Course Objectives

 To recognise and identify the

benefits/disadvantages of paint systems.
 To understand the importance of surface
ATC 88 preparation.
BGAS Painting Grade 2/3  To understand methods of application and
testing.
 To understand paint system inspections.
 To interpret requirements of standards.
 To meet the syllabus requirements for the BGAS-
CSWIP Painting Inspector Examination.

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Course Times A cascade system of two grades:

Break Times/Prayer Times

 Grade one, offshore grade.
Smoking/Mobile Phones  Grade two, painting inspector.

Homework (every evening)

Course material

Practical equipment You must have grade 2 to obtain grade 1.

Queries

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Examination Details Practical Examination

Grade 2 Theory: 50 Multi Choice one and a half hours Abrasives: identification and uses.
allowed. Rust grade – identification.
Blast cleaning grade – identification.

Practical (Includes use of gauges etc) 50 multichoice, Hand and power tool grade – identification.
In two parts 25 questions Practical Theory and 25 Profile measurement: testex and needle gauge.
Practical).
Dry film thickness measurements.
One and a half hours allowed.
Identification of equipment.
This is a closed book exam. Use of whirling hygrometer and scales.
Paint fault identification.

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1
 Candidate Requirements Prior to
Course
Event enrolment form
PLEASE SEND A PHOTOCOPY WITH YOUR PAYMENT AND THE NECESSARY ENCLOSURES TO:
TWI Training & Examination Services
Pages to note: course text
Customer Services TWI North

2 x passport photographs:
Granta Park Aurora Court, Barton Road
Great Abington Riverside
Cambridge CBI 6AL OR Middlesbrough TS2 1RY

Page 23.1 to 23.13 (131-143) revision questions.

Tel.: +44 (0)1223 891162 Tel.: +44 (0)1642 210512
Fax. +44 (0)1223 891630 Fax: +44 (0)1642 252218
E-mail: trainexam@[Link] E-mail: twinorth@[Link]

(print name, and sign on the back)

Course bookings – please complete page 1
Course and Exam packages – please complete pages 1-3
Exam bookings – please complete pages 1-3

Page 23.14 to 23.16 (144-145) inspection calculations.

PLEASE USE CAPITAL LETTERS THROUGHOUT
Event ref _____________ Event date _________________________
Event title ________________________________________________
_________________________________________________________
Delegate’s first name (s)
_________________________________________________________

Page 23.16 (146) relative humidity/dew point calculations.

Delegate’s surname
_________________________________________________________

Date of birth (dd/mm/yy) _____________________________________

Completed event enrolment form

Permanent private address
_________________________________________________________
_________________________________________________________

Pages to note: pa10

_________________________________________________________
_________________________________________________________
_________________________ postcode ______________________
Private tel no_______________________________________________

Page 16, section 7 : application of paint.

E-mail____________________________________________________
Correspondence address (if different from above)
_________________________________________________________
_________________________________________________________

Confirmation of payment details

_________________________________________________________
Invoice/Sponsor address (if different from Employer address)
_________________________________________________________
_________________________________________________________
Page 21, table spa 1e : preferred systems.
Employer name and address
_________________________________________________________
0
_________________________________________________________
_________________________________________________________
_________________________ postcode ______________________
Page 27, table spa 3c : hot duty surfaces (above 340 c).
Contact name ______________________________________________
Telephone_________________________________________________
Fax ______________________________________________________

Page 28, table spa 4a : damp metal surfaces.

A valid eyesight test
E-mail____________________________________________________
Please tick if you are
 A member of The Welding & Joining Society
 An employee of an Industrial Member of TWI
 Member of Institute of Mechanical Engineers (for ATC65 course only)

Page 39, 40, 41 table spa 6a,b,c : non-ferrous surfaces.

Industry Sectors: (Please tick one only)
 Power Generation  Automotive
 Electronic  Oil, Gas & Petrochemical

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Corrosion (Section 1)
Electrical Circuit

A current flows from positive to negative, from

Defined as: anode to cathode, (+ to -).

The degradation of a material by chemical or The corrosion is caused by electrons travelling in

Electro-chemical means. exactly the opposite direction from cathode to
anode, (- to +).
Electro-chemically, implies 2 mechanisms:
The corrosion current is the ions returning to the
anode in the circuit.
 An electrical circuit, always dc.
 A chemical reaction, producing corrosion.

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Corrosion Theory

3 factors needed for corrosion to occur:

 Anode, a positively charged area.
 Cathode, a negatively charged area.
 Electrolyte, a substance which will conduct a
current and be broken down by it.

An electrolyte will dissociate into positive and

negative ions.

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2
 Where the electrons move to -ve, cathode
becomes the cathode,
negatively charged.

Where electrons move from

becomes the anode,
positively charged. +ve, anode
A corrosion cell – AKA a battery?

14
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=
Corrosion in a metal object,
such as a pipe for example. 1 micron 2 4600 atoms of iron

A negative area of metal -

-
(cathode) is connected to a -
- 26
PROTONS
positive area (anode) by the 1 electron +

pipe wall itself. As a result, -

electrons can flow from the Physical size of 1 electron
anode to the cathode. 1 proton = 1836 electrons
Iron atom = 26 electrons
Electrons travel at 18600 miles per + 26 protons
second! (1/10 speed of light). + 30 neutrons

15
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The Combustion Triangle What is Corrosion

Corrosion is like a
slow burning fire

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3
 The Corrosion Triangle

Cathode Electrolyte
Electrolyte

Anode Cathode
Shows electrical circuit
Anode
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Factors Accelerating Corrosion

Anodes corrode. The combination of

elements (oxidation) takes place at the
anode. Temperature
Cathodes are protected, hydrogen is  Steel is thermodynamically unstable.
evolved at the cathode as the electrolyte  As the steel heats up, it gains molecular
dissociates into positive and negative ions. freedom, becomes more active, and
undergoes corrosion more readily.

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Hygroscopic (Osmotic) Blisters Factors Accelerating Corrosion

Tiny, pin head size, Aerobic conditions, (presence of oxygen)

water filled blisters.
Caused by Introduce oxygen, double the ions,
hygroscopic salts (iron (twice the number of hydroxyl ions) which will
sulphates and iron passivate twice the number of iron ions at the
chlorides) grow into anode which will theoretically produce twice the
larger blisters causing corrosion!
dis-bondment.

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4
 Factors Accelerating Corrosion Microbial (Anaerobic) Corrosion

Microbial influenced corrosion (MIC)  Sulphate reducing bacteria (SRB) under anaerobic
(absence of oxygen) conditions produce hydrogen
Presence of some types of bacteria on the sulphide.
metal surface:
 SRBs can also form deposits that are linked to
 Sulphate reducing bacteria (SRB’s). under-deposit corrosion.

 Metal eating microbes (MEM’s).  Most aggressive conditions will exist in static
water or under deposits where SRBs are
protected from disturbance.

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FACTORS INFLUENCING CORROSION

4. BACTERIA ON THE SURFACE
SULPHUR REDUCING BACTERIA (S.R.B)
Thrive in oxygen free (or stagnant) areas. They remain dormant Affected units or equipment
until they find oxygen free sites. Hydrogen sulphide (acid)
producing bacteria, very active between 25-45°C. Rapid  Heat exchangers.
corrosion - often more than 5mm/year. Once established, bacteria  Bottom water of storage tanks.
colonies are very difficult to eradicate - they exist beneath slimes  Piping in contact with some soils.
and deposits where biocide has difficulty reaching them  Piping with stagnant or low flow.
 Systems where cooling water is not treated.
METAL EATING MICROBES (M.E.M)  Fire water systems.
Usually
Sulphate form small
Reducing holes in the direction
Bacteria of Corrosion
Microbial gravity, similar to
weld porosity
Severe internal microbial corrosion

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Factors Accelerating Corrosion Bi-metallic Corrosion

Acids and alkalies  When 2 different metals are in direct contact or

joined by a conductive wire, in an environment
 Acids and alkalies are both electrolytic. where an electrolyte is present, one of the metals
will corrode.
 They both dissociate into ions.
 The metal which will corrode is dependent on its
position in the galvanic list.
For example;
 The position in the list determines which metal
HCl, Hydrochloric acid becomes the anode, and the distance between
them determines the electrical potential and rate of
NaOH, Sodium hydroxide (alkalide)
corrosion.

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5
 The Galvanic List

MATERIAL POTENTIAL

Graphite + 0.25 v
Titanium - 0.0 v
Silver - 0.1 v
Nickel - 0.15 v
Lead - 0.2 v
Admiralty Brass - 0.3 v
Copper - 0.3 v
Tin - 0.35 v
Millscale - 0.4 v
Low Alloy Steel - 0.7 v
Mild Steel - 0.7 v
Aluminium Alloys - 0.9 v
Zinc - 1.0 v
Magnesium - 1.6 v
Carbon steel bolts in stainless steel pipework

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Bi-metallic Corrosion Calculations

Formulae
When the potentials of the metals are known, the
galvanic list can also be known as :

 The electro-motive forces series.

 The electro-chemical series. WFT
Solvent
V.S% DFT (% of WFT)

Note: both the position in the list and the free

potential can alter with a different electrolyte and Pigment and
temperature. Binder Extenders

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Calculations Volume Calculations

Example: what WFT would be required to provide a Example: how much paint would be required to
DFT of 85 µm, if the paint used was of 66% VS? cover an area of 500m2 to a DFT of 85µm, if the
paint used was of 66 % VS?

WFT= 100 x DFT 100 x 85 If volume = WFT x area

%VS 1 66 1 1000

128 microns = 128µm X 500m2 = 64 Litres

= 1.51 x 85 =
1000

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6
 Weather Conditions

Considerations
Tonight
 % Relative humidity (max 90%).
Go to page 23.14 in your course notes, and using
the formula on page 11.4, try the WFT, DFT and  Air temperature (dry bulb temperature).
VS% calculations.
 Steel temperature (>30C above dew point).
 Calculated dew point temperature.
 Manufacturers recommended minimum
application temperature (approx 50C typically).

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Whirling Hygrometer (Aspirated Whirling Hygrometer (Aspirated

Hygrometer) Hygrometer)
Is mercury in a continuous, unbroken stream?
Pre-use checklist
(If not, rectify with a magnet)
Does the hygrometer spin freely?
Is it clearly readable?
Is there a wick?
Is the wick clean?
Is the reservoir filled? (Distilled water) Is the wick wet, (must be distilled water)?
Is there a wick? Is the wick fastened around the bulb neck?
Is the wick clean? Is the mercury in a continual , unbroken stream?
Is the wick wet?
If not , rectify by pulling back with a magnet.
Is the wick fastened around bulb?

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WHIRLING OR ASPIRATED Weather Conditions - Dew Point

HYGROMETER Calculations

Rotate as fast as possible for 30 - 40 seconds

(4 metres /sec minimum). Example: Dew point
Line Up Temp Readings

Wet bulb reading taken immediately. 0

Dry bulb = 15 c
Dew Point
0
Wet bulb = 10 c
Face towards any breeze. If not, walk forward to 0
Align 10 c wet (red)
create an airflow. 0
With 15 c dry (black)
Test conducted as close to the area of painting as Read DP temp inside
possible. the eliptical window
0
2 consecutive readings within 0.2 c of each other. opposite the wet bulb
0
temp (DP = 5.5 c)

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7
 Dew Point Calculator Weather Conditions: Definitions

To determine % Relative humidity (RH)

Read %RH here
relative humidity
Defined as:
0
Dry bulb 15 c
0 The amount of water vapour in the air, expressed as
Dew point 5.5 c
a percentage (%) of the amount of water vapour
which could be in the air at that same temperature.

Read RH% from Dew point (DP)

Line up
Dp and dry bulb
tip of black arrow, Defined as:
Temperatures in the small
elliptical window. The temperature at which water vapour in the air will
condense.

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Measuring Steel Temperatures Surface Preparation (Section 2)

Limpet Gauge Thermocouple

Why prepare a surface?
Magnetic contact Electronic contact
wait 15 Min’s before reading Immediate reading  To remove contaminants and provide a surface
to which the paint will readily adhere.
 This will effectively provide a longer service life
from the coating.

Two factors for consideration

 Degree Of Cleanliness.
 Degree of roughness or surface profile.

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Surface Preparation by Dry Abrasive

Blasting

Surface Profile Some surface defects may be revealed

after surface cleaning.
The height of the surface profile is determined by:
 Size of Abrasive.
 Velocity of Abrasive.
 Hardness of Abrasive.
 Density of Abrasive.
 Angle of Impingement.

