1

Coating Inspector Program Level 2

List of Figures

Chapter 1: Introduction
Figure 1.1: CIP Level 2 Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1.2: Class Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.3: Class Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.4: Working in Teams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 1.5: Team Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 2: Advanced Corrosion

Figure 2.1: Rusted Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 2.2: Energy Mountain for Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2.3: Life Cycle of Iron in Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2.4: Corrosion Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2.5: General Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2.6: General Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2.7: Localized Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2.8: Localized Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2.9: Pitting Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2.10: Pitting Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2.11: Oxygen Concentration Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2.12: Ion Concentration Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2.13: Crevice Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2.14: Galvanic Corrosion Resulting from Carbon Steel Welded to
Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 2.15: How Cathodic Protection Works . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 2.16: Galvanic Anode Cathodic Protection System . . . . . . . . . . . . . . . . . . 11
Figure 2.17: Aluminum Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 2.18: Impressed Current Cathodic Protection System . . . . . . . . . . . . . . . . 12
Figure 2.19: Impressed Current Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 2.20: Cathodic Disbondment Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 3: Environmental Controls

Figure 3.1: DH Equipment Outside Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 3.2: Enclosed Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 3.3: Enclosed Water Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 3.4: Air Pollution and the Corrosion Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 3.5: Psychrometric Chart (Mollier Diagram) . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3.6: Corrosion Rate (Oxide Formation) vs. Percent of Relative Humidity . 5

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Figure 3.7: Refrigeration Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 3.8: Dehumidification Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3.9: Typical Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3.10: Rotary Honeycomb Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 3.11: Air Movement Using Dehumidification . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 4: Advanced Environmental Testing Instrumentation

Figure 4.1: Electronic Hygrometers (Dew Point Meters) . . . . . . . . . . . . . . . . . . . . 2
Figure 4.2: Using a Hygrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 4.3: PosiTector DPM used as Data Logger (w/optional attachments) . . . . . 3
Figure 4.4: Oven Data Logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4.5: Wind Speed Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4.6: Wind Data Logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 4.7: Screen-shot of Elcometer ElcoMaster™ Data Management Software . 7

Chapter 5: Advanced Environmental Testing Instrumentation — Practice Lab

Chapter 6: Centrifugal Blast Cleaning

Figure 6.1: Monorail Centrifugal Blasting Unit – Part Before and After . . . . . . . . 1
Figure 6.2: Multi Table Blasting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 6.3: Swing Table Blasting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 6.4: Beam Blasting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 6.5: Rail Car Blasting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 6.6: Small Plate Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 6.7: Large Plate Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 6.8: Plate Blasting Unit (right to left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 6.9: Typical Centrifugal Blasting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 6.10: Small Centrifugal Blast Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 6.11: Cut-a-Way Diagram of a Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 6.12: Pipe Unit - Skew Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 6.13: Portable Deck Unit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 6.14: Blast Unit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 6.15: Blast Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6.16: Centrifugal Blasting Unit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 6.17: Worn Vane from a Centrifugal Blasting Unit . . . . . . . . . . . . . . . . . . . 7
Figure 6.18: Abrasive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 6.19: Air Wash Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 6.20: Skimmer Plates in Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 6.21: Abrasive Curtain, Air Flow, and Scrap Bypass . . . . . . . . . . . . . . . . . 9
Figure 6.22: Abrasives Traveling Through Abrasive Separator . . . . . . . . . . . . . . . 9

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Figure 6.23: Abrasive Blasting Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 6.24: Abrasive Blasting Standards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 6.25: Abrasive Handling Machine Diagram . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 6.26: Steel Shot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 6.27: Steel Grit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 6.28: Abrasive Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 7: Waterjetting
Figure 7.1: Typical UHP Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 7.2: Trailer Mounted UHP Pump/Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 7.3: Typical Shoulder Gun w/Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 7.4: Robotic Waterjetting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 7.5: Different Guns/Tips/Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 7.6: Underwater Waterjetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 7.7: Waterjetting Steel Substrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 7.8: Waterjetting Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 7.9: Proper Operator Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 7.10: Tips/Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 7.11: Fan Nozzle/Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 7.12: Typical Braided Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 7.13: Foot Guard for Gun Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 7.14: TurtleSkinâ Water Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 7.15: Improper PPE (notice no gloves) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 8: Interpersonal Relationship Dynamics in the Workplace

