measurement of dew point and relative humidity. Measurement of steel surface temperature. surface Preparation Identification of types of abrasiv Visual assessment of cleaned surfaces - BS7079. Surface profile measurement. Coating Thickness Measurement Calibration of instruments. Measurement of DFT samples. Holiday Detection Calibration of instruments. Set up for various coating types. Coating Samples and Situations Identification of coating samples and faults. Discussion of photographed faults and situationsBL B2 B2.1 MILL COATING INSP SURFACE TREATMENT Use of pre-treatment under resin powder coatings Nature of pre-treatment and how used Application principles/specification requirements Standards and inspection COATINGS Standards - BG/PS/CW1, CW2, CW3, CW4, CW6, CW9 Types of coating used ~ CTE with primer and reinforcements Bitumen with primer and reinforcements extruded PE & mastic fusion bonded powder (FBE) M.C.L. (perhaps + primer) concrete weight coating (anti-slip measures) Compatibility of various materials listed above Primers and their application Cut-backs, protection of bevels, chamfers, etc. Application methods and general principles Repair techniques Fault. finding techniques Safety aspects Fusion Bonded Powder Coatings Methods of heating and temperature control, measurement application temperatures Storage of powder/temperature effect Thermosetting nature of material Electrostatic spray principles/application Powder gel time, particle size, film formation techniques, moisture curing parameters, thickness requirements and control Use of reclaimed powder and implications Cooling and heated pipe cessation/cure Cut~-backs Faults and fault finding and repairs Fittings/pipe considerationsB2.2 B2.3 B2.4 B3 B3.1 Multi-Component Liquid Coatings (MCL). Methods of heating (where used) and temperature control, measurement, application temperatures and environmental considerations. Storage of materials, thermosetting nature of material Spray and brush applications, equipment and mixing techniques. curing parameters, pot life. cut-backs. Faults, fault finding and repairs. Fittings/pipe considerations. Extruded Polyethylene Coatings (PE) Storage of mastic and polyethylene Heating of mastic, its application, thickness control, etc. Extrusion and application of polyethylene cut-backs Faults, fault finding and repairs Coal Tar Enamel (CTE) and Bitumen Coatings Storage of materials Heating of material - temperature control Application of primer Application of enamel/bitumen Introduction of reinforcing layers Cut-backs Faults, fault finding and repairs Concrete Appreciation of application principles, methods and effect upon coatings ‘Anti-slip" bands Cure parameters - inspections, testing for continuity Cut~backs Repairs TESTING AND INSPECTION Fusion Bonded Powder Coatings (FBE) visual, adhesion, holiday detection, impact, D. time, moisture, flexibility, C.D., strain polar. water soak, thickness.B3.2 B3 3 B3.4 B3. Ba u Multi~Component Liquid coatings Impact, adhesion, visual, heat blister, cure, holiday detection, water soak, C!p., strain polarisation, flexibility, thickness. Extruded Polyethylene Coatings visual, destructive, impact, holiday detection, tensile/elongation, heat reversion, peel, thickness. Coal namel_and_ Bil Coat ings Visual, tapping, destructive, holiday detection, impact, Zahn viscosity, penetration, softening point, (ring and ball), adhesion, thickness. Concrete Visual, moisture, size grading, coring, strength tests, water absorption, thickness, continuity checks on rebars, ‘ringing’, etc., repairs. REPA, Methods and materials available, with their limitations and special application requirements Preparation Mixing and application Cure, inspections and testingOcL ci. c1.2 c1.3 c1.4 ~e- SITE COATING INSPECTOR COATINGS Standards BG/PS/CW2, CWS, CW6, CW9, Sswa Application methods and general principles Types of coatings used: fusion bonded powder (FBE) multi-component liquid (+ primer) cold applied tapes heat shrink materials concrete coating Compatibility between materials listed above and with other factory coatings Primers and their application Cut-back and removal of temporary protection Safety aspects Fusion Bonded Powder Coatings Methods of heating, temperature