NACE CIP Level 1 Study Guide

Define Corrosion - The deterioration of a substance, usually a metal from a reaction with its environment What is passivation? - A layer of oxides formed on the surface of a metal that provides corrosion protection. What is an example of passivation? - Stainless Steel What are the elements of a corrosion cell? - Anode, Cathode, Metallic Pathway, Electrolyte Describe what happens at the anode. - The metal dissolves into the electrolyte What is the function of the electrolyte? - Allows the passage of ions to connect the corrosion cell What is the function of the metallic pathway? - Allows the flow of electrons to connect the corrosion cell What is the galvanic series? - A listing of metals in order of reactivity (more or less noble) in seawater at 25 C The general rules of galvanic corrosion are: - The less noble (or more reactive) metal when connected to a more noble (or less reactive metal) will corrode preferentially Name the five most important factors that affect the rate of corrosion. - Humidity, oxygen, chemical salts, pollutants, temperature General corrosion is: - Results in a relatively uniform loss of material over the entire surface, Results in a general thinning of the affected surface, Relatively easy to inspect, Does not casue catastrophic failures Localized corrosion is: - Typically pitting and crevice corrosion. It is typically of the most concern as damage is concentrated and loss of integrity or structural failure can result. List some of the common tools/methods used for corrosion control. - Design, Inhibitors, Material Selection, Cathodic Protection, Protective Coatings, Splash Zone Systems, Alteration of the Environment How does NACE define the inspector's role? - The inspector's role is that of a quality control technician responsible for observing and reporting conformance or deviation from the project specification. What is the inspector's responsibility when it comes to safety on the project? - Safety enforcement is not the responsibility of the inspector; however, it is his/her responsibility to report any issues that may affect the project. Name some tests that may need to be conducted during surface preparation and coating operations. - Temperature, Relative Humidity, Dew Point, Anchor Profile, Surface Cleanliness Name some of the documentation/reports that may be required to be maintained on a coatings project. - Daily/weekly summary, material usage reports, manpower and equipment, non conformance, and conformance What are the most important characteristics of a good report? - Objective, Accurate, and Detailed. What is the inspector's primary responsibility and what should the inspector not do as it pertains to the specification. - The Inspector's primary responsibility as the inspector is to "enforce" specification. The inspector is NOT to make changes to the specification for any reason. What type of information could you expect to find on a Product Data Sheet? - Surface preparation and application information such as recommended level of surface cleanliness, recommended application methods and equipment such as tip sizes. Also, environmental parameters for application such as max and min temperatures, curing times, recoat windows. What type of information could you expect to find on a Safety Data Sheet? - Health, safety and environmental. The PPE required. Physical characteristics. Emergency responder information. Explain the difference between Quality Assurance (QA) and Quality Control (QC). - Quality Assurance - Any systematic process of checking to see whether a product or service being developed is meeting specs. Quality Control - A procedure or set of procedures intended to ensure that a manufactured product or performed service adheres to a defined set of quality criteria or meets the requirements of the client or customer Identify some of the defects that can be caused by incorrect application temperatures. - Failure to cure, too rapid solvent evaporation, poor film formation Describe relative humidity. - The amount of moisture in the air compared to saturation level What is the dew point temperature? - The temperature at which moisture will begin to form on a steel surface. Name some of the effects wind may have on a coatings project. - blowing abrasives, causing excessive drift or overspray, accelerating solvent evaporation, contributing to the formation of dry spray What are some of the common errors when using an electronic hygrometer? - Failure to acclimate the instrument to the environment with adequate time. Explain the process for use of the sling psychrometer. - Make sure the wick is wet and clean, continue to "sling" until 3 consecutive readings are achieved List three desirable properties of a coating? - Chemical Resistance, water resistance, ease of application, cohesive strength, impact resistance, dielectric strength Two broad classifications of a coating are: - Organic/Inorganic, Convertible/nonconvertible, thermosetting/thermoplastic What are the two primary components of a liquid applied coating? - Pigment, Vehicle (Resin or Binder) What are the three methods by which a coating provides corrosion control? - barrier, inhibitive, sacrificial What are the three different ways a coating can adhere to the surface? - Chemical, Mechanical, Polar, or combo of all three The two broad classifications for curing mechanisms are: - Convertible and Non- Convertible List two Non-convertible coating types: - Chlorinated rubber, vinyl List three convertible coating curing mechanisms - oxidation, co-reaction (polmerization), hydration, fusion List two characteristics of oxidation cure coatings - Not suitable for immersion service, not suitable for use over alkaline substrates, limited dry film thickness per coat List three coating types that cure by polymerization - epoxies, polyurethanes, polyureas, polyaspartics, polysiloxanies Induction time is: - the time required by the product data sheet (coatings manufacturer) between mixing the coating and the start of application What is the main requirement for a hydrolysis coating cure? - Moisture Industrial and marine coatings are commonly referred to by - generic resin type Oil based coatings applied over alkaline surfaces may result in - saponification List five of the formal sections usually contained in a good specification - scope of work, terms and definitions, pre-job conference, application, sampling coatings, inspection What are two of the inspector's responsibilities as it relates to the specification? - Enforce the specification, NOT to make changes to the specification During the surface preparation, surface cleanliness should be inspected (as a minimum) the following three times: - Before any surface preparation activities, after surface preparation - before coating begins, between each application of coating in a multi-coat system Factors during surface preparation that may effect service life include: - residues of oil, grease, and soil. rust on the surface. loose or broken mill scale. rust scale. anchor pattern. surface condensation. Common design defects include: - Hard to reach or inaccessible areas. rivets, bolts, or other connectors. welds. gaps. overlapping surfaces. threaded areas. dissimilar metals. construction aids Common fabrication defects include: - weld spatter, skip welds, sharp corners & Edges Four typical SSPC SP1 pre-cleaning methods include: - Solvent wipe with cloth or rag, immersion of the substrate in solvent, solvent spray, vapor degreasing, emulsion cleaining, chemical paint stripping, use of alkaline cleaners One standare for use with Power Tool Cleaning is: - ISO St2. ISO St3. SSPC SP-3. SSPC SP-11 Four examples of tools used for Power Tool Cleaning are: - rotary wire brushes, impact tools, needle scaler, disc sanders, piston scalers Two Abrasive Blasting methods include: - Centrifugal blasting, sand-injected water blast, slurry blast, wet abrasive blast, dry grit blasting Visual Standards for abrasive blasting include - SSPC-Vis 1, ISO 8501-1 SSPC SP 10/NACE 2 limits staining to ___ per each unit area - 5% SSPC SP 5/NACE 1 limits staining to ___ per each unit area - 0% SSPC SP 6/NACE 3 limits staining to ___ per each unit area - 33% The two types of abrasive blasting nozzles include: - Straight, Venturi The specified level of surface cleanliness must be achieved and maintained - immediately prior to coatings application Advantages of centrifugal blast equipment include: - Dust and fines are contained, abrasives are easily recycled, blasting and priming can be an inline operation, general overall economy compared to air blasting, no compressors, piping, or air handling equipment needed for wheel blasting