Figure 8.1: Johari Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 8.2: Dominance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 8.3: High “D” Influence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 8.4: Influence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 8.5: High “I” Influence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 8.6: Steadiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 8.7: High “S” Influence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 8.8: Conscientiousness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8.9: High “C” Influence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8.10: Perfectionist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 9: Safety Awareness

Figure 9.1: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 9.2: Thermal Spray Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 9.3: Thermal Spray Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Figure 9.4: Fumes and Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 9.5: Steel Beam Leaving Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 9.6: Acid Pickling Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 9.7: Applicator Wearing Proper PPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 10: Advanced Nondestructive Test Instruments

Figure 10.1: Elcometer 137 Illuminated Magnifier . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 10.2: Portable Surface Microscope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 10.3: Stereo Zoom Microscope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 10.4: ProScope HR Hand-Held Digital Microscope . . . . . . . . . . . . . . . . . . 4
Figure 10.5: MiScope® Hand-Held Digital Microscope . . . . . . . . . . . . . . . . . . . . 5
Figure 10.6: EXTECH MC108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 10.7: Benchtop pH/Conductivity Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 10.8: Hand-Held pH Meter — Oakton® pH/mV/Temperature
Basic pH 11 Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 10.9: Moisture Meter with Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 10.10: Moisture Meter without Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 10.11: Eddy-Current DFT Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 10.12: Screenshot of Elcometer ElcoMaster™ Data Management
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chapter 11: Advanced Nondestructive Test Instruments — Practice Lab

Chapter 12: Lining and Special Coatings

Figure 12.1: Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 12.2: Glass-Fiber Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 12.3: Rolling 100% Epoxy into Glass Mat . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 12.4: Reinforced Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 12.5: Conventional Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 12.6: Bio-Fouling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 12.7: Bio-Fouling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 12.8: Comparison of Ablative and Self-Smoothing Coatings . . . . . . . . . . . 7
Figure 12.9: Flaking Caused by Missed Recoat Window . . . . . . . . . . . . . . . . . . . . 7
Figure 12.10: Spot and Feathered Blasted Surface . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 12.11: Fireproofing Resistance for Structures or Vessels . . . . . . . . . . . . . . 8
Figure 12.12: Electrostatic Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 12.13: Fluidized Bed Dipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 12.14: Charging a Pre-Weighed Amount of Powder into a Hollow Mold . 14
Figure 12.15: Placing a Mold into a Heated Oven . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 12.16: The Powder Forms a Protective Coating when Cooled . . . . . . . . . 14

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Figure 12.17: Plural Component Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 12.18: Plural Component Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 12.19: Plural Component Spray Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 12.20: Mixing Block for Plural Component Spray Unit with Insulated
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 12.21: Heated System with Insulated Hoses . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 12.22: Centrifugal Spray for Pipe Internals . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 13: Thick Barrier Linings

Figure 13.1: Various Mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 13.2: Section of FGD Duct, Rubber Lined . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 13.3: Beveled Edge of Rubber Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 13.4: Loose Lap Seam in a Rubber Lining . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 13.5: Warning Label on Rubber-Lined Tank Car . . . . . . . . . . . . . . . . . . . . 8

Chapter 14: Advanced Standards and Resources

Chapter 15: Coating Concrete and Inspection

Figure 15.1: Components of Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 15.2: Steel and Wood Floats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 15.3: Brooming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 15.4: Bugholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 15.5: Blisters in Concrete Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 15.6: Guniting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 15.7: Deterioration of Concrete and Corrosion of Rebar Due to Action of
Chloride Ions on Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 15.8: Abrasive Blast Cleaned Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 15.9: Acid Etching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 15.10: Stoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 15.11: Steel Trowelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 15.12: Cracks in Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 15.13: Applicator Spraying Concrete Coatings for Concrete . . . . . . . . . . 13
Figure 15.14: Inspection Tools: Wet Film Thickness Gauge, Tooke Gauge,
and Ultrasonic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chapter 16: Test Instruments for Coating Concrete