control and measurement and the merits thereof. Inspection ~ environmental considerations application temperatures coating quality Sequence of operations, powder application and equipment, film formation, repairs, coating thicknes: overlap, powder reclaim/re-use. Multi-Component Liquid Coatings Environmental conditions and considerations, RH, dewpoint Testing Mixing of components, pot life, methods of application, equipment, cure-times Repairs Cold Applied Tapes Material types and properties - grease based, self-adhesive, laminate Use of primers Application procedures, sizes/pipe size Testing Repairs Heat Shrink Materials Material types, properties Use of primers Application procedures Testing and repairscl. C2 c3 ca cs -9- Methods of application, repairs, testing for contacts INSPECTION Substrate temperature measurement Visual inspection during and after application Adhesion, holiday detection, thickness Ambient conditions/dewpoint/RH Knowledge of laboratory tests - CD, sP, Water Soak REPAIRS Methods, materials, preparation, application, merits of various systems STRINGING, WELDING, BENDING, DITCHING, BACKFILL Precautions during stringing and welding Problems with pipe bending care of coating during ditching, sclection of backfill and covering of pipe Compaction PEARSON SURVEY Methods available, limitations Recording results Implication of faults, repairs PWL/RGR/JMA 6.4.90weep PPro 10. ul 12, 13. 14, 15, 16. 17. 18. 19. 20, 21 22, 23, 24, 25, SITE COATING INSPECTION QUESTION PAPER I (Surface preparation) What type of abrasive would normally be used for site blasting? Which British Gas specification relates to safety during blast cleaning’? Which Swedish standard relates to surface preparation? What is meant by 513? What is meant by Sa2!? How is oil or grease removed from a pipe surface prior to dry abrasive blasting? What is a rogue peak? Can copper slag abrasive be used more than once? Can shot or grit be re-used in a factory blasting operation? What do you understand by the term amplitude in relation to a blasted finish? Name the corn plaster method of measuring amplitude and describe its use. What is a micrometer in relation to a millimeter? What is a knock out por? What is the usual type/shape of a blasting nozzle? What is the maximum allowable pressure from a blasting, compressor to be in accordance with British Gas requirements? How can pressure be measured near the blasting nozzle? Describe the use of a dead mans handle. Explain the sequence of operations during the Footneriduplex process. Describe the disadvantages of wire brushing for surface preparation. What is the BS 70797 Describe the action of stee! shot on a substrate during blasting compared to steel grit Why is sand containing silica not used as a blasting abrasive? Name two methods of measuring peak to trough height How many micrometers in a thou"? What is a typical maximum time lapse between blasting and coating?5, 10. AL 12. 13, 14, 15, 16, 17. 18, 19, SITE COATING INSPECTION QUESTION PAPER 2. (F amels/tapes) What is the British Gas specification for coal tar enamel materials? What is meant by the viscosity of a material? Describe the difference between high anc low viscosity. ~ How are/were coal tar enamel coatings applied in the factory; list the sequence of operations, Can bitumen coating be over-wrapped with coal tar? Describe a test to differenciate coal tar from bitumen {s it permissible to wrap welded butt joints using coal tar if the abutting pipes are coated with polyethylene cladding? What precautions must be taken to prevent far warts when handling/using coal tar enamels? What type of primer was/is used prior to the application of a. Bitumen, b. Coal tar. What is asphalt? Why is a herbicide incorporated in bitumen coatings? ‘What was/is the application temperature of coal tar enamels? What was/is the maximum temperature coal tar can reach in the melting pot and what action would be taken if this temperature was exceeded and why? What was/is the application temperature of bitumen enamels? Where does bitumen come from? How could the temperature in a melting/dope pot be determined? Is it necessary to agitate enamel in a melting/dope pot? Why is limewash applied to the external surface of enamel coated pipes? What do you understand by the terminology disbonded thermog lass? How may the temperature of a pipe surface be measured in low ambient temperature conditions? What is meant by icicles on an enamel coated pipe? List eight types of coating/wrapping materials How much enamel is required between the inner wrap and the pipe surface? How are rogue peaks removed if it is necessary 10 do so? What do you understand by the terminology biced through in relation to enamel flo coatings? What is the total minimum thickness over the plate and over the weld for enamel coatingsPC OPne 10 11 12, 13. 