Surface Surface Surface

cracks breaking pitting
laminations

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8
 Surface Preparation Methods Dry Abrasive Blasting

 Dry abrasive blast cleaning.

 Wet blasting.  Abrasives.

 Hand and power tool cleaning.  Profile and adhesion.

 Flame cleaning.  Profile measurement and assessment.

 Pickling (chemical cleaning).  Rust grades and degree of cleanliness.

 Vapour degreasing.  Equipment.

 Weathering.

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Dry Abrasive Blasting: Abrasives Dry Abrasive Blasting: Abrasives

Copper slag.
Expendable. Most
commonly used site Contaminated
abrasive. copper slag.
Must only be used once, Must not be re-used.
as it shatters upon
impact.
It is non-metallic.

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The Danger of Sand Used as an

Dry Abrasive Blasting: Abrasives
Abrasive
SI 1657: Statutory Instrument (LAW) more than 1%
free silica (upon impact) is banned.
Garnet.
This information is normally found on COSHH or
This is a mineral. material safety data sheets.
It can be either Causes: silicosis and pneumonicosis
expendable, or can be
re-cycled, but must be Chronic obstructive pulmonary disorders, caused by
cleaned before re-use. breathing dust from a variety of minerals, (coal,
copper, sand etc).
They cause airflow blockage and breathing
difficulties, resulting in serious illness, disability and
death.

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9
 Dry Abrasive Blasting: Abrasives Dry Abrasive Blasting: Abrasives

Metallic shot Metallic grit and shot mix.

Used in enclosed Mixing ratio depends on

systems, needs to be spec. As does the particle
cleansed before re- sizes. Used in enclosed
use. Gradually wears systems.
down cycle by cycle. Grit cuts the profile, shot
controls the peaks.

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Dry Abrasive Blasting: Abrasives

Blasting chamber
Metallic grit. with under-floor
abrasive recovery
Must be recycled for system.
economic reasons.
Not used for site
work, and it must be Allows recycling of
cleansed before re- abrasive grit/shot
use. for economic
reasons.

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Dry Abrasive Blasting: Abrasives Dry Abrasive Blasting: Abrasives

Particle size distribution: sieves to BS 410

Walnut shell
Agricultural by-
product, not used
on steel.
As with other
abrasives, it is
available in various
particle sizes.

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10
 Sizing of Abrasives Adhesion

Defined as:
 G = grit. Irregular shape, sharp edges which The force required to separate two surfaces in
gradually become blunted after many cycles of use. contact.
Stress relieves surface.

 S = Shot, Spherical shape, work hardens. There are two theories of adhesion;
 Molecular interference: a physical method (for
 There are various systems relating to size: example: Velcro).

 The SAE, using the J 444 sieve system.  Molecular attraction: a chemical method (for
 BS 7079 Part E, particle size distribution. example: a Magnet).

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Profile Irregularities Surface Damage

Prolonged blasting in one

area produces rogue peaks
Blasting can deform a
Sliver into an upright
shard of metal called a
Hackle. < 13mm approx. size

A rogue peak is an isolated peak of excessive

amplitude, rectified by abrasion with emery paper Lamination Surface Breaking Lamination, or Sliver
or similar.
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Profile Measurement:
Laminations
Surface Profile Needle Gauge

Gauge must be calibrated

to zero on a flat, smooth
glass plate, set to zero,
and lock the bezel in
place.

It can not be used on

curved surfaces, such as
pipes.

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11
 Surface Profile Assessment
Surface Profile Measurement:
Surface Comparator to BS 7079 Pt C, ISO
Dial Micrometer and Surface Replica Tape
8503

Shot blast comparator.

Not used for surface
cleanliness.
Only for assessment of
shot blasted substrates.
Grit blast comparator can
also be used on substrates
blasted with grit/shot mix.

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Rust Grades Rust Grades

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Blast Cleaning Grades (BS EN 7079

Blasting Grades A Sa 2.5 and Sa 3
Part A)

Please note: as closely adherent mill scale can not

be removed with light blast cleaning, or even
thorough blast cleaning:

There are no grade A Sa1 or Sa 2 photographs! In

BS 7079 Part A.

However we do have:

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12
 Blasting Grades B Sa 1 and Sa 2 Blasting Grades B Sa 2.5 and Sa 3

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Blasting Grades, Comparisons Blasting Grades C Sa 1 and Sa 2

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Blasting Grades C Sa 2.5 and Sa 3 Blasting Grades D Sa 1 and Sa 2

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13
 Blasting Grades D Sa 2.5 and Sa 3

SCREEN TEST ONE

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Question 1 Question 2

Two examples of hygroscopic salts would be:

What is an electrolyte?
 Iron phosphates and iron chromates.
 Iron chlorates and iron oxides.  It is a mixture of salts and water.
 Iron sulphates and iron chlorides.  A substance which will conduct electricity and
cause rusting.
 Iron sulphides and iron silicates.
 Oxidising liquid which will attack steel.
 A substance which will conduct a current and
be broken down by it.

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Question 3 Question 4

Corrosion is defined as: Hydrogen is evolved at:

 Rusting of the Cathode by electro physical  The anode at all times.

means.  The cathode as corrosion takes place.
 Oxidation of a metal in contact with water.  The cathode in the form of hydrogen gas.
 Degradation of a material by chemical or  The anode as corrosion takes place.
electrochemical means.
 Breakdown of the metal by hydrogen.

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14
 Question 5 Question 6

Which blasting grade best describes thorough What is the minimum standard of surface
Blast cleaning? cleanliness specified by SPA1a of BGC/PS/PA
10?
 Sa 2.
 Sa 2½.  Rust Grade C.
 Sa 3.  St 3.
 Sa 1.  Sa 2½.
 30 to 75 microns.

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Question 7 Question 8

In a corrosion circuit, electrons flow from: Rust grade A can be described as:

 Anode to cathode, via electrolyte.

 Positive to negative.  Tightly adhering mill scale, with evident heavy
 Electrolyte to steel. pitting.
 Cathode to anode, via electrolyte.  Clean white metal.
 Tightly adhering mill scale, with no apparent
corrosion.
 Mill scale which has begun to flake, or can be
scraped away.

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Question 9 Question 10

Abrasive used on site for British Gas projects Which is the more noble metal:
must be:
 Steel.
 Mixed with sand, to reduce cost.  Aluminium.
 Dried in an oven prior to use.  Magnesium.
 Expendable.  Tin.
 Used up to a maximum of three times only.

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15
 Question 11 Question 12

Mill scale is made up of which three oxide Two factors to be considered when inspecting a
compounds? surface preparation, are:

 Rust, iron oxide, and scale.  Cleanliness and roughness.

 RSJ, RSC, and RSA.  Rust grade and material type.
 Wustite, magnetite, and haematite.  Abrasive type and time.
 Iron sulphate, iron chloride, and iron  Surface area and type of contamination.
phosphate.

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Question 13 Question 14

The Galvanic List is also known as:

Which of the following is Rust Grade C?
 The metallic corrosion potential chart.
 The electromotive forces series.  Tightly adhering mill scale which can be
 The element forces order. brushed clean.
 The electronic chemical series.  Loosely adhering mill scale with no evident
pitting.
 Mill scale almost totally removed, visible rust,
no heavy pitting.
 Heavy pitting clearly visible, heavy corrosion.

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Question 15 Question 16

The thickness of mill scale is approximately:

At the beginning of the corrosion process the
iron atom changes it’s polarity from:  25μm to 100μm.
  100 to 150μm.
 Neutral to positive.  Zero.
 Neutral to negative.  Dependant upon the material thickness.
 Positive to negative.
 Positive to neutral.

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16
 Question 17 Question 18

The force required to separate two surfaces in Blasting in one area for too long, produces what?
contact, can also be termed:
 Hackles.
 Viscosity.  Rogue Peaks.
 Profile.  Slivers.
 Adhesion.  Laminations.
 Blasting.

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Question 19 Question 20

Metallic shot also has which affect upon the What is the main cause of flash rusting on a
material? substrate?

 Stress relieves.  Rogue peaks.

 Physically deforms.  Oxygen.
 Work hardens.  Hackles.
 Causes Slivers.  Hygroscopic salts.

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Question 21 Question 22

What is the main advantage of using Testex Which of the following could be classified as a
papers for surface profile measurement? major cause of microbial corrosion:

 It also measures cleanliness.  Sulphur eating metal.

 Most accurate over a large area.  Sulphur reducing bacteria.
 Easy to use.  Rust inhibitive salts.
 Permanent record.  Iron phosphates.

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17
 Question 23
Question 24

Three factors which accelerate the rate of How many abrasive blast cleaning photographs
corrosion are: are in BS 7079 part A?

 Temperature, time, and coating system.  4.

 Bi-metallic contact, hygroscopic salts, and  14.
bacteria.  8.
 Coating system, pipe diameter, and ultra  16.
violet light.
 blasting grades, rust grades, and surface
profile.

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Question 25

British Gas PA 10 specifies a surface profile of:

Swap your papers please
 30 microns to 75 microns.
 100 microns to 150 microns.
 10 microns to 40 microns.
 more than 90 microns. Put your name on your paper,
and pass it to someone else to check.

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Question 1 Question 2

Two examples of Hygroscopic Salts would be: What is an electrolyte?

a. Iron phosphates and iron chromates. a. It is a mixture of salts and water.

b. Iron chlorates and iron oxides. b. A substance which will conduct electricity and
c. Iron sulphates and iron chlorides. cause rusting.
d. Iron sulphides and iron silicates. c. Oxidising liquid which will attack steel.
d. A substance which will conduct a current and
be broken down by it.

Answer: C
Answer: D

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18
 Question 3 Question 4

Corrosion is defined as: Hydrogen is evolved at:

a. Rusting of the cathode by electrophysical a. The anode at all times.

means. b. The cathode as corrosion takes place.
b. Oxidation of a metal in contact with water. c. The cathode in the form of hydrogen gas.
c. Degradation of a material by chemical or d. The anode as corrosion takes place.
electrochemical means.
d. Breakdown of the metal by hydrogen.

Answer: C Answer: C

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Question 5 Question 6

Which blasting grade best describes thorough What is the minimum standard of surface
blast cleaning? cleanliness specified by SPA1 of BGC/PS/PA 10?

a. Sa 2. a. Rust Grade C.
b. Sa 2½. b. St 3.
c. Sa 3. c. Sa 2½.
d. Sa 1. d. 30 to 75 microns.

Answer: C
Answer: A

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Question 7 Question 8

In a corrosion circuit, electrons flow from: Rust grade A can be described as:

a. Anode to cathode, via electrolyte. a. Tightly adhering mill scale, with evident
b. Positive to negative. heavy pitting.
c. Electrolyte to steel. b. Clean white metal.
d. Cathode to anode, via electrolyte. c. Tightly adhering mill scale, with no apparent
corrosion.
d. Mill scale which has begun to flake, or can be
scraped away.

Answer: D
Answer: C

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19
 Question 9 Question 10

Abrasive used on site for British Gas projects Which is the more noble metal:
must be:
a. Steel.
a. Mixed with sand, to reduce cost. b. Aluminium.
b. Dried in an oven prior to use. c. Magnesium.
c. Expendable. d. Tin.
d. Used up to a maximum of three times only.

Answer: D
Answer: C

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Question 11 Question 12

Mill scale is made up of which three oxide Two factors to be considered when inspecting a
compounds? Surface Preparation, are:

a. Rust, iron oxide, and scale. a. Cleanliness and roughness.

b. RSJ, RSC, and RSA. b. Rust grade and material type.
c. Wustite, magnetite, and haematite. c. Abrasive type and time.
d. Iron sulphate, iron chloride, and iron d. Surface area and type of contamination.
phosphate.

Answer: A
Answer: C

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Question 13 Question 14

The galvanic list is also known as: Which of the following is Rust Grade C?

a. The metallic corrosion potential chart. a. Tightly adhering mill scale which can be
b. The electromotive forces series. brushed clean.
c. The element forces order. b. Loosely adhering mill scale with no evident
d. The electronic chemical series. pitting.
c. Mill scale almost totally removed, visible rust,
no heavy pitting.
d. Heavy pitting clearly visible, heavy corrosion.

Answer: B
Answer: C

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20
 Question 15 Question 16

At the beginning of the corrosion process the The thickness of mill scale is approximately:
iron atom changes it’s polarity from:
a. 25μm to 100μm.
a. Neutral to positive. b. 100 to 150μm.
b. Neutral to negative. c. Zero.
c. Positive to negative. d. Dependant upon the material thickness.
d. Positive to neutral.

