Introduction Now that you have had the opportunity to navigate through the “bottomless” tank lining specification and locate key information (Module 10), and attend a pre-construction conference and develop an inspection plan based on the project specification and the manufacturer’s product data sheets (Module 11), you will have an opportunity to conduct inspections of surface preparation and coating operations on a simulated project. Learning Outcome Completion of Module 12 will enable the coatings inspector to perform coatings inspection, document inspection data, and compare inspection results to specification requirements. Workshop Instructions Eight (8) stations have been set-up around the perimeter of the training room, Each station contains inspection equipment and testing surfaces that represent the “Bottomless” tank. Your role is to use the inspection equipment and inspect the work performed by the painting contractor, document the results on the SSPC inspection forms attached, and note Protective Coatings Inspector Training eae (02013 SSPCModule 12: Simulated QA/OC Inspection of “Bottomless” Tank Lining Installation any non-conformities. The inspection plan you developed in Module 11 can be used to help assess whether the results of your inspections conform to the requirements of the specification. If this were a real project, you would perform the inspections on your own as the work proceeded, in a specified sequence. However, in order to prevent bottlenecks and to optimize the workshop time, perform the inspections in any order on this simulated project with your group. That is, each group should proceed to any inspection station that is unoccupied, perform the inspection and document the results. We will reconvene once each group has completed each of the stations to review the results of your inspections, and to answer any questions that may have arisen during the workshop. While you will be working in groups, each participant is responsible for completing the inspection forms. There will not be sufficient time for each person in the group to collect individual data at each station. However each person in the group should perform a portion of the inspection at each station, rather than having one or two individuals dominate the group. There are brief instructions for each of the eight (8) stations below, and there are charts to help you understand exactly what should be recorded. Be certain to document the information directly on the inspection forms, or record the information and transfer the data to the inspection forms. Protective Coatings Inspector Training ©2013 SSPCModule 12: Simulated QA/QC Inspection of "Bottomless" Tank Lining Installation ———————— ee Station 1 - Ambient Conditions, Surface Temperature and Illumination Sling Psychrometer and Analog Surface Temperature Thermometer Condi Reading Date Time of day Dry Bulb Reading (air temperature ort’) Wet Bulb Reading (f) Depression of the Wet Bulb Thermometer (t-t) Relative Humidity Dew Point Temperature Surface Temperature Spread between dew point and surface temperature Electronic Psychrometer Condition Reading Date Time of day Air Temperature (T.) Relative Humidity (RH) Dew Point Temperature (Tz) Surface Temperature (T.) ‘Spread between dew point and surface temperature (p) Lightmeter (Record Lux or Foot Candles) es Amount of Light Amount of Light (Foot Candles) (Lux) 1 2 3 4 5 ‘AverageModule 12: Simulated QA /OC Inspection of “Botton Jass"* Tank Lining Installation Station 2 - Compressed Air Cleanliness Test; Surface Oil Detection; Abrasive Test Compressed Air Cleanliness Test Blotter A Blotter Satisfactory | Unsatisfactory Date & Time of Test Blotter B Surface Oil Detection Test Test Procedure | Satisfactory | Unsatisfactory Date & Time of Test Water Break Abrasive Test Test Procedure Satisfactory | Unsatisfactory Date & Time of Test Conductivity Oil Content Conformance to SSPC-AB1Module 12: Simulated QA/QC Inspection of “Bottomless” Tank Lining Installation Stat in 3 — Surface Profile Depth Surface Profile (replica tape) Test ‘Surface Profile Scien Surface/Measurement (mils) lace Tape Here A(t) A(2) A(3) Station 4 — Surface Chloride Test Area Chloride (ug/em*) Calculate surface concentration (jig/en?) using the following formula: PPM reading from Quantab strip X Volume of water used for extraction/Area of latex cell Convert surface concentration (ig/em*) to conductivity using the following formula: $=2XEX(ANV), where: Conductivity (uS/cm) A= Area of Latex Cell (12.25 em?) E = Chloride (ugiem?y V = Volume of Water Used for Extraction oatings Inspector Training PCModule 12. Simulated QA/OC Inspection of “Bottomless” Tank Lining Installation Station 5 — Surface Cleanliness (SSPC VIS 1) Surface Cleanliness Achieved? Test Area Initial Condition (Yes/No) Station 6 — Mixing and Thinning of Topcoat; Calculating Wet Film Thickness Information The contractor has mixed 10 gallons (two-5 gallon containers) of the specified topcoat and has thinned it 10%. The mix ended at 10:00 am. The mixed paint temperature is 73° F. The coating will be applied by airless spray. Record the information requested in the chart below and/or on the inspection forms. Coating Manufacturer Product No. Maximum thinner permitted Batch Number Part A Amount of Part A Added to the Mix Batch Number for Part B Amount of Part B Added to the Mix Paint Temperature Induction Time Potlife Thinner No. Thinner Batch Number Amount of Thinner Added (in ounces)Moiule 12: Simulated Q4/OC Inspection of “Bottomless” Tank Lining Installation Calculating Wet Film Thickness Calculated WET of primer (thinned 10%) Calculated WET of finish coat (thinned 10%) ———— Station 7A — Measurement of Dry Film Thickness of Primer (Type 1 Gage) The “Bottomless” tank is 18 meters (60 feet) high with a roof diameter of 30 meters (100 feet), Determine the total number of square meters (square feet) assuming that the interior of the roof and walls are all flat. Total area of all interior surfaces: Number of coating thickness measurements per coat: Measure and record the thickness from the center of the coated plates, assuming that they represent 100 square feet of coated surface. (Each panel represents a spot) Spot 4 Spot 2 Spot 3 Spot 4 Spot 5 ‘Ave: Ave: Ave: Ave: Ave: Area Average: The specified dry film thickness is 3.0-5.0 mils when measured in accordance with SSPC-PA 2 Level 3. Does the thickness of the primer conform to the specification? Station 7B — Measurement of Dry Film Thickness of Primer + Topcoat (Type 2 Gage) Measure and record the thickness from the center of the coated plates, assuming that they represent 100 square feet of coated surface. (Each panel represents a spot) Protective Coatings Inspector Training ©2013 SSPCModule 12: Simulated QA/OC Inspection of “Bottomless” Tank Lining Installation Spot 1 Spot 2 Spot 3 Spot 4 Spot 5 ‘Ave: Ave: Ave: Ave: Ave: Area Average: The specified cumulative dry film thickness is 8.0-15.0 mils when measured in accordance with SSPC-PA 2 Level 3. Does the cumulative thickness of both coats conform to the specification? Station 8 — Low Voltage (wet sponge) Pinhole Detection Pinholes Detected Test Area Date & Time of Test No YesModule 12: Simulated QA/OC Inspection of “Bottomless” Tank Lining Installation Paint Inspection Project Documentation Record Project: Project Location Company Name: | Start Date: Contact Finish Date: ‘Record receipt ofall documentation and acknowledge verification of receipt Dato Documentation, Spectators, Pins, and Revisions Issued Date sued Recent Ackrowledgement Dale | | | 'SSPC OCS 2.03 Revicion 1 09/2005 Protective Coatings Inspector Training 12013 SSPCModule 12: Simulated Q4/OC Inspection of “Bottomless” Tank Lining Installation Paint Inspection eC 5 2 Pepa tap Daily Coating Inspection Report | == eee ee Papaicna emis: Teen aaa Desaer Corse Sorcia agar g [Contaae Soe Favaor Description of Areas and Work Performed Hold Point inspections Performed 1. 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