14 15. 16. 17. 18, 19. 20, SITE COATING INSPECTION QUESTION PAPER 3 (Enamels/tapes) What is meant by the term holiday? What is the abbreviation C.T.E.? Describe the operation for repairing pinholes on coal tar coated pipe Describe the operation for repairing a damaged area of 150 mm x 150 mm ona 750 mn diameter pipe, coated with coal tar How soon after application can adhesion checks be carried out on coal tar or bitumen coatings? What voltage is required for holiday detecting coal tar coatings? Describe how a bond test is carried out on enamel coatings What precautions must be taken if using xylene as a degreaser? What is meant by the lash point of a liquid/solvent? How may coal tar enamel be removed from a pipe? Is it permissible to use turpentine or white spirit as a degreaser? Why are barrier creams and protective clothing worn when handling coal tar enamels? How is a primer applied? Primers must overlap.existing coatings by how much? What precautions are taken to prevent solvent loss from primer application containers? What is the minimum thickness for polyethylene cladding and the underlying mastic in accordance with PS/CW4? How is damaged polyethylene cladding repaired if damaged? What voltage is required for holiday detecting PE cladding? How are damaged polyethylene coatings repaired? What is the material specification for cold applied self-adhesive tapes and cold applied laminate tapes? Name two British Gas approved cold applied self-adhesive tapes. What are cold applied self-adhesive used for? What is the abbreviation M.C.L.? Name three British Gas approved cold applied laminate tapes and their corresponding primers What is the voltage required for holiday detecting cold applied laminate tapes”©22. 23. 24. 25, SITE COATING INSPECTION QUESTION PAPER 4 (Enamels/tapes) Are cold laminate tapes compatible with coal tar and bitumen coatings? What precautions must be applied when backfilling over pipes wrapped with cold applied laminate tape? Are primers considered essential for cold applied laminate tape systems? How much overlap is required for cold laminate tapes on joint coatings? Which specification covers the application of cold applied tapes? Why do Batish Gas not now approve the use of hot applied tape? What materials make up a hot applied tape? What is Denso tape? What is a flood box? ‘What are mastics and puities used for? Is it possible to holiday detect grease based tapes? What is Metrosol 1341 and Metrosol 1340? Describe the use of heat shrinkable plastics. May valves be coated with brushing mastics in accordance with the current BG PS CWS? What is the expected thickness of a brush or spray applied compound? What is a typical voltage for a holiday detector battery? Explain the use of a holiday detector on a tee-piece. What happens to the kV dial when a holiday is detected? Explain the operation of a holiday detector on FBE coated pipe Is it possible to holiday detect wet coated pipe? ‘What will happen if the voltage selected for holiday detection is too high for the coating” What material would be used to repair damaged brushing mastic coatings? What is the title for the BGC PS P10? What is the specification which covers handling and storage of steel pipes bends and tees” What is a thermoplastic coating?AY os 14. 15. 16. 17. 18. 19. 20, 22. 23. 