Answer: A Answer: A

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Question 17 Question 18

The force required to separate two surfaces in Blasting in one area for too long, produces what?
contact can also be termed:
a. Hackles.
a. Viscosity. b. Rogue Peaks.
b. Profile. c. Slivers.
c. Adhesion. d. Laminations.
d. Blasting.

Answer: C Answer: B

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Question 19 Question 20

Metallic shot also has which affect upon the What is the main cause of flash rusting on a
material? substrate?

a. Stress relieves. a. Rogue peaks.

b. Physically deforms. b. Oxygen.
c. Work hardens. c. Hackles.
d. Causes Slivers. d. Hygroscopic salts.

Answer: C Answer: A

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21
 Question 21 Question 22

What is the main advantage of using Testex Which of the following could be classified as a
papers for surface profile measurement? major cause of microbial corrosion:

a. It also measures cleanliness. a. Sulphate eating metal.

b. Most accurate over a large area. b. Sulphate reducing bacteria.
c. Easy to us. c. Rust inhibitive salts.
d. Permanent record. d. Iron phosphates.

Answer: D Answer: B

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Question 23 Question 24

Three factors which accelerate the rate of How many Abrasive Blast Cleaning photographs
corrosion are: are in BS 7079 part A?

a. Temperature, time, and coating system. a. 4.

b. Bi-metallic contact, hygroscopic salts, and b. 14.
bacteria. c. 8.
c. Coating system, pipe diameter, and ultra d. 16.
violet light.
d. Blasting grades, rust grades, and surface
profile.
Answer: B

Answer: B
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Question 25

British Gas PA 10 specifies a surface profile of:

a. 30 microns to 75 microns.
b. 100 microns to 150 microns.
c. 10 microns to 40 microns.
d. More than 90 microns.

Answer: A

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22
 Wheelabrators (Centrifugal Blast
Units)

Abrasive Particle
Speed 220 Mph

Series Of Drums
Rotating At 2600
Rpm
ATC 88
BGAS Painting Grade 2/3

100% Surface
Coverage

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Wheelabrators or Centrifugal Blast Automatic Blasting Machines

Units Wheelabrators
 Operate at approx. 2600 RPM.
 Totally enclosed (good operator safety).
 Automatic chain driven roller feed.
 Varying number of operating wheels.
 Gravity fed abrasive (re-usable).
 Airwash cleansing system for abrasives.
 Preferred abrasive is metallic shot.

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Centrifugal Blasting Chamber Dry Abrasive Blasting Equipment

 COMPRESSORS pressure rating in psi capacity in cfm.

 BACK PRESSURE AT NOZZLE hypodermic needle
gauge.
 VAPOUR TRAPS, knock-out pots (removal of oil and
water from air stream).
 PRESSURISED BLAST POTS of suitable capacity.
 CARBON IMPREGNATED HOSES, to reduce static shock.
 NOZZLES, Venturi (450 mph) and Straight bore (200
mph).
 SAFETY TO IGE SR 21 (Institute of Gas Engineers :
Safety Regulations).

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1
 Typical Set-up of a Dry
Abrasive Blasting Operation
Internal view of VENTURI NOZZLE increases speed of
Pressurised abrasive from 200 mph to 450 mph.
blast pot
Compressor
Carbon
Vapour traps
impregnated
(knock out pots)
reinforced hose

Whiplash
prevention
cables
External bayonet
type couplings
Blasting nozzle

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Blasting Safety

Typical portable site Carbon impregnated hose.

blasting machines.
Hose must have external,
Bayonet type couplings,
Reccova valve, fitted to
with whiplash restraints.
other end of air lines to
dead man handle.

Exhaust beware! Air Filter

(breathing air not
supplied directly
from compressor).

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Blasting Safety

Carbon impregnated hose

whiplash cables air-fed
helmet protective visor
leather apron dead man’s
handle gauntlets.

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2
 Bayonet Type (Chicago) Couplings Dead Man’s Handle

Blasting nozzle Air Connection

trigger which
must be under
Fail Safe Trigger
the direct
control of the
operator.

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Measuring Blast Pressure at the Wet Blasting: Methods

Nozzle
 High pressure pure water blasting
Hypodermic needle gauge <30,000psi.
 High pressure water plus abrasive injection.
Method  Low pressure water plus abrasive injection.
Alert the operator.  Steam cleaning.
Shut off abrasive.
 Air blasting with water injection.
Insert the needle
through the hose, with
the needle towards the
nozzle, at an angle of
approximately 45
degrees.

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Ultra High Pressure Water Jetting, Wet Blasting

>30,000 PSI

Abrasive blasting with water injected in to the

UHP Water Jetting Low Pressure abrasive stream at the blasting nozzle
(above 30,000 psi) water cleaning

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3
 Hand and Power Tool Cleaning, (BS
7079 Pt A)
Steam Cleaning Hand and power wire brushes, chipping
High Pressure Water
hammers, needle guns, emery cloth.
Jetting – up to
30,000 psi
St 2 Thorough hand and power tool cleaning.

St 3 Very thorough hand and power tool

cleaning.

Note: because millscale is harder than the brush

bristles, (phosphor bronze / beryllium bronze).
There is no standard for rust grade A!

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Jason’s Hammer and a Needle Gun Surface Preparation

Hand and power tool cleaning B St 2 and St 3.

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Surface Preparation
Surface Preparation

Hand and power tool cleaning C St 2 and St 3. Hand and power tool cleaning D St 2 and St 3.

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4
 Flame Cleaning

 Pickling is acid bath followed by washing.

1 EXPANSION, co-efficient of expansion.
 Footner’s Duplex system.
2 DEHYDRATION, moisture is evaporated.
 Pickling followed by passivation.
3 HEAT PENETRATION, heat conducted into substrate.  Passivation is treatment in phosphoric or
chromic acid, which passivates the steel by
forming a layer of rust- inhibitive salts which
also aid adhesion and provide resistance to
cathodic disbondment.

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Surface Preparation, Chemical

Footner’s Duplex System
Cleaning
 Remove oil and grease and check using UVA
lamp (contamination shows up yellow/green).
PH indicator papers,
 Immerse in 5-10% sulphuric acid, 5-25 mins
used to measure
@ 65-700C.
acidity or alkalinity of
 Rinse in clean water. the substrate after
 Immerse in 2% Phosphoric/chromic acid, with final wash.
0.5% iron filings, 1-2 mins @ 800C.
For BGAS the pH
 Rinse in clean water.
should be between
 Check ph level between 4.5 and 7.0. 4.5 and 7.

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Surface Contaminants and Tests Surface Contaminants and Tests

(Section 3) (Section 3)
 Soluble chlorides: silver nitrate test.
Hygroscopic salts : potassium ferricyanide, (now called
potassium hexacyanoferrate)  Mill scale: copper sulphate (only for Sa 3
grade).
 Oil or grease: solvent (not aliphatic) or U/V
LAMP.
 Moisture: talcum or chalk.
 Dust: sellotape.

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5
 Quantitative Tests for Hygroscopic
Salts

Merkoquant test Bresle sample patch

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Salts Detection, Bresle Sample Patch

Paint Technology (Section 4)
Kit
 There are 3 main groups of paint:
 Paints containing solvents.
 Solvent free multi-pack, (MCL’s)
 Powder paints.

All have the same basic constituents:

 Binder (film former, non-volatile, vehicle).

 Solvent.
 Pigments and other additives.

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Binder properties

Ease of application to: Binders used in Other binders (non BGAS)

 Give adhesion to the substrate. National Grid (BGAS)
specifications
 Provide resistance to abrasion.
 Acrylics.
 Provide chemical resistance.  Cellulose resins.
 Alkyds.
 Provide cohesive strength.  Chlorinated rubber.
 Epoxies.
 Provide dialectric strength.  Emulsions.
 Ethyl and methyl
 Resist the passage of water.  Natural oils and resins.
silicates.
 Change from a liquid into a solid.  Phenolic resins.
 Polyurethane
 Styrene and vinyl.
 Hold the pigments in suspension.  silicones

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6
 Oils Resins

Natural oils are produced from the seeds of a plant. Natural resins are from the main plant, tree
trunk). Resins are naturally brittle and fast
Examples: drying, therefore need modification. This is
done by addition of oils.
Linseed, soya, olive, coconut, tung, castor.
Natural resins are Copals and Dammars and
These oils must combine with oxygen, therefore must Coumarones, Amber and Laq. Other resins
be unsaturated. such as frankincense and myrrh are more
A saturated oil already has enough oxygen bonds, valued for their perfume qualities.
and will not solidify and form a film.

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Oils Oil Paints

Drying Oils LONG OIL PAINT more than 60% Oil to Resin.
Three sets of double bonds along a carbon backbone,
react readily in ambient conditions. (unsaturated oils). Elastic and slower drying, mainly used in domestic
applications (decorative materials).
Semi-drying Oils
One or two sets of double bonds, not as reactive as MEDIUM OIL PAINT between 45% and 60% Oil to
drying oils. Need a catalyst (heat) to start Resin.
polymerisation.
SHORT OIL PAINT less than 45% Oil to Resin.
Non-drying Oils (saturated oils)
Cannot be used as binders, will not polymerise, no Faster drying, suitable for steelwork. More brittle,
activity points. They are used as plasticisers, to give with shorter over-coating time.
flexibility and ease application. Modifies the film
A mixture of oil and resin = oleoresinous.
properties.

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Binder - Solvent Combinations Binder - Solvent Compatability

WATER
Vinyls, acrylics, epoxies, alkyds, bitumens,  Compatibility for over-coating.
polyurethanes, acrylated rubbers.  Correct solvent group for binder.
WHITE SPIRIT  Flashpoint and toxicity considerations.
Natural oils, natural resins, alkyds, phenolics.

XYLENE
Chlorinated rubber.

ACETONE
Epoxy.

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7
 Solvents Solvents

Strong solvents for strong binders. Solvent strength: its ability to dissolve the binder.
Weaker solvents for weaker binders.

The stronger solvents have a low number of Evaporation rate: controls polymerisation and
carbon atoms in the chemical formula. drying.

Flash point: safety factor of the solvent.

The higher the number of carbon atoms, the
higher the boiling point of the solvent,
Toxicity: safety levels of exposure.

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Polymers

A string or structure of repeated units

Polymers are 3
Linear Polymer dimensional in
Pre formed, reversible, very sensitive to some HC Linear the dry paint film.
solvents, thermoplastic. Also called solution polymer.
Branched polymer Branched
Oxidation drying, non-reversible. Natural oils and
resins , become very brittle with age.
Crosslinked polymer
Cross
Chemically curing, very strong, multi-directional
Linked
polymerisation, examples: epoxies, urethanes and
polyurethanes.

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Pigments Pigments

Animal, vegetable, mineral, or synthetic. Anti-corrosive: rust inhibitive properties.

Particle size varies from 1/ th micron to average size

10 Metallic: work sacrificially.
of 1 micron.
Opaque: inert, provide opacity and colour.
Contribute to cohesive strength, abrasion resistance,
durability, opacity and in some instances, Extenders: add bulk, reduce cost.
impermeability, and resistance to u/v rays.
Laminar: provide impermeability.
Pigments must not dissolve in the vehicle.

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8
 Anti-corrosive (Rust Inhibitive) Metallic Pigments
Pigments
Primer Colour Also used to protect the substrate by cathodic
Red lead (basic) protection.
(natural oils and resins) Toxic Red
Calcium plumbate Toxic Material must be below steel in the galvanic list.
White
Coal Tar Toxic Black Two most commonly used are :
Zinc Chromate Toxic Yellow

Zinc phosphate most common Purple/Grey  ZINC (better for galvanic protection).
 ALUMINIUM (excellent ultra-violet reflective
Barium Metaborate. properties).
Zinc Phosphosilicate.

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Opaque Pigments Extender Pigments

Inert particles which have excellent light Low priced, readily available materials, also known as
scattering properties in order to give covering fillers. They add bulk, improve intercoat adhesion,
(opacity) and colour. increase cohesive strength, and give extra thickness
to paint film at low cost.
 CARBON Black
 COBALT Blue  CLAYS Kaolin , China Clay (White)
 CHROMIUM Greens/Yellows/Oranges  CHALK Calcium Carbonate (White)
 IRON Browns/Reds/Yellows  TALCUM Magnesium Silicate (White)
 CALCIUM Reds/Yellows  SLATE FLOUR Aluminium Silicate (Dark Grey)
 TITANIUM DIOXIDE White

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Laminar pigments Laminar Pigments

Plate-like pigments which provide impermeability.
In theory, they have a leafing effect, overlapping as
the coating dries.
Common laminar pigments:
 Graphite.
 Glass flake. Standard Pigment Mio Theoretical
 Aluminium flake (ultra-violet reflective).
 Micaceous Iron Oxide (Mio) (ultra-violet reflective).
Attributes of Mio:
UV A and B reflection, retards permeation, Delaminated Mio
durability, provides adhesion to next layer.