Figure 16.1: Plastic Sheet Test on Concrete Floor . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 16.2: Calcium Chloride Moisture Vapor Emission Test on Concrete Floor 2
Figure 16.3: Concrete Moisture Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Figure 16.4: TCP Profiler kit with ICRI panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 16.5: Examples of CP Putty replica panels . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 16.6: ICRI Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 16.7: M1 Jumper In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 16.8: M1 Jumper Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 16.9: High-Voltage Holiday Detector in Use with Rolling Spring
Electrode .......................................................7

Chapter 17: Concrete Inspection Equipment — Practice Lab

Chapter 18: Pipeline Mainline and Field Joint Coatings

Figure 18.1: Pipeline Terrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 18.2: Construction Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 18.3: Pipeline Rupture and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 18.4: 2-Layer Extruded Polyethylene Coating . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 18.5: Side Extruded Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 18.6: 3-Layer Extruded Polyethylene Coating . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 18.7: Cross-head Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 18.8: Fusion Bonded Epoxy Mainline Coating . . . . . . . . . . . . . . . . . . . . . . 5
Figure 18.9: Schematic of FBE Coating Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 18.10: DFT Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 18.11: Holiday Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 18.12: Tape over Primer on Steel Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 18.13: Pipe Coated with Coal Tar Enamel/Asphalt . . . . . . . . . . . . . . . . . . . 8
Figure 18.14: Coal-Tar Enamel being Applied with Glass Fiber Mat . . . . . . . . . . 8
Figure 18.15: Insulated Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 18.16: Application of Polyurethane Foam to Pipe . . . . . . . . . . . . . . . . . . . . 9
Figure 18.17: Concrete Coated Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 18.18: Concrete Coated Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 18.19: Tubular Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 18.20: Surface Preparation for Sleeve Application . . . . . . . . . . . . . . . . . . 11
Figure 18.21: Verification of Pre-Heat Temperature . . . . . . . . . . . . . . . . . . . . . . 11
Figure 18.22: Centering the Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 18.23: Heat Shrink Sleeve Application . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 18.24: Shrinking the Sleeve (note the slack) . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 18.25: Shrinking Closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 18.26: Holiday Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 18.27: Acceptable Peel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 18.28: Unacceptable Peel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 18.29: Liquid Epoxy Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 18.30: Liquid Epoxy Application - Roller . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Figure 18.31: Liquid Epoxy Application — Brush . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 18.32: Cold-Wrap Tape Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 18.33: Fish Mouth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 18.34: Hot-Applied Tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 18.35: Complete Wrap on Pipe Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 18.36: Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 18.37: Typical FBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 18.38: FBE Field Joint Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 18.39: Hot Melt Stick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 18.40: Cold Petrolatum (Wax) Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 18.41: Petrolatum (Wax) Tape Surface Prep . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 18.42: Petrolatum/Wax Tape Application . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 18.43: Repair Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 18.44: Melt Stick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 18.45: Holiday Test on Repaired Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Chapter 19: Destructive Instruments and Tests