24 25, SITE COATING INSPECTION QUESTION PAPER 5 (Enamels/tapes) What are the duties of an inspector covering a ditching operation? Is it permissible to ditch coal tar coated pipe when the ambient temperature is 25°C? What happens to the base of a trench excavated in rock prior to ditching? Describe the backfilling operation in accordance with BGC PS P10? What is the minimum depth between the top of the pipe and the surface of the top soil in accordance with BGC PS P10? Describe a simple method to check for laminated coal tar coatings What is the safest method to handle pipes in accordance with BGC PS L3? Is it necessary to pad cradles and batten carriers? Describe the method for handling bends or tees. Describe the stringing operation on a pipeline. Is it necessary to chock pipes when using cradles during transportation? Are holiday detectors AC or DC? What do you understand by the terminology soft standings in relation to the storage of pipe? How many bearers and pads (hard standings) are required when stacking pipe of standard wall thickness coated with polyethylene cladding? When stacking polyethylene clad pipe how many pads are required between tiers? What is the maximum number of tiers if stacking coal tar coated pipe 900 mm diameter? What is the maximum number of tiers if stacking FBE coated pipe 42" diameter? How many bearers and pads (hard standings) are required when stacking pipe of standard wall thickness coated with epoxy powder? How would the joint be coated/wrapped if a pipe coated with epoxy powder was welded to a pipe clad with polyethylene? Is it permissible in accordance with BG PS CWS to overlap onto polyethylene cladding with primer for cold applied laminate tapes? What is meant by guniting? Describe a Pearsons survey Define the term brothers in relation to the handling of pipe. List four safety precautions during dry abrasive blasting, Is it possible to ditch a length of pipe into a trench half full of water?oO2 a oe n 12. 13. 14, 15. 16. 17. 18. 19. 20, 21 22. 23. 24 25, SITE COATING INSPECTION QUESTION PAPER 6 (Powder coatings/MCL's) What do you understand by the terminology blueing of steel? Which British Gas specification covers field applied epoxy powders? Can epoxy powder coatings be applied on butt joints if the ajoining pipes are coated with polyethylene cladding? How is the degreasing operation carried out prior to blasting for epoxy powder coatings’? What amplitude is required on blasted joints prior to the application of epoxy powder coatings? What grade of preparation is required for epoxy powder coating? By how much it is necessary to overlap onto the FBI actory coating during blasting”? What is a sliver? If there is any jagged or disbonded areas remaining on the factory coating after blasting is necessary to feather the edges back; by how much? If a sliver is present on a blasted surface what action must be taken? How are the blasted joints heated prior to powder application in the field? What is a typical application temperature for epoxy powder? What safety precautions are required during heating? The temperature of the steel during heating should never exceed .......°C. How are the steel temperatures measured after heating? How soon after heating must the epoxy powder be applied? ‘What is the minimum and maximum coating thickness for factory and field applied epoxy powder coatings? How is the coating thickness measured? By how much should the field coating overlap the factory coating? What do you understand by overspray? Is the epoxy powder melted prior 10 application or when it hits the pipe? Is overspray reclaimed? How is differential curing of epoxy powder coatings reduced? Why must the spray container be checked during powder application? Can reclaimed powder be reapplied?SITE COATING INSPECTION Qui 'STION PAPER 7 (Powder coatings/MCL's) How often are thickness checks required on field applied epoxy powder coatings in accordance with the relevant British Gas specification? What do you understand by WFT and DFT? Where on epoxy powder coated joints are thickness checks taken’? Describe the calibration of a banana guage? What action is taken if an epoxy powder coated joint has insufficient thickness? Is it permissible to store powder ovemight in the application container? When working with epoxy powder what safety precautions should be undertaken”? How soon after coating with FBE can holiday detection be carried out? How much voltage is required for the holiday detection of FBE coatings? What is special about the springs used for the holiday