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9
 Critical Pigment Volume
Concentration (CPVC) Other Additives

Anti-settling agents:
 Aids to shelf life.

Plasticisers:
 Reduce brittleness, aid application, improves
flexibility.
Below CPVC Near CPVC Above CPVC
Driers:
 Allow even through drying of oxidising films.
Poor opacity, high gloss, blistering
Good opacity, cohesive strength, gloss, impermeability, Anti-skinning agents:
Porous, low cohesive strength, poor adhesion  Retard the formation of surface skins.
Pigment/binder ratio can vary from paint to paint.

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Solutions and Dispersions

Solutions and Dispersions
(Section 5)
Dispersion: a solid or a liquid within another liquid,
where there is no solubility.
SOLVENT: Will dissolve another material.
There are two types of dispersion
SOLUTE: Is dissolved in the solvent
1 Suspension: fine particulate solids dispersed
SOLUTION: The resultant liquid produced by within a liquid, no solubility.
dissolving a solute in a solvent. Example: Sand + Water
EXAMPLE: 2 Emulsion: a liquid dispersed within another liquid
where there is no solubility.
Solvent + solute = solution
Example: Oil + Water
Would be sugar + water = sweet water

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Drying and curing of Paint Films Drying and Curing of Paint Films
(Section 6)

Solvent evaporation Oxidation

 No chemical reaction.  Uses atmospheric oxygen.

 Polymers are preformed and saturated.  Oxygen chemically combines with unsaturated
double bonds.
 Linear polymers closed at the ends by hydrogen
and have no double bonds.  Process can be accelerated by addition of driers.

 Also called reversible or non-convertible.  Also called convertible or non-reversible.

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10
 Drying and Curing of Paint Films Curing Agents Used in 2-pack
Epoxies
Chemical curing AMIDES: Fully cured in 7 days at 20°C.

Must be mixed in the correct ratio (2 pack). AMINES: Fully cured in 3 days at 20°C.
Pot life (period after opening and mixing where the
paint remains in a usable condition). ISOCYANATES: Suitable for use where low
Induction period (stand time, to allow for wetting of temperatures are unavoidable, fully cured in 16
particles and crosslinking to begin). hours at 20°c.
In 1984, at the union carbide plant in bhopal, india,
These must be observed and controlled! water was accidentally released into a methyl
 Convertible or non-reversible. isocyanate storage tank, resulting in 7000 fatalities.
 Chemically cross-linking polymers. Very toxic, CO2 is produced when applied in damp
conditions. Great care needed during use and
removal!
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Drying and Curing of Paint Films:

Coalescence

High boiling point solvents

penetrate the spheres and
Solvent Evaporation fuse the binder globules,
creating a solid film
Screen Test Two

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Question 1 Question 1

Which of the following is Rust Grade C? When using a Venturi Nozzle at 100psi, the
abrasive exits at approximately what speed?
a. Tightly adhering mill scale which can be
brushed clean. a. 200 mph.
b. Loosely adhering mill scale with no evident b. 450 mph.
pitting. c. 1200 mph.
c. Mill scale almost totally removed, visible rust, d. 100 mph.
no heavy pitting.
d. Heavy pitting clearly visible, heavy corrosion.

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11
 Question 2 Question 3

The optimum pressure to achieve 100% Sand is not permitted as a dry blast abrasive, as
efficiency in abrasive blast cleaning is? directed by:

a. 75 psi. a. BGC/PS/PA10.
b. 450 psi. b. BS 7079 Part A.
c. 100 psi. c. COSHH.
d. 220 psi. d. BS 410.

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Question 4 Question 5

How many times can garnet be used as an The correct ratio of a working mix would be:
abrasive for BGAS site use?
a. 70-80% Grit: 20-30% Shot.
a. Up to 3 times, if cleaning of abrasive is b. 50% Grit: 50% Shot.
possible. c. 70-80% Shot: 20-30% Grit.
b. None. d. 20-25% Sand:75-80% Copper Slag.
c. As per the specification.
d. 20 times.

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Question 6 Question 7

Flame cleaning uses which mechanisms? Carbon Impregnated hoses are used to:

a. Expansion, decontamination, and force. a. Create static electricity.

b. Oxidation, penetration, and de-lamination. b. Prevent static electricity.
c. Heat penetration, expansion, and c. Reduce friction.
dehydration. d. Reduce static electricity.
d. Oxidation, weathering, and pressurisation.

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12
 Question 8 Question 9

One of the most important safety items of What is the approximate speed of the abrasive
equipment in abrasive blasting is: particles exiting a wheelabrator?

a. Dry abrasive mix. a. 450 mph.

b. The banana gauge. b. 220 mph.
c. Dead mans handle. c. Mach 3.
d. 100 psi compressor. d. 100 psi.

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Question 10 Question 11

Where would you normally use a comparator Amplitude refers to what?

gauge?
a. The peak-to-trough height of a blast profile.
a. To check surface cleanliness. b. The amount of noise a blasting operation
b. To determine surface roughness. creates.
c. To control cleaning of abrasives. c. The velocity of the abrasive particles.
d. To assess the rust grade of a material. d. The roughness of an abrasive particle.

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Question 12 Question 13

What is the material used in surface replica tape, What is the cause of rash rusting?
used to measure profile?
a. Oxygen.
a. Miler. b. Rogue peaks.
b. Testrex. c. Hackles.
c. Mylar. d. Hygroscopic salts.
d. Mylon.

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13
 Question 14 Question 15

The test for the presence of hygroscopic salts, How many photographs of flame cleaning
is: standards are shown in BS 7079 Part A?

a. Potassium hexacyanoferrate test. a. 4.

b. Copper sulphate test. b. 14.
c. Iron phosphate test. c. 8.
d. Iron chromate test. d. 16.

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Question 16 Question 17

Which abrasive has the effect of stress relieving Where would it be advisable to use steel grit as
the substrate? an abrasive?

a. Copper slag. a. When a deep profile is required.

b. Metallic shot. b. On high pressure pipework.
c. Steel grit. c. In enclosed blasting units.
d. Garnet. d. On offshore installations.

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Question 18 Question 19

What is the minimum number of readings Which test would be used to determine for
required for a Dial Micrometer? soluble salts in a marine environment?

a. Minimum of 10. a. Potassium hexacyanoferrate.

b. Minimum of 12. b. Copper sulphate.
c. One only. c. Iron phosphate.
d. As many as you wish, but the average d. Silver nitrate.
reading is recorded.

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14
 Question 20 Question 21

The standard for the test sieves used for the The most common type of abrasive used for
sizing of abrasives is: BGAS site work is:

a. BS 7079 part A. a. Copper slag.

b. BS 410. b. Grit and shot mix.
c. BGC/PS/PA10. c. Garnet.
d. SI 1657. d. Metallic shot.

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Question 22 Question 23

Compared to a venturi nozzle, a straight bore Anchor pattern, key, peak-to-trough, are names
nozzle would give: given to what?

a. Better paint application. a. The abrasive properties.

b. More speed. b. The cross section of a blast.
c. Larger area coverage. c. The total area of blasted substrate.
d. Greater accuracy. d. The potential of adhesion.

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Question 24 Question 25

What is a knock out pot? High pressure wet blasting operates up to which
pressure?
a. A drum used for mixing paint and thinners.
b. The area on the equipment where static a. 100 psi.
electricity can build up and be hazardous. b. 450 psi.
c. A vessel for removing oil and moisture from c. 30,000 psi.
the air stream. d. 2,250 mph.
d. A container where any blockages of the
nozzle can be tapped free.

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15
 Question 1

When using a Venturi Nozzle at 100psi, the

abrasive exits at approximately what speed?

SWAP YOUR PAPERS PLEASE a. 200 mph.

b. 450 mph.
Put your name on your paper,
c. 1200 mph.
and pass it to someone else to d. 100 mph.
check

Answer: B

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Question 2 Question 3

The optimum pressure to achieve 100% Sand is not permitted as a dry blast abrasive, as
efficiency in abrasive blast cleaning is? directed by:

a. 75 psi. a. BGC/PS/PA10.
b. 450 psi. b. BS 7079 Part A.
c. 100 psi. c. COSHH.
d. 220 psi. d. BS 410.

Answer: C Answer: C

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Question 4 Question 5

How many times can garnet be used as an The correct ratio of a working mix would be:
abrasive for BGAS site use?
a. 70-80% Grit: 20-30% Shot.
a. Up to 3 times, if cleaning of abrasive is b. 50% Grit: 50% Shot.
possible. c. 70-80% Shot: 20-30% Grit.
b. None. d. 20-25% Sand: 75-80% Copper Slag.
c. As per the specification.
d. 20 times.

Answer: C
Answer: B

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16
 Question 6 Question 7

Flame cleaning uses which mechanisms? Carbon Impregnated hoses are used to:

a. Expansion, decontamination, and force. a. Create static electricity.

b. Oxidation, penetration, and de-lamination. b. Prevent static electricity.
c. Heat penetration, expansion, and c. Reduce friction.
dehydration. d. Reduce static electricity.
d. Oxidation, weathering, and pressurisation.

Answer: C Answer: D

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Question 8 Question 9

One of the most important safety items of What is the approximate speed of the abrasive
equipment in abrasive blasting is: particles exiting a wheelabrator?

a. Dry abrasive mix. a. 450 mph.

b. The banana gauge. b. 220 mph.
c. Dead mans handle. c. Mach 3.
d. 100 psi compressor. d. 100 psi.

Answer: C Answer: B

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Question 10 Question 11

Where would you normally use a comparator Amplitude refers to what?

gauge?
a. The peak-to-trough height of a blast profile.
a. To check surface cleanliness. b. The amount of noise a blasting operation
b. To determine surface roughness. creates.
c. To control cleaning of abrasives. c. The velocity of the abrasive particles.
d. To assess the rust grade of a material. d. The roughness of an abrasive particle.

Answer: B Answer: A

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17
 Question 12 Question 13

What is the material used in surface replica tape, What is the cause of rash rusting?
used to measure profile?
a. Oxygen.
a. Miler. b. Rogue peaks.
b. Testrex. c. Hackles.
c. Mylar. d. Hygroscopic salts.
d. Mylon.

Answer: C Answer: B

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Question 14 Question 15

The test for the presence of hygroscopic salts, How many photographs of flame cleaning
is: standards are shown in BS 7079 Part A?

a. Potassium hexacyanoferrate test. a. 4.

b. Copper sulphate test. b. 14.
c. Iron phosphate test. c. 8.
d. Iron chromate test. d. 16.

Answer: A Answer: A

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Question 16 Question 17

Which abrasive has the effect of stress relieving Where would it be advisable to use steel grit as
the substrate? an abrasive?

a. Copper slag. a. When a deep profile is required.

b. Metallic shot. b. On high pressure pipework.
c. Steel grit. c. In enclosed blasting units.
d. Garnet. d. On offshore installations.

Answer: C
Answer: C

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18
 Question 18 Question 19

What is the minimum number of readings Which test would be used to determine for
required for a Dial Micrometer? soluble salts in a marine environment?

a. Minimum of 10. a. Potassium hexacyanoferrate.

b. Minimum of 12. b. Copper sulphate.
c. One only. c. Iron phosphate.
d. As many as you wish, but the average d. Silver nitrate.
reading is recorded.

Answer: C Answer: D

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Question 20 Question 21

The standard for the test sieves used for the The most common type of abrasive used for
sizing of abrasives is: BGAS site work is:

a. BS 7079 part A. a. Copper slag.

b. BS 410. b. Grit and shot mix.
c. BGC/PS/PA10. c. Garnet.
d. SI 1657. d. Metallic shot.

Answer: B Answer: A

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Question 22 Question 23

Compared to a venturi nozzle, a straight bore Anchor pattern, key, peak-to-trough, are names
nozzle would give: given to what?

a. Better paint application. a. The abrasive properties.

b. More speed. b. The cross section of a blast.
c. Larger area coverage. c. The total area of blasted substrate.
d. Greater accuracy. d. The potential of adhesion.