Figure 19.1: Illustration of the Measurement Principle utilized by Tooke Gauge . 4
Figure 19.2: Elcometer 121-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 19.3: Making Cut with Tooke Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 19.4: Calculating Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 19.5: Elcometer 195 Saberg Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 19.6: Measuring DFT of Paint Chip with Micrometer (ASTM D 6677) . . . 9
Figure 19.7: Elcometer 107 Cross Hatch Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 19.8: X-Cut After Tape Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 19.9: Making Cuts with X-Acto Knife for Cross-Hatch Tape Test . . . . . 11
Figure 19.10: Cross-Hatch Cutter with Six Blades . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 19.11: Using Cutter Tool to Make Cuts . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 19.12: Tape after Cross-Hatch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 19.13: Classification of Adhesion Tape Test Results . . . . . . . . . . . . . . . . 12
Figure 19.14: Elcometer 106 Adhesion Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 19.15: Roughening Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 19.16: Close Up of Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 19.17: Placing Claw Over Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 19.18: Turning Hand Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 19.19: Close Up of Dolly after Pulling . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 19.20: Dollies with Various Amounts of Adhered Coating . . . . . . . . . . . 16
Figure 19.21: Defelsko Positest AT Manual and Automatic . . . . . . . . . . . . . . . . 18
Figure 19.22: Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 19.23: Screenshot of PosiSoft Software . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 19.24: Elcometer 108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 19.25: Elcometer 110 PATTI ® Adhesion Tester . . . . . . . . . . . . . . . . . . . 23

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Figure 19.26: Elcometer 501 Pencil Hardness Tester . . . . . . . . . . . . . . . . . . . . . . 25

Figure 19.27: Elcometer 3120 Shore Durometer . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 19.28: Barcol 934 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 19.29: Testing with Barcol Impressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 19.30: Cross Section of Barcol 934 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chapter 20: Destructive Instruments and Tests — Practice Lab

Chapter 21: Surface Preparation, Coating and Inspection of Special Substrates

Chapter 22: Maintenance Coating Operations

Figure 22.1: Typical Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 22.2: Heavy Contaminant Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 22.3: Gauges and Dial Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 22.4: Without Feathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 22.5: With Feathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 22.6: Spot Blast on Weld Seam (Feathered Edge) . . . . . . . . . . . . . . . . . . . . 5
Figure 22.7: Spot Blasted and Feathered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 22.8: Corner Cleaned and Ready for Coating . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 22.9: Spot Repair – Curling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 22.10: WFT Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 22.11: Pull-Off Adhesion Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 23: Non Liquid Coatings

Figure 23.1: Hot-Dip Galvanizing Kettle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 23.2: Various Layers of Hot-Dip Galvanizing . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 23.3: Acid Picking Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 23.4: Fabricated Piece Being Dipped into the Zinc Bath . . . . . . . . . . . . . . . 4
Figure 23.5: Steel Beam Leaving Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 23.6: Fabricated Steel Leaving Galvanizing Bath . . . . . . . . . . . . . . . . . . . . 4
Figure 23.7: Typical Galvanized Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 23.8: General Roughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 23.9: Dross Protrusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 23.10: Uneven Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 23.11: Flux Inclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 23.12: Ash Inclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 23.13: Dull-Gray Galvanized Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 23.14: Rust Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 23.15: Wet Storage Stain (White Rust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Figure 23.16: Faying Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 24: Coating Surveys

Figure 24.1: Offshore Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 24.2: Refinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Chapter 25: Specialized Tests and Test Equipment

Figure 25.1: ASTM G 95 Cathodic Disbondment Test . . . . . . . . . . . . . . . . . . . . . 2
Figure 25.2: AA/AE Spectrophotometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 25.3: Interior of a GC-MS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 25.4: GLC Output Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 25.5: Infrared Spectrum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 25.6: FT-IR Spectrophotometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 25.7: How FT-IR Spectrophotometer works . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 25.8: Differential Scanning Calorimeter (DSC) for Thermo-analysis . . . . . 5

Chapter 26: Coating Types, Failure Modes, and Inspection Criteria

Figure 26.1: Pinholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 26.2: Blistering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 26.3: Delamination from Substrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 26.4: Cracking (Coating shown is not bituminous) . . . . . . . . . . . . . . . . . . . 3
Figure 26.5: Chalking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 26.6: Amine Blush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 26.7: Amine blush in removal process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 26.8: Blistering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 26.9: Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 26.10: Delamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 26.11: Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 26.12: Delamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 27: Peer Review

Coating Inspector Program Level 2 ©NACE International 2011

July 2011