detection of FBE coatings? How are pinholes etc. marked when found by holiday detection? ‘Are epoxy powder coatings thermosetting or thermoplastic? ‘What do you understand by thermosetting and thermoplastic? How do epoxy powder coatings cure? How often are curing checks carried out on epoxy powder coatings and how are the samples taken? Describe briefly how the curing tests are carried out? Describe polymerization and crossiinking. Describe the adhesion test carried out on epoxy powder coatings and how often are they taken? Why were epoxy powder coatings developed? Explain relative humidity? Explain dew point? Explain the repair procedure for pinholes in epoxy powder coating? Explain the repair procedure for a damaged area of 10 mm”? Explain the repair procedure for a damaged area of 1600 mm’? How does an induction coil heat the steel pipe?Su aun 10. iL 12. 13, 14, 15. 16. 17. 18. 19. 20, 21 22, 23. 24 25, SITE COATING INSPECTION QUESTION PAPER 8 (Powder coatings/MCL’s) Describe the use of a melt stick for the repair of epoxy powder coatings Describe the use of two-pack epoxy repair materials? Can thinners be applied to epoxy two-pack prior to application? What do you understand by the terms por life and induction period? What DFT is required for two-pack epoxy repairs Can heat shrinkable plastics be used for repairs on epoxy powder coatings in accordance with British Gas specifications? Can cold laminate tapes be used for repairs on epoxy powder coatings in accordance with British Gas specifications? What do you understand by the term gel-time? Urethane material should be in accordance with which British Gas specification? {s it permissible to coat a joint using a urethane coating if the pipe is coated with epoxy powder? Are tie-in welds coated with epoxy powder? What instrument is used for the measurement of relative humidity and dew point? Is it permissible, to British Gas standards, to apply FBE coatings during rain, snow or mist? Is it permissible, to British Gas standards, to apply urethane coatings when the metal temperature is 12°C? What is Scotchkote 206N? What is a typical pot life of a urethane tar two-pack coating? What is the maximum permissible relative humidity for the application of a two-pack urethane coating? What are the two materials that make up a urethane tar base? How is it possible to shorten the cure time of a urethane two-pack coating? What is the difference between Protegol 32-10 and Protegol 32-10L? Can Protegol 32-10L be used on pipe to be thrust bored? {ls Protegol 32-10L compatible with Protegol 32-10? {s Protegol 32-10L compatible with epoxy powder coatings? 's Protegol 32-10L compatible with coal tar coatings? Describe the application of Protegol 32-10L?NQ2WAWN 10, AL. 12. 13. 14, 15. 16. 17. 18. 19. 20. 21 22 23, 24, 25, SITE COATING INSPECTION QUESTION PAPER 9 (Powder coatings/MCL's) What is the minimum overlap required when using twvo-pack urethane on pipes couted with coal tar? What must be done at the interface of the two coatings on the above question? When can a pipe be handled after coating with urethane? Is it permissible to spray apply Protego! 32-10L if not, how is it applied? Is it permis ible 10 spray apply Protegol 32-10, if not, how is it applied? What is the difference between airless spray and conventional spray? If spraying is used to apply a urethane coating, it is necessary to flush out the spray gun after use. What precautions must be taken before the next application of urethane? What would happen if this was not done properly? What kV is used on urethane tar coatings? How often is a hardness/cure test carried out on a urethane coating? Describe how an adhesion test is carried out on urethane coatings and how often? Describe briefly how epoxy powder is applied to pipes in a coating mill What is the minimum thickness for Protegol 32-10L in accordance with CW5? How much overlap is required onto FBE coated pipe using a urethane coating in accordance with the requirements of CW5? What is an approximate range for epoxy powder particle size? What precautions must be undertaken to prevent damage on factory epoxy powder coatings during welding? What precautions must be undertaken to prevent damage on factory epoxy powder coatings