Answer: D Answer: B

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19
 Question 24 Question 25

What is a knock out pot? High pressure wet blasting operates up to which
pressure?
a. A drum used for mixing paint and thinners.
b. The area on the equipment where static a. 100 psi.
electricity can build up and be hazardous. b. 450 psi.
c. A vessel for removing oil and moisture from c. 30,000 psi.
the air stream. d. 2,250 mph.
d. A container where any blockages of the
nozzle can be tapped free.

Answer: C
Answer: C

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Question 1

Which of the following is not a drying

mechanism?

a. Coalescence.
Screen Test Three b. Oxidation.
c. Stove drying.
d. Chemical curing.

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Question 2 Question 3

A solution is: Which of the following is a natural oil?

a. The resultant liquid in a polymerisation event. a. Dammar.

b. The resultant liquid after dispersing a solid. b. Alkyd.
c. The resultant liquid after dissolving a material c. Castor
in another liquid. d. Xylene.
d. The resultant liquid after dispersing a liquid in
another liquid.

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20
 Question 4 Question 5

Which of the following are said to be reversible? Which of the following are quantitative tests?

a. Cross-linked polymer. a. Potassium hexacyanoferrate.

b. Branched polymer. b. Copper sulphate.
c. Linear polymer. c. Silver nitrate test.
d. Convertible coating. d. Bresle sample patch.

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Question 6 Question 7

A whirling hygrometer is also called a : What is the meaning of compliant?

a. Pfund cryptometer. a. In accordance with PA 10.

b. A psychrometer. b. In accordance with Environmental Protection
c. A pyknometer. Act.
d. A rotational viscometer. c. As per engineers instructions.
d. As per manufacturers recommendations.

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Question 8 Question 9

What is the recommended stand-off distance A typical remedy for burnishing would be:
and speed at which the abrasive leaves a Venturi
Nozzle? a. Power brushing.
b. Emery paper or similar.
a. 450 mm and 220 mph. c. Needle gun.
b. 220 mm and 450 mph. d. Addition of thinners.
c. 220 mm and 220 mph.
d. 450 mm and 450 mph.

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21
 Question 10 Question 11

Which of the following is part of the Footners Which of the following is not a natural resin?
Duplex System?
a. Copal.
a. 1-2% sulphuric acid @ 65-800c for 5-25 b. Amber.
mins. c. Dammar.
b. 5-10% sulphuric acid @ 70-800c for 5-10 d. Linseed.
mins.
c. 5-10% sulphuric acid @ 65-700c for 5-25
mins.
d. 5-10% chromic/phosphoric acid @ 65-700c
for 1-2 mins.

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Question 12 Question 13

Which of the following is not a natural oil? Which of the following is an extender?

a. Castor. a. Graphite.
b. Amber. b. Mica.
c. Olive. c. Glass Flake.
d. Linseed. d. China Clay.

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Question 14 Question 15

Which of the following is an opaque pigment? Which of the following is an additive?

a. Graphite. a. Opaque pigments.

b. Compound of hromium. b. Rust inhibitive pigments.
c. Zirconium octoate. c. Thickening agents.
d. Zinc phosphate. d. Thinners.

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22
 Question 16 Question 17

What is the specified minimum standard of Which of the following binders are reversible?
cleanliness required by BGAS for non-ferrous
substrates? a. Epoxy.
b. Urethane.
a. Sa 2 ½. c. Chlorinated rubber.
b. Sa 3. d. Silicone.
c. St 1.
d. Sa 1.

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Question 18 Question 19

What is the maximum allowable time lapse Which of the following is not a commonly used
between surface preparation, and painting? binder?

a. 24 hours. a. Epoxy.
b. 4 hours. b. Zinc.
c. 20-30 minutes. c. Urethane.
d. 7 days. d. Vinyl.

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Question 20 Question 21

Wire brushes used for BGAS hand and power Using the correct calibration shim, a banana
tool cleaning, must be made from which gauge can be calibrated on:
material?
a. Bare steel.
a. Tungsten or stainless steel. b. Painted surfaces.
b. Copper or brass. c. Steel with a blast cleaned surface.
c. Beryllium bronze or phosphor bronze. d. Any metal surface.
d. The same material as the pipe.

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23
 Question 22 Question 23

Which of the following are commonly used as A paint drying by chemical reaction is said to be:
anti-settling agents?
a. Linear polymer.
a. Heavy metal salts. b. Convertible.
b. Bentones and waxes. c. Non-convertible.
c. Saturated oils. d. Reversible.
d. Extender pigments.

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Question 24 Question 25

Which of the following is not a laminar pigment? Which two materials are commonly used as
sacrificial anodes?
a. Graphite.
b. Glass flake. a. Copper and tungsten .
c. Magnesium silicate. b. Aluminium and graphite.
d. Mica. c. Zinc and aluminium.
d. Lead and tin.

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Question 1

Swap your papers please Which of the following is not a drying mechanism?

a. Coalescence.
b. Oxidation.
Put your name on your c. Stove drying.
paper, and pass it to d. Chemical curing.
someone else to check.
Answer: C

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24
 Question 2 Question 3

A solution is: Which of the following is a natural oil?

a. The resultant liquid in a polymerisation event. a. Dammar.

b. The resultant liquid after dispersing a solid. b. Alkyd.
c. The resultant liquid after dissolving a material c. Castor
in another liquid. d. Xylene.
d. The resultant liquid after dispersing a liquid in
another liquid.
Answer: C
Answer: C

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Question 4 Question 5

Which of the following are said to be reversible? Which of the following are quantitative tests?

a. Cross-linked polymer. a. Potassium hexacyanoferrate.

b. Branched polymer. b. Copper sulphate.
c. Linear polymer. c. Silver nitrate test.
d. Convertible coating. d. Bresle sample patch.

Answer: C Answer: D

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Question 6 Question 7

A whirling hygrometer is also called a : What is the meaning of compliant?

a. Pfund cryptometer. a. In accordance with PA 10.

b. A psychrometer. b. In accordance with Environmental Protection Act.
c. A pyknometer. c. As per engineers instructions.
d. A rotational viscometer. d. As per manufacturers recommendations.

Answer: B Answer: B

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25
 Question 8 Question 9

What is the recommended stand-off distance A typical remedy for burnishing would be:
and speed at which the abrasive leaves a
Venturi Nozzle? a. Power brushing.
b. Emery paper or similar.
a. 450 mm and 220 mph. c. Needle gun.
b. 220 mm and 450 mph. d. Addition of thinners.
c. 220 mm and 220 mph.
d. 450 mm and 450 mph.

Answer: B
Answer: D

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Question 10 Question 11

Which of the following is part of the Footners Duplex Which of the following is not a natural resin?
System?
a. Copal.
0
a. 1-2% sulphuric acid @ 65-80 c for 5-25 mins. b. Amber.
0
b. 5-10% sulphuric acid @ 70-80 c for 5-10 mins. c. Dammar.
0
c. 5-10% sulphuric acid @ 65-70 c for 5-25 mins. d. Linseed.
0
d. 5-10% chromic/phosphoric acid @ 65-70 c for 1-
2 mins.

Answer: D
Answer: C

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Question 12 Question 13

Which of the following is not a natural oil? Which of the following is an extender?

a. Castor. a. Graphite.
b. Amber. b. Mica.
c. Olive. c. Glass Flake.
d. Linseed. d. China Clay.

Answer: B Answer: D

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26
 Question 14 Question 15

Which of the following is an opaque pigment? Which of the following is an additive?

a. Graphite. a. Opaque pigments.

b. Compound of Chromium. b. Rust inhibitive pigments.
c. Zirconium octoate. c. Thickening agents.
d. Zinc phosphate. d. Thinners.

Answer: B
Answer: C

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Question 16 Question 17

What is the specified minimum standard of Which of the following binders are reversible?
cleanliness required by BGAS for non-ferrous
substrates? a. Epoxy.
½
b. Urethane.
a. Sa 2 . c. Chlorinated rubber.
b. Sa 3. d. Silicone.
c. St 1.
d. Sa 1.
Answer: C
Answer: D

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Question 18 Question 19

What is the maximum allowable time lapse between Which of the following is not a commonly used
surface preparation, and painting? binder?

a. 24 hours. a. Epoxy.
b. 4 hours. b. Zinc.
c. 20-30 minutes. c. Urethane.
d. 7 days. d. Vinyl.

Answer: B
Answer: B

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27
 Question 20 Question 21

Wire brushes used for BGAS hand and power Using the correct calibration shim, a banana
tool cleaning, must be made from which gauge can be calibrated on:
material?
a. Bare steel.
a. Tungsten or stainless steel. b. Painted surfaces.
b. Copper or brass. c. Steel with a blast cleaned surface.
c. Beryllium bronze or phosphor bronze. d. Any metal surface.
d. The same material as the pipe.
Answer: C
Answer: C

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Question 22 Question 23

Which of the following are commonly used A paint drying by chemical reaction is said to be:
as anti-settling agents?
a. Linear polymer.
a. Heavy metal salts. b. Convertible.
b. Bentones and waxes. c. Non-convertible.
c. Saturated oils. d. Reversible.
d. Extender pigments.

Answer: B Answer: B

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Question 24 Question 25

Which two materials are commonly used as

Which of the following is not a laminar pigment? sacrificial anodes?

a. Graphite. a. Copper and tungsten .

b. Glass flake. b. Aluminium and graphite.
c. Magnesium silicate. c. Zinc and aluminium.
d. Mica. d. Lead and tin.

Answer: C Answer: C

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28
 Paint Systems
(Single or Multilayer)

Primer: anti corrosive to protect the steel.

Mio: protects primer, provides impermeability.

ATC 88 Mid coat or build coat: protects underlying coating,

BGAS Painting Grade 2/3 builds thickness, and provides good adhesion for
subsequent layer.

Finish coat: aesthetic , correct colour, provide a

smooth surface to allow cleaning and shedding
of water.

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Primers Midcoat or Build Coat

Rust inhibitive pigments passivate the substrate.

Mordant or wash primers (t-wash), acid reaction

with the substrate produces inhibitive salts. No
measurable thickness.

Etchant primers, (polyvinyl butyral) similar

Reaction but leaves a measurable thickness of 15-
25 um. Extender particles increase surface area to
provide adhesion for any subsequent layer.

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Finish Coat

Mainly aesthetic, but have other properties. Moisture tolerant:- moisture has no appreciable ill
effect.
Moisture curing polyurethane:- uses water vapour
Gloss finish, to assist in shedding water.
from the atmosphere to cure, damp or moist, but not
wet.
Solar reflective (white), heat absorbent (black). Low RH is a problem (min 35%).
Damp: no signs of water, but temperature is below
dew point.
Moist: no standing water, but a noticeable film of
water.
Wet: droplets or standing water are present
Moisture sensitive: moisture reacts with the
isocyanates to produce carbon dioxide.

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1
 Paint Systems Paint Systems

Sacrificial systems
Powder Coatings
 Thermoplastic or thermosetting.
 Most commonly thermosetting, needs heat. Zinc

Steel
 Convertible coatings chemically cured.
 Usually electrostatically applied.
Particles in close contact The zinc acts as a barrier,
 Thin plate ,heat applied after powder. allow electron circuit and corrodes in its own
when an electrolyte right until there is coating
 Thicker plate, heat applied before powder.
enters the film. damage and both metals
are exposed to
electrolyte. Zinc oxides
are formed, and repairs
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Waterborne Coatings (Section 8) Paint Manufacture (Section 9)

Use water instead of hydrocarbon solvents. 1. Ball Mill

Most binders now available water borne.
Steel balls rotate in cylinder,
Environmentally friendly, cheap, and
grind mill base to required
compatible with any binder.
particle size (5000 - 40000 lts).
Many coats can be applied in a day.
Disadvantages include smaller application window,
storage conditions and weather.
Coatings used on BGAS contracts must be compliant.
A compliant coating is one which complies with the
requirements of the environmental protection act
1991.
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Paint Manufacture (Section 9) Paint Manufacture (Section 9)

2. Attritor Mill
3. High speed disperser

Upright static cylinder, A 2500 rpm blender, produces mill base.

the steel balls are
moved by motorised (see Figure 9.2 in course notes for picture of a high
paddles. speed disperser).

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2
 Paint Manufacture (Section 9) Paint Manufacture (Section 9)

4. Kady Mill (another type is silverson mill) . 5. Sand Mill (pearl mill or bead mill).
Mill base injected at bottom, forced through sand,
For the manufacture of emulsions and waterborne refined, removed at top. Water cooled.
paints.