during the handling of the pipes using side booms? What precautions must be undertaken to prevent damage on factory epoxy powder coatings during bending of the pipe? In accordance with BGC PS L3, is it permissible to use steel hooks to lift pipe coated with epoxy powder? To CWS, if the air temperature is 10°C is it permissible to apply urethane coatings? Is epoxy powder inflammable? What is the problem with long term storage of epoxy powders? If it is required to remave an epoxy coating on a joint, how would this be carried out? Is it permissible to degrease a urethane coating or an epoxy coating using white spirit? List the 4 stages of transformation for epoxy from powder to hard film. An FBE coated pipe is welded to a urethane coated fitting; how would the joint be coated”SITE COATING INSPECTION QUESTION PAPER 10 (Powder coatings/MCL's) How long would a brush/trowel applied urethane coating require to fully cure at 20°C? When would a brushytrowel applied urethane coating be touch dry? What precautions are necessary to prevent damage (0 FBE coated pipe when profile cutting? Is it permissible to thrust bore a pipe coated with FBE on a British Gas pipeline under construction? {s Ht permissible to British Gas specifications to gunite a pipe if the pipe is coated with rst How would urethane coatings be removed if required? How wide is the band of epoxy powder coating when applied in the field? What do you understand by the terms Tp/ and Jg2 in relation to a DSC scan? What is the acceptance tolerance relating to Tg] and Tg2? What do you understand by the terminology residual exotherm in relation to DSC? What do understand by the terminology endothermic reaction? What are the following abbreviations: MIBK and DSC? Name an epoxy powder application company approved by British Gas? Sketch an epoxy powder coating set-up used on pipelines, showing blasting, heating and coating operations Is it possible to ditch FBE coated pipe during hot weather? What are hygroscopic salts? What does the BGC PS SSW4 relate to? What is Plasgard 410? What is Interpon Quickset? What is a fluidized bed used for? How far from the end of the pipe does the factory epoxy powder coating terminate, when applied in accordance with BGC PS CW6 Part 2? Why is it not good practice to apply epoxy powder coatings too thick? The epoxy powder material used on British Gas pipelines shall be in accordance with which specification? What are potassium ferricyanide test papers used for? If it is required to overcoat epoxy powder coatings, e.g. with apaint system on an AGL what preparation must be undertaken and why?MwNe 15. 16. 17, 18. 19. 20. 21. 22. 23. 24, 25. SITE COATING INSPECTION QUESTION PAPER I (Cathodic protection) Name two methods of applying cathodic protection. Why does an uncoated steel pipe corrode? Name the type of reference electrode used by BG to measure pipe to earth potential? Why would magnesium anodes be used rather than zine anodes with the sacrificial anode CP system? Is it possible to apply to0 much cathodic protection, if so what effect does this have? What effect on CP would a foreign structure have if it came into contact with the pipe? What is another name for a sacrificial anode? Is it necessary to coat CP plaies? Explain briefly how the sacrificial anode system works. Explain briefly how the impressed current system works. What is an electrolyte? ‘What type of anodes are used on the impressed current system? Name three promoters of corrosion. Express -0.85V in mV; then explain the significance of this figure in relation to cathodic protection. What is aground bed? What work is carried out at the intersection where a foreign pipeline crosses a pipeline to which cathodic protection is being applied and why? Is corrosion eliminated with cathodic protection? What is the cause of cathodic disbondment? Is it possible to use graphite anodes to protect a buried steel pipeline? Is it good practice to bury the pipeline to be cathodically protected in a carbonaceous backfill? What is interference? What is an isolation joint used for? Why is it not possible to cathodically protect an A.G.L? What adverse conditions would cause the the amperage and voltage output to be adjusted on an impressed current CP system? What is a transformer rectifier?PwnaAnaun Ml 12. 