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13

Paint Manufacture (Section 9) Paint Manufacture (Section 9)

Sand Mills
6. Colloid Mill
(High speed stone
mill)

Vertical or horizontal

2 stone discs (approx 10” dia) bottom disc rotates at

3600 rpm. Base is gravity fed to centre of discs.
Ground by centrifugal force and friction.

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Paint Manufacture (Section 9) Paint Manufacture (Section 9)

7. Triple Roll Mill

8. Single Roll Mill
Used to produce
Used to produce small batches of expensive materials
mastics, fillers and
(gilts, silvers etc.)
putties. 3 rolls travel at
different speeds, paste
sticks to faster of rolls.

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3
 Testing of Paints for Properties and Paint Testing
Performance (Section 10)
BS 3900 Methods of test for paint. Determination of volatile/non-volatile
BGC PS PA9 Table 2 : RESULTS REQUIRED BY
BGAS. Procedure:
1. Clean glass plate and rod is weighed.
2. Add 2g of paint, and weigh again.
Tests subdivided into: 3. Place into hot air oven (or hot plate).
 Tests on wet materials. 4. Stir paint to evaporate solvent (volatile).
 Tests on dry materials.
Note: No naked flame!

When dry, weigh glass plate to determine ratio of

volatile/non-volatile.

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Paint Testing Flash Point of Solvents

Flash Point Abel closed cup

Test carried out in accordance with BS 3900 part A8

using abel cup.

Defined as: the temperature at which vapour from a

solvent will ignite in the presence of an external
source of ignition.

High flashpoint is safer than a low flashpoint.

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Paint Testing

The density cup is used to check for addition of

The density (SG) Cup thinners, or the correct mix ratio of 2 pack paints.
Caused by
PART A PART B Mixing Site test Data sheet
too much
(Base) (Catalyst) Ratio result says
of PART
1.35 0.95 6:1 1.29 1.35 A
1.28 0.80 6:1 1.21 1.40 A
1.40 0.79 1.27 1.20 B
4:1
1.19 0.75 5:1 1.11 1.39 A
1.22 0.80 7:1 1.16 1.08 B
1.50 0.82 4:1 1.36 1.16 B
Pyknometer, SG cup, weight per litre, weight per gallon.

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4
 Paint Testing Hegman Grind Gauge

Hegman grind gauge Particles submerged by scraper bar.

For fineness of grind, degree of dispersion.

Particles protrude through the film if they are too

large to be submerged. The surface changes from
gloss to matt, and where between 5 and 10
protrusions is noted, this is the degree of dispersion
or fineness of grind.
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Paint Testing Paint Testing

Viscosity

Defined as: Viscosity

A fluid’s resistance to flow. Krebs Stormer Viscometer
Rotational viscometer with Kinematic Viscosity.
rotothinner measures dynamic
viscosity. Driven by a falling weight,
Units = poises. the heavier the weight the
faster it rotates. Criteria
1 poise = The force required to 200 rpm units stoke or poise.
maintain unit velocity between 2
surfaces separated by 1cm of
fluid.

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Paint Testing

Flow Viscosity Ford flow cup in its retort Lid containing spirit level.
stand.
Ford flow cup showing the
4mm hole.

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5
 Paint Film Thicknesses (Section 11)

WFT measurement: Eccentric Wheel.

Ford flow cup in use. Must be used circumferentially on curved surfaces.

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WFT Measurement: Comb Gauges

Must be used longitudinally on curved surfaces. Last wet tooth First dry tooth

25 35 45 60

Steel

Comb gauge shows WFT reading of 35/45 um

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Destructive Test Gauges: The PIG Destructive Test Gauges: The PIG

Turn PIG 90deg. Light comes on - view graticule

scale through eyepiece. Tables in instruction book
give conversion factors for each blade, from
graticule units into microns.

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6
 Destructive Test Gauges: The PIG

Destructive test gauges. The Saberg test drill.

View through eyepiece
with graticule scale.
Tables in instruction
book give conversion
factors for each blade,
from graticule units to
microns.

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DFT Measurements, Magnetic Dry Film Thickness

Measurement, Magnetic
The banana gauge 211 Calibration shims
The tinsley pencil (foremans gauge)

Purple 25um
Blue 50um
Brown 125um
Scale moves to the curser White 250um
Yellow 500um

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DFT Measurements: Electronic

Gauges
Dry film thickness measurement, magnetic, horseshoe
gauge (used on TSA).
Electrophysic
Mini test The exacto Elcometer 456

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7
 Tests For Mechanical Properties Tests for Mechanical Properties
On Paint on Paint

Abrasion resistance
Impact resistance:
Sample plates are weighed, and placed beneath
abrasive discs for a number of cycles, then Tubular impact tester.
weighed again to determine abrasion 1kg weight dropped 1 metre onto the paint
resistance. surface of a test panel. Assessed for damage,
direct or indirect.

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Accelerated Testing,
Weatherometers

Flexibility test: conical mandrel 0

Humidity cabinets: 95% humidity and 55 C.
Test plate bent over 3mm to 37mm diameter
mandrel Salt spray cabinets: Salt laden environment.

Water soak test: Panel submerged, weighed.

Temperature cycling: hotter and colder than normal

operating temperatures.

Prohesion testing: (Protective adhesion) 3% salt

0
water spray @ 35 c, (60 min on : 60 min off) no
Check location where undercut, blisters etc. Beyond 3mm boundary, after
cracking begins test duration of 1000 hours.

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Drying and Curing Tests: Ballotini Drying and Curing Tests

Test
BK (Beck-koller) drying time recorders

Steel block
Hopper Glass plate
graduated in hours
containing inserted into
of travel
small glass front slot and the
beads stylus drawn
across.

Solvent evaporation
time, sol/gel
transition, surface
dry and final dry
times recorded.
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8
Mechanical Thumb Test, Through Wolff-Wilborn Pencil Scratch Test
Drying

Uses the pencil

hardness rating.

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Opacity: The Pfund Cryptometer Use Of The Pfund Cryptometer

1. View through the glass

prism.
2. Record the point where
the background can no
longer be seen.
3. This is the opacity
thickness.

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Hiding Power Charts and Gloss

Adjustable Applicator

Measured with a glossmeter (reflectometer)

Gloss can be affected by:

 Pigment volume concentration.

 Fineness of grind (particle size).
 Resin type.
 Refractive index.
 Solvent type.

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9
 Degree of Digital Gloss Meter (Reflectometer)
Gloss

Measures % of light
Received, from amount
of light transmitted

High Low > 80% = Gloss finish

< 80% = Matt finish
Air
Water
RI, stick appears to bend

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Adhesion Tests: Cross Cut

Adhesion Testing: V Cut Test
(Cross Hatch) Test

Cut v using craft

knife
Apply leverage

Insert blade tip

30 0

Cut 6 lines vertical and 6 lines horizontal,

creating 25 x 2mm squares.
Apply an agreed tape.
Testing for: primer to substrate failure, intercoat
Pull off and compare % area of detachment
adhesion failure and cohesive failure.
as per BS 3900 PT E6.

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Adhesion Tests The Dolly Test

Failure force
measured in Paint adhesion tester
Expendable psi on this dolly test
aluminium scale
dolly

Circular
cutter

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10
 Hydraulic Adhesion Test Equipment

Hand Operated Type

Re-usable dolly
(with scale of failure force
on view)

Units are: Mega- pascales

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Question 1

What is a pyknometer?

a. Opacity testing equipment.

Screen Test Four b.
c.
Whirling hygrometer.
Density cup.
d. Windspeed measuring equipment.

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Question 2 Question 3

What is the name of the mill used to Which of the following is not an adhesion test?
produce mastics, fillers, and putties?
a. Dolly test.
a. Triple roll mill. b. Cross hatch.
b. Ball mill. c. Krebs Stormer.
c. Single roll mill. d. HATE.
d. Bead mill.

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11
 Question 4 Question 5

What is the name given to the drying test

Which of the following is not a drying test?
involving the use of glass beads?
a. Koenig Albert.
a. Wolff wilborne.
b. Beck Koller.
b. Taber.
c. Mechanical Thumb.
c. Ballotini.
d. Ballotini.
d. Erichsson.

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Question 6 Question 7

What type of machinery is used to produce large A typical pot life of a paint used in BGAS
production runs of popular paints? specifications would be:

a. Triple roll mill. a. 20-30 minutes.

b. Colloid mill. b. 12-24 hours.
c. Kady mill. c. 6-8 hours.
d. Sand mill. d. 3-7 days.

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Question 8 Question 9

What is the specified temperature at which a

HATE is an abbreviation of what?
Flash Point Determination test must be carried
out?
a. High Adhesive Tension Equipment.
b. Humidity Affected Electrical Tolerance.
a. 200C.
c. Hydraulic Adhesion Test Equipment.
b. Up to 4500C.
d. Hardness and Temperature Evaluation.
c. There is no specific temperature.
d. 25 0C in seawater.

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12
 Question 10 Question 10

In paint testing, why is temperature cycling carried

out? Which of the following would not affect the degree
of gloss?
a. To check for water absorption.
b. To check flexibility. a. Surface profile.
c. To check contraction cracking. b. Critical Pigment Volume Concentration.
d. To prove the service life of the coating system. c. Solvent type.
d. Degree of dispersion.

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Question 12 Question 13

What is the name of the equipment used to

What diameter is the conical mandrel, which is determine particle aggregate size?
used in the flexibility test?
a. Beck-koller.
a. 8 mm to 25 mm.
b. 12mm to 18mm. b. Hegman gauge.
c. 5mm to 50mm. c. Wolfe-Wilborne.
d. 3mm to 37mm. d. Krebs-Stormer.

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Question 13 Question 14

Which specification covers the internal coating of

small bore steel pipes? What product should be used for repairs to pipe
coatings in damp conditions?
a. BGC PS PA 10.
b. BGC PS PA 9. a. Moisture sensitive isocyanates.
c. BGC PS PA 8. b. Water-borne acrylics.
d. BGC PS PA 7. c. Moisture curing polyurethane.
d. Chlorinated rubber.

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13
 Question 15 Question 16

What would be the correct course of action upon

discovering that the contractor has applied a coat
What surface preparation is specified in PA 10 for of paint, out of sequence?
weathered galvanised steel?
1 a. Blast and re-coat.
a. Sa 2 /2, followed by T-Wash mordant primer. b. Apply the correct coating over the top.
b. Sa 3, followed by etch primer. c. Inform the engineer.
c. Hand abrasion with a stiff bristled brush only. d. Add an extra protective coating.
d. Sa 1 followed by water washing.

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Question 17 Question 18

The function of a finish coat is mainly to What is the name of the vessel used to determine
provide: the viscosity of free flowing fluids, as per BGAS
specifications?
a. Impermeability and adhesion.
b. Aesthetic properties and water shedding. a. Ford Flow cup No 4.
c. Cathodic protection and passivation. b. Zahn cup.
d. Increased thickness at low cost. c. Abel cup.
d. Pyknometer.

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Question 19 Question 20

The BGas specified site painting conditions are:

Which of the following is not a test for contaminants? a. Maximum wind speed 4 m/sec, relative humidity
maximum 95%.
0
a. Sellotape. b. Maximum 90% relative humidity, dew point 3 C
b. Banana gauge. above steel.
0
c. Talcum powder. c. Maximum 90% relative humidity, dew point 3 C
d. Solvent. less than steel.
0
d. Maximum 27 C, relative humidity 95%
maximum.

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14
 Question 21 Question 22

Which test would be used to determine for soluble

salts in a marine environment? Which of the following is an extender pigment?

a. Potassium hexacyanoferrate. a. Magnesium silicate.

b. Sulphuric acid. b. Aluminium oxide.
c. Iron phosphate. c. Manganese napthanate.
d. Silver nitrate. d. Barium metaborate.

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Question 23 Question 24

With every 11 degree rise in temperature, the According to PA10, what is the correct course of action
air’s ability to hold water: upon discovering foreign bodies embedded in the paint
film?
a. Would rise by 11%.
b. Would half. a. Apply an extra protective barrier coat.
c. Would double. b. Re-blast and re-coat.
d. Would decrease by 11%. c. Lightly abrade with emery paper, apply stripe coat.
d. Make a report to the engineer only.