13, 14, 15. 16, 17, 18. 19. 20. 21 22, 23, 24. SITE COATING INSPECTION QUESTION PAPER 12 (Miscellaneous) Which BG standard relates to concrete coating of pipes? What is the ume limit benween water addition and the application of a concrete coat Can reclaimed concrete material be used? To what distance from the pipe ends is concrete applied? What is meant by the term ringing? What is spalling? Which gas may be used to fill the annular space of a sleeve? Name four ingredients of concrete What do you understand by the abbreviations: o.e.s., mel, p.p.m.? Which surface preparation method is used for coatings applied to BG PS PA8? For what reason would a silver nitrate test be used? What is the minimum d.£1. of f b.c. before guniting is permitted? Describe the impingement method of concrete application Give three examples of paint binders. What is meant by the term rapping? Name two inert opaque pigments. Other than the binder, name three constituents of a paint What is a hackle? Name the three basic corrosion protection methods. What are the functions of a primer? Name four drying mechanisms for a paint film? What is meant by convertible and non-convertible paints? What is meant by the term volatile in relation to solvents? Which document lists the occupational exposure limits? What are the advantages and disadvantages of a water bore coating?GSP, | corer Boas Werte tesr Moniaas 10" Maw, 93 ome DiffereNce TN SrandaNde ofeeanc Berazet QisernmeNe x FG? Di Hees & WH lees Coedasion Occur 2 3) Name DieKeteNT TUES me OF Memons to | erate A__Suerace . AN Do Barris Gas use Sand FOR Aaaasie. ALasrialG {AND Wy? _ Hewat Do Seu uvdneesialo ABOUT he Ter Anitieris OQ} Descaée me Meccdude WHEN UsinlG Sureace Reece aA [Wier 15 THe Ger SH Cras SEes lication faa _ LASSe8INGr (ReCnearion ef Steer SuasrAres? Di Waar is An Se2? 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WIT Ue a eonate Komnig MoT Removed of CARKERE) @O Wow is esr stanksere Pasnc AvHERED TO THE SoRFACE, APART PROM Her ABPLUCATIONL 3. SITE COATING INSPECTOR - PRACTICAL Identify: Shot, grit, shov/grit mix, copper slag. Gnit blasted versus shot blasted surface. Grade of blast finish. Blue steel Surface profile needle gauge. Coked enamel ‘Tapes and similar: cold applied laminate, cold applied self-adhesive, hot applied, grease based, inner wrap, outer wrap, Rockguard. h. Buchholz indentor and microscope. Over/underheated epoxy samples. Contaminated epoxy coating, Spacers for reinforcement for concrete coatings. Comb gauge for measuring w.f.t moe aoge mee Assess pieces of enamel coating: Check inner wrap is not within 1 mm of inner surface Check for laminations, Check thickness. Check for holes. Check for disbonded outer wrap. Check for coking peacge Use or explain the use of: Banana gauge. Testex tape and dial micrometer. Holiday detector. Hygrometer and scale aege Assess situation photographs: PRIORITIES Practical Currently used and approved systems for coating on site. Application of coatings. Repair of damaged coatings. Surface preparation. Holiday detection. Relative humidity ‘and dew point. Cathodic protection. British Gas standard requirements. 10. Everything else! Cer anawee©laswe 1: Jan 96 : Rev Peo ower Corrosion General Theory - QP-E1 Define the term electrolyte. How does corrosion of steel occur? Is the corrosion circuit a.c. or d.c.? Where does corrosion occur - anode or cathode? Which three factors are required for a corrosion current to exist? Ina corrosion circuit, which way do electrons flow? Name four external factors which can accelerate corrosion, Which is more noble, steel or zinc? Which is more electro-negative, copper or steel? If steel and zinc were coupled in series, which metal would corrode? If magnesium and zine were coupled in series, which metal would corrode? When the potentials of metals are known, by what other name could we call the galvanic series? What is the approximate thickness of millscale? What are the three compounds which together form millscale? In which environments are chloride salts most likely to be found? In which environments are sulphate salts most likely to be found? Name three metals which could be used as galvanic anodes on a steel pipeline, Name the two hygroscopic salts commonly found on substrates. Which gas is released during ionisation at the cathode? What is polarization? © Ruane & TP ONeill owori96Issue 1 Jan °96: Revo Ruane & . Pe ONeill omar 9 10, Painting Inspection General Theory - Maths - QP-A1 What is the density of paint if 5 litres weighs 7.35 kg? What is the specific gravity of the paint in question 1? What is the paint’s SG if 25 litres weighs 33.5 kg? How much would 15.3 litres of paint weigh if its density is 1.60 g/cm?? A 2-pack paint is mixed at a ratio of 1:1. The base, part A, has a density of 1.48 e/em’, the curing agent, part B, has a density of 0.92 g/cm’, What will the combined density be? A 2-pack paint is mixed ata ratio 3 parts pack A (density 1.65 g/om:), to 1 part pack B (density 0.85 g/em?), What is the density of the combined parts? A 2-pack paint is mixed at a ratio 7 parts pack A (density 1.59 g/em®), to 1 part pack B (density 0.78 g/cm’), What is the density of the combined parts? A 2-pack paint has a density of 1.50 g/em?. The density of the base was 1.72 g/em’, the density of the activator was 0.85 g/cm’, The mixing ratio should have been 3:1. Has the paint been mixed in the correct proportions? A 2-pack paint has a density of 1.37 g/cm’. The density of the base was 1.62 g/cm’, the density of the activator was 0.95 g/cm’, The mixing ratio should have been 4:1. Has the paint been mixed in the correct proportions? What was the mixing ratio if a 2-pack paint has a density of 1.47 g/cm’. ‘The density of the base was 1.68 g/cm’, the density of the activator was 0.85 g/cm. What was the mixing ratio? © Ruane & TP O'Neil 801/96Ruane & Tesue 1: Jan 96 + Rev PEO Nel OPAzT Painting Inspection General Theory - Maths - QP-A2 10, ul 12, 14. 15. 18. 19. 20. ‘What was the volume solid content the paint if it was applied with a w.f. of 50 pm and a df. of 25 pm was obtained? What was the v.s.% of a paint with a d.ft. of 43 um, ifthe paint was originally applied with a 72. um w.ft.? What w.f.t. would be applied to leave a d.ft. of 140 pum using a paint with 58% volume solids? ‘What d.f.t. would result if a paint with 39% volume solids had a w-f.t. of 70 pm? What would be the w.ft. if 19 litres of paint was used to cover an area of 9 mx 9 m? ‘What d.f.t. would be obtained if a paint with 48% volume solids was applied 140 um thick What was the v.s.% of a paint if it was applied with a w-f.t. of 120 pm and a dt. of 72 um was obtained? What w.f.. would be applied to leave a d.£.. of 65 yim using a paint with 49% volume solids? What w.£., would be applied to leave a d.ft. of 138 um using a paint with 56% volume solids? ‘What was the w.f-t, if 24 litres of paint was used to cover a circular area of a 5 metre radius’? What would be the d.f.t,, if 15 litres of paint with a volume solids content of 44% covered an area of 12 mx 7m. What would be the d.f., if 14 litres of paint with a volume solids content of 49% covered an area of 14m x 8m? What volume of paint would be required to cover an area of 290 m’ if the volume solids content is 43% and a minimum d.f+. of 65 jum is specified? What volume of paint would be required to cover an area of 300 m?, if the volume solids content is 49% and a minimum df. of 70 jm is specified? ‘What would be the d.f.t,, if 3 gallons of paint with a volume solids content of 49% covered a cicular area 9 metres diameter? ‘What df. would be achieved if 4.5 gallons of paint is used to cover a circular area 14 m in diameter? The volume solid content of the paint is 43%, What d.f.t. would be achieved if 22 litres of paint is used to cover a circular area 23 yards in diameter? The volume solid content of the paint is 56%. How much paint would be required to paint the external surface of a 4m diameter circular cylinder standing 7 m in height? ‘The flat circular top of the cylinder must also be coated. The paint to be used is solvent free and the surface of the cylinder has been wire brushed. The d.f.t required is 130 um. What d.f-. would be achieved if 5.2 gallons of paint is used to cover a circular area 27.5 yards in diameter? The volume solid content of the paint is 67%. How many cubic centimetres are there in a gallon? © Ruane & TP ONeill M096Oo