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Question 25

According to PA10, is the addition of Thinners Swap your papers please

allowed?

a. Yes, at the engineers discretion, up to 20% max.

b. Only if the paint is difficult to apply.
c. Yes, in accordance with the product data sheets. Put your name on your paper, and
d. No, under no circumstances. give it to someone else to check

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15
 Question 1 Question 2

What is a pyknometer? What is the name of the mill used to produce

mastics, fillers, and putties?
a. Opacity testing equipment.
b. Whirling hygrometer. a. Triple roll mill.
c. Density cup. b. Ball mill.
d. Windspeed measuring equipment. c. Single roll mill.
d. Bead mill.
Answer: C
Answer: A

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Question 3 Question 4

Which of the following is not an adhesion test? Which of the following is not a drying test?

a. Dolly test. a. Koenig Albert.

b. Cross hatch. b. Beck Koller.
c. Krebs Stormer. c. Mechanical Thumb.
d. HATE. d. Ballotini.

Answer: A
Answer: C

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Question 5 Question 6

What is the name given to the drying test What type of machinery is used to produce large
involving the use of glass beads? production runs of popular paints?

a. Wolff wilborne. a. Triple roll mill.

b. Taber. b. Colloid mill.
c. Ballotini. c. Kady mill.
d. Erichsson. d. Sand mill.

Answer: C
Answer: D

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16
 Question 7 Question 8

What is the specified temperature at which a

A typical pot life of a paint used in BGAS
Flash Point Determination test must be carried
specifications would be:
out?
a. 20-30 minutes.
a. 200C.
b. 12-24 hours.
b. Up to 4500C.
c. 6-8 hours.
c. There is no specific temperature.
d. 3-7 days.
d. 25 0C in seawater.

Answer: C Answer: C

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Question 9 Question 10

HATE is an abbreviation of what? In paint testing, why is temperature cycling carried

out?
a. High Adhesive Tension Equipment.
b. Humidity Affected Electrical Tolerance. a. To check for water absorption.
c. Hydraulic Adhesion Test Equipment. b. To check flexibility.
d. Hardness and Temperature Evaluation. c. To check contraction cracking.
d. To prove the service life of the coating system.

Answer: C Answer: C

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Question 11 Question 12

Which of the following would not affect the degree What diameter is the conical mandrel, which is
of gloss? used in the flexibility test?

a. Surface profile. a. 8 mm to 25 mm.

b. Critical Pigment Volume Concentration. b. 12mm to 18mm.
c. Solvent type. c. 5mm to 50mm.
d. Degree of dispersion. d. 3mm to 37mm.

Answer: A Answer: D

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17
 Question 13 Question 13

What is the name of the equipment used to

Which specification covers the internal coating of
determine particle aggregate size? small bore steel pipes?

a. Beck-koller. a. BGC PS PA 10.

b. Hegman gauge. b. BGC PS PA 9.
c. BGC PS PA 8.
c. Wolfe-Wilborne.
d. BGC PS PA 7.
d. Krebs-Stormer.

Answer: B Answer: C

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Question 14 Question 15

What product should be used for repairs to pipe What surface preparation is specified in PA 10 for
coatings in damp conditions? weathered galvanised steel?
1
a. Moisture sensitive isocyanates. a. Sa 2 /2, followed by T-Wash mordant primer.
b. Water-borne acrylics. b. Sa 3, followed by etch primer.
c. Moisture curing polyurethane. c. Hand abrasion with a stiff bristled brush only.
d. Chlorinated rubber. d. Sa 1 followed by water washing.

Answer: C Answer: C

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Question 17
Question 16

What would be the correct course of action upon

The function of a finish coat is mainly to
discovering that the contractor has applied a coat
provide:
of paint, out of sequence?
a. Impermeability and adhesion.
a. Blast and re-coat.
b. Aesthetic properties and water shedding.
b. Apply the correct coating over the top.
c. Cathodic protection and passivation.
c. Inform the engineer.
d. Increased thickness at low cost.
d. Add an extra protective coating.

Answer: C Answer: B

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18
 Question 18 Question 19

What is the name of the vessel used to determine

the viscosity of free flowing fluids, as per BGAS Which of the following is not a test for contaminants?
specifications?
a. Sellotape.
a. Ford Flow cup No 4. b. Banana gauge.
b. Zahn cup. c. Talcum powder.
c. Abel cup. d. Solvent.
d. Pyknometer.

Answer: A Answer: B

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Question 20
Question 21

The BGas specified site painting conditions are:

Which test would be used to determine for soluble
a. Maximum wind speed 4 m/sec, relative humidity salts in a marine environment?
maximum 95%.
0
b. Maximum 90% relative humidity, dew point 3 C a. Potassium hexacyanoferrate.
above steel. b. Sulphuric acid.
0
c. Maximum 90% relative humidity, dew point 3 C c. Iron phosphate.
less than steel. d. Silver nitrate.
0
d. Maximum 27 C, relative humidity 95%
maximum.
Answer: D
Answer: C

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Question 22 Question 23

Which of the following is an extender pigment? With every 11 degree rise in temperature, the
air’s ability to hold water:
a. Magnesium silicate.
b. Aluminium oxide. a. Would rise by 11%.
c. Manganese napthanate. b. Would half.
d. Barium metaborate. c. Would double.
d. Would decrease by 11%.

Answer: A Answer: C

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19
 Question 24 Question 25

According to PA10, what is the correct course of action According to PA10, is the addition of Thinners
upon discovering foreign bodies embedded in the paint allowed?
film?
a. Yes, at the engineers discretion, up to 20% max.
a. Apply an extra protective barrier coat. b. Only if the paint is difficult to apply.
b. Re-blast and re-coat. c. Yes, in accordance with the product data sheets.
c. Lightly abrade with emery paper, apply stripe coat. d. No, under no circumstances.
d. Make a report to the engineer only.

Answer: B Answer: C

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20
 Cathodic Protection: Sacrificial
System

ATC 88
BGAS Painting Grade 2/3 Zinc block
(anode)

Steel pipe
(cathode)

Must be in direct contact or joined by a conductive cable

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Cathodic Protection: Sacrificial Cathodic Protection:

System Impressed Current

Transformer /
rectifier
(negative) Positive
Sacrificial zinc connected connection
anodes to pipe to ground
There is no
bed (anode)
(Cathode) current/
electron flow if
the coating is in
good condition

When barrier coating of buried pipe is damaged,

corrosion circuit commences. (Electrons travel from
cathode to anode via the electrolyte)

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Impressed Current Transformer Cathodic Protection:

Rectifier Unit Monitoring Potentials

Copper/copper
sulphate half-cell
reference electrode

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1
 Pinhole/Holiday Detection:
Cathodic Disbondment Test
Sponge Detector

Voltage Range
9 to 90v. (Some have
only 2 settings)
intermediate 67.5v.
Sponge is wetted in
water with a drop of
detergent.
Excess squeezed out,
Test in progress Inspection on completion then passed over the
substrate.

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Holiday/Pinhole High Voltage Holiday Tester

Detection

Typical high voltage set for

pinhole detection. Operates Holiday Detection on
up to 15kv too high for cross-country pipeline.
Test springs now not allowed on BGAS projects
normal paint systems.

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Holiday Detection of Paint Application

Coated Pipe

Application methods
Contoured Brush

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2
 Conventional spray

Suction feed Gravity feed

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Paint application: Conventional Spray Paint Application: Airless Spray

Advantages Disadvantages Airless Spray

Gun
 Inexpensive nozzles.  Heavy hose lines.
 Good atomisation.  Operator fatigue.
 More Accuracy.  Specialised
 Less cleaning after containers.
use.  Slow application
 Better finish achieved. rates.
 Lower working
pressure.
 Concentrated spray
pattern. Portable Pump

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Paint Application: Airless

Spray

Air Circuit: Blue

Paint Circuit: Red

One Way Ball Valve

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3
 Paint Application: Airless Spray Paint Application: Electrostatic
Spraying

Advantages Disadvantages
Negatively charged
Spray gun component
 High deposition rates.  Poor atomisation.
 Can apply high viscosity  Expensive nozzles.
fluids.  Coatings limitations.
 Versatile (no air hose).  Increased maintenance.
 High transfer efficiency.  High skill required.
 Lower waste.  Increased safety risk
 Large area coverage.  (+ or - 3500 psi).
 Uses manufacturers paint  Lower quality finish. Positively charged particles
 containers.

Ionised air volume

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Paint A

Hot duty surfaces (> 340 0C)

Advantages Disadvantages (BGC/PS/PA10 PAGE 29 Table SPA 3c)

 High transfer efficiency.  Bulky, delicate guns.

 Requires extra Requires the highest grade of cleanliness:
 Good edge cover.
cleanliness. Profile 75um/Grade sa 3 (check for mill scale)
 Good wraparound.
 Uniform film thickness.  Fire/Safety hazard.
 Low wastage.  Component must be 1 Thermally sprayed aluminium.
conductive.
2 Inorganic zinc silicate.
 High maintenance
costs. 3 Polysiloxane inorganic coating.

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TSA: Thermally Wire and Pistol Type

Sprayed Aluminium TSA Applicator Gun

 The preferred system, giving longest life.

 Wire and pistol type (most common).
 High purity wire.
 Butane/propane and oxygen fuel gas.
 Propelled by compressed air onto substrate.
 Thickness approx 100 - 125 um. Wire feed
trigger

For high temperature service silicone sealer must

be applied.
Fuel gas Oxygen Compressed air

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4
 TSA: Thermally Visual Inspection
Sprayed Aluminium

Steel coated with TSA

Wire and Pistol Type

Steel blast cleaned to Sa 21/2 Loss of adhesion (poor surface

preparation)

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Paint, Faults and Bittiness

IZS: Inorganic Zinc Silicate

 Alternative to TSA. Inclusions, either
 Apply as per manufacturers recommendation. airborn or from the
paint itself.
 Apply silicone sealer.
Could also be caused
 Apply heat to cure sealant (turn the system on).
by partially cured paint,
Polysiloxane inorganic coating which is out of shelf
 Alternative to TSA and IZS. life.
0
 Will withstand temperatures up to 1100 c.
(Flocculation)
 Apply as per manufacturers recommendation.
Coating Faults: Blistering
 This is not sealed.

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Coating Faults:
Bleeding

Blisters can contain gas, liquid or crystals.

The solvent from the
top coat softens the
under lying material
and allows it to pass
into and through the
layer, causing
discolouration.
(Brown for bitumen,
yellow for coal tar).

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5
 Coating Faults: Chalking Coating Faults Cissing

Caused by
inadequate surface
Degradation of the
preparation.
binder due to disruptive
factors in the A difference in surface
environment energy causes local
lack of adhesion.

Epoxies are especially Larger spots known as

vulnerable. fish eyes and large
areas referred to as
crawling.

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Coating Faults: Cissing Coating Faults: Cracking

Mud cracking
Differential expansion and
coating age.

Crazing/hair cracking Crocodiling/alligatoring

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Coating Faults: Curtains,

Coating Faults: Cratering
Sags, Runs and Tears

Caused by over
application.
Bowl shaped depressions.
To remedy: remove
Caused by escaping solvent excess material, lightly
or gases. abrade and recoat.
High viscosity paint will
not flow to fill the
depressions. Resulting in
small bowls and craters.

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6
 Coating Faults: Flaking Coating Faults: Holidays

As material ages, it
gets brittle, cracks
and starts to Defined as :
detach.
A void, a miss, or an
Oxidising paints are uncoated area.
especially vulnerable.
(Natural oils and
resins).

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Coating Faults: Lifting Algae and Mould Growth

Caused by solvent strength and also lack of

observance of stated overcoating time.

Remedy: treat with biocidal agent for 24 hours, then

clean with detergent/stiff bristle brush/water washing.

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Orange Peel Coating Faults: Ropiness

Similar appearance
to the skin of
a citrus fruit. Brushmarks

Caused by brushing
Caused by paint when film is almost
viscosity problems dry, or when paint
or by applicator viscosity is too high.
technique.

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7
 Coating Faults: Wrinkling and Defect: Rash or Spot
Rivelling Rusting

Cause: rogue peaks, or

possibly by contamination
of the paint film by
foreign matter, such as
grit or dirt etc.

Paint forms a skin, trapping solvent below the surface. As this

eventually dries, the skin contracts, causing the surface to wrinkle.

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Colour BS 4800

Primary Colours: Red, Yellow and Blue Hue

The human eye operates on only these three pigments. Plus, From 00 (neutral) to 24 even numbers only.
other various colours can be created by combining to various
degrees. Brightness
From A (max white) to E (max black).
Colour has 3 main attributes
Hue Saturation
Refers to the basic colour (red, green, yellow, blue etc.) 01 to 56 Higher number = stronger colour.
Lower number= greyer the colour.
Brightness
The darkness or lightness of the colour.
Black and white, and all the grey colours in between, are
Saturation achromatic colours as they lack hue.
How vivid the colour appears (also known as chroma, intensity,
weight). Anything having colour is said to be chromatic.

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Colour: The Munsell System Ral System

(USA)
L= Luminance, chroma Yellow through green ,blue
a= From green to red Purple, red and back to System uses cards
b= From blue to yellow yellow containing 210 colours.

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8
 Product Identification by Pipe Colour
Pipe Colour Coding to BS 1710 (Section 13) Health and Safety

Uses BS 4800 to identify product COSSH Regulations

Product Named Colour BS 4800 APP. REF
(Control of substances hazardous to health )
Air Light Blue 20 E 51

Acids and Alkalies Violet 22 C 37

Gases (except Air)

Fluids
Yellow Ochre

Black
08 C 35

00 E 53
 Harmful or Irritant Corrosive
Toxic or Very Toxic
Fresh Water Auxiliary Blue 18 E 53

Water Green 12 D 51

Electrical Services Orange 06 E 51

Hazard warning symbols.
Min/Vegetable/Animal Brown 06 C 34
Oils, Combustible liquids

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Health And Safety: (COSHH

Hazard Warning Symbols Regulations)
Abbreviations

EH 40 HSE guidance notes: list of all known harmful substances.

OEL Occupational exposure limit ( there are 2 types).

MEL Maximum exposure limit must never be exceeded! The

Explosive Oxidizing Extremely Highly maximum exposure to airborne substance over a reference
period.
flammable flammable OES Occupational exposure standard
The concentration level of an airborne substance (averaged over a
Can be found on safety data reference period) which is considered safe to be exposed to, day after
sheets and on the paint tin label. day (ppm).

RAQ Required air quantity

Dangerous for
HASAWA Health and safety at work act (1974)
the environment

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Protective Masks Health And Safety: Drager Tube and

Bellows

Dust only! Solvents

Each depression of the bellows draws 100 cc of air

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9
 Drager Tube and Bellows Duties of a Painting Inspector

To test the air quality when using solvents. Ensure that all work is carried out in accordance
with the specification requirements.
Varying crystal types for different solvents.

Example: Xylene (OEL: 100 ppm)

No deviation from specification unless permission
given in writing from a higher authority, ie clients
Raq: 500 cc (5 depressions). engineer.
Crystals will change colour, (white to red/brown).
Toxicity levels read from the scale on the tube. Report any deviation from specifications.
Especially malpractices.

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Visual Inspection Report Writing

Blast cleaned surfaces:

All information requested on a report sheet should be
Slivers, hackles, laminations, cracks, pitting.
completed.

Wet paint films: The information provides traceability in the event of

Runs, sags, cissing, uneven coverage. any future breakdown.

Good reports and documentation are essential to

Dry paint films:
ensure efficient handover to another inspector in the
Quality of finish, paint faults, opacity (grinning), event of illness or other emergencies.
coverage, holidays.

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Daily Checks
Day To Day Activities – Record

Beginning of the day

1. Environmental conditions. Environment, equipment, materials, previous days
2. Confirmation of materials used work.
(abrasives, paint, pipe data etc).
3. Confirmation of equipment (calibrations etc). During the day
4. Adherence to specification application faults Environment, equipment, materials, each
5. Adverse weather conditions operators work, application faults, the standards.
(start and stop times etc).
At the end of the day
The days work, housekeeping, all daily reports.

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10
 Records - End of Contract Purpose of a Quality
Plan

 All daily records signed off.

 To ensure stated paramenters are met.
 A complete register of control documents.
 A complete record of test results.  Establish the integrity of the system.
 All NCR’s should be closed out.  To provide tracable records.
 Complete waste disposal records.  To reduce the risk of error.
 A complete correspondance file.

Inspection Is not quality assurance.

Inspection is not quality control.

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Question 1

This paint defect is

referred to as:
Screen Test Five
a. Flaking.
b. Chalking.
c. Grinning.
d. Cissing.

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Question 2
Question 3

The main difference between airless and conventional What is the name of the equipment used to
spray is: determine particle aggregate size?

a. Conventional spray gives better deposition rate. a. Beck-koller.

b. Conventional spray gives less waste. b. Hegman gauge.
c. Airless spray gives better quality finish.
c. Wolfe-Wilborne.
d. Conventional spray gives better atomisation.
d. Krebs-Stormer.

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11
 Question 4 Question 5

What are the 3 attributes, which make up the colour

What voltage settings are commonly used for
of a paint?
sponge test holiday detection?
a. White, black, and primary colour.
a. 5 Kv to 15 Kv.
b. Hue, brightness and saturation.
b. 15 Kv maximum.
c. Red, yellow, and blue.
c. 9v to 90 v.
d. Contrast, density, and definition.
d. 110v or 240v.

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Question 6
Question 7

This is the hazard warning symbol Another name for a vapour trap is?
for:
a. Air wash cup.
a. Toxic or very toxic. b. Dry out pot.
b. Harmful or irritant. c. Knock out pot.
c. Corrosive. d. Pressure regulator.
d. Explosive.

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Question 8 Question 9

Beryllium Bronze is a material used in the Which of the following are primary colours?
manufacture of:
a. Blue yellow and green.
a. Welding electrodes. b. Red green and white.
b. Power wire brushes. c. Red white and blue.
c. Comb gauges. d. Red yellow and blue.
d. Venturi Nozzle liners

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12
 Question 10 Question 11

When carrying out holiday detection using the What would be the main problem of a low CPVC?
sponge tester, what can we add to the water?
a. High opacity.
a. Salt. b. Permeability.
b. Detergent. c. Low Gloss.
c. Xylene. d. Low opacity.
d. Inhibitor.

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Question 12 Question 13

BGC/PS/PA10 contains which table, specifying Thermally sprayed aluminium is normally

the preferred coating systems? applied by which system?

a. Spa 6a. a. Electric arc spray.

b. Spa 1e. b. Sheradising.
c. Spa 4a. c. Wire and Pistol.
d. Spa 3c. d. Electro-plating.

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Question 14 Question 15

Padding refers to what?

Which of the following is not a system for paint
a. Protection for pipes during transport and colour classification?
storage.
b. Protective clothing for TSA application. a. BS 4800.
c. A paint application method. b. BS 5252.
d. Material used to soak spillages. c. Munsell.
d. BGC/PS/CW5.

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13
 Question 16 Question 17

When testing for Xylene using a Drager Bellows, the Which pH range covers acids?
crystals will change colour:
a. 7 to 14.
a. Orange to black. b. 0 to 7.
b. White to red/brown. c. 0 to 14.
c. White to green. d. 5 to 10.
d. White to black.

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Question 18 Question 19

What is the specified abrasive overlap requirement

The specified method of
on repair areas?
removal of this of type of
contamination is:
a. 250 mm.
b. Twice pipe diameter.
a. Dry abrasive blasting.
c. 100 mm.
b. Hand abrasion.
d. 1 metre.
c. Xylene.
d. High pressure washing.

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Question 21
Question 20

Where a silicone sealer is applied to an Inorganic Which would be considered to be the most toxic?
Zinc Silicate coating system, how is the sealer
cured? a. Acetone.
b. Xylene.
a. Propane torch. c. Ethanol.
b. Electric induction pads. d. Toluene.
c. It cures when the system begins to operate.
d. It does not require curing.

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14
 Question 22 Question 23

The document issued by the HSE listing all known In the electrostatic spray painting process, the
harmful substances, is: component must be:
a. COSHH. a. Positively charged.
b. SI 1657. b. Negatively charged.
c. EH40. c. 9 volts DC.
d. IGE SR 21. d. 15 Kv DC.

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Question 24 Question 25

Where bleeding is evident on a pipe which was

previously coated with coal tar, the staining This is caused by:
would be which colour?
a. Expansion and contraction.
a. Black b. Age and environment.
b. Brown c. Solvent strength.
c. Yellow d. Surface contamination.
d. Red

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Question 1

Swap your papers please

This paint defect is referred
to as:

a. Flaking.
Put your name on your paper, b. Chalking.
and pass it to someone else to c. Grinning.
d. Cissing.
check

Answer: B

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15
 Question 3
Question 2

The main difference between airless and What is the name of the equipment used to
conventional spray is: determine particle aggregate size?

a. Conventional spray gives better deposition rate.

b. Conventional spray gives less waste. a. Beck-koller.
c. Airless spray gives better quality finish. b. Hegman gauge.
d. Conventional spray gives better atomisation. c. Wolfe-Wilborne.
d. Krebs-Stormer .

Answer: D Answer: B

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Question 4 Question 5

What are the 3 attributes, which make up the

colour of a paint? What voltage settings are commonly used for
sponge test holiday detection?
a. White, black, and primary colour.
b. Hue, brightness and saturation. a. 5 Kv to 15 Kv.
c. Red, yellow, and blue. b. 15 Kv maximum.
d. Contrast, density, and definition. c. 9v to 90 v.
d. 110v or 240v.

Answer: B Answer: C

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Question 6 Question 7

This is the hazard warning symbol Another name for a Vapour Trap is?
for:
a. Air wash cup.
a. Toxic or very toxic. b. Dry out pot.
b. Harmful or irritant. c. Knock out pot.
c. Corrosive. d. Pressure regulator.
d. Explosive.

Answer: C
Answer: B

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16
 Question 8 Question 9

Beryllium bronze is a material used in the Which of the following are primary colours?
manufacture of:
a. Blue yellow and green.
a. Welding electrodes. b. Red green and white.
b. Power wire brushes. c. Red white and blue.
c. Comb gauges. d. Red yellow and blue.
d. Venturi nozzle liners.

Answer: D
Answer: B

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Question 10 Question 11

When carrying out holiday detection using the What would be the main problem of a low CPVC?
sponge tester, what can we add to the water?
a. High opacity.
a. Salt. b. Permeability.
b. Detergent. c. Low gloss.
c. Xylene. d. Low opacity
d. Inhibitor.

Answer: B Answer: D

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Question 12 Question 13

BGC/PS/PA10 contains which table, specifying the Thermally sprayed aluminium is normally applied by
preferred coating systems? which system?

a. Spa 6a. a. Electric arc spray.

b. Spa 1e. b. Sheradising.
c. Spa 4a. c. Wire and pistol.
d. Spa 3c. d. Electro-plating.

Answer: B Answer: C

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17
 Question 14 Question 15

Padding refers to what? Which of the following is not a system for paint
colour classification?
a. Protection for pipes during transport and storage.
b. Protective clothing for TSA application. a. BS 4800.
c. A paint application method. b. BS 5252.
d. Material used to soak spillages. c. Munsell.
d. BGC/PS/CW5.

Answer: C
Answer: D

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Question 16 Question 17

When testing for Xylene using a Drager Bellows, Which pH range covers acids?
the crystals will change colour :
a. 7 to 14.
a. Orange to black. b. 0 to 7.
b. White to red/brown. c. 0 to 14.
c. White to green. d. 5 to 10.
d. White to black.

Answer: B Answer: B

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Question 18
Question 19

What is the specified abrasive overlap The specified method of

requirement on repair areas? removal of this of type of
contamination is:
a. 250 mm.
b. Twice pipe diameter. a. Dry abrasive blasting.
c. 100 mm. b. Hand abrasion.
d. 1 metre. c. Xylene.
d. High pressure washing.

Answer: C
Answer: D

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18
 Question 20
Question 21

Where a silicone sealer is applied to an inorganic zinc Which would be considered to be the most toxic?
silicate coating system, how is the sealer cured?
a. Acetone.
a. Propane torch. b. Xylene.
b. Electric induction pads. c. Ethanol.
c. It cures when the system begins to operate. d. Toluene
d. It does not require curing.

Answer: C Answer: D

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Question 22
Question 23

The document issued by the HSE listing all known In the electrostatic spray painting process, the
harmful substances, is: component must be:

a. COSHH. a. Positively charged.

b. SI 1657. b. Negatively charged.
c. EH40. c. 9 volts DC .
d. IGE SR 21. d. 5 Kv DC.

Answer: C Answer: B

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Question 25
Question 24

Where bleeding is evident on a pipe which was

previously coated with coal tar, the staining would This is caused by:
be which colour?
a. Expansion and contraction.
a. Black. b. Age and environment.
b. Brown. c. Solvent strength.
c. Yellow. d. Surface contamination.
d. Red.

Answer: C Answer: C

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19