Classification: Internal Use #

PART 2

Questions and Answers given in BGAS Book

Technical Training Services

Al Jubail-KSA
+966571884471
ttsjubail@gmail.com
Classification: Internal Use #

Corrosion op - Monday
1 Is the electrical circuit in a corrosion reaction AC or DC?
DC
2 Does corrosion occur at the cathode or at the anode?
Anode
3 Name the three factors needed for corrosion to occur.
Cathode, Anode, Electrolyte
4 What is meant by the term electrolyte?
A substance, which will conduct a current and be broken down by it. (Be dissociated by it)
5 What is corrosion?
Degradation of a material by chemical or electrochemical means.
6 In the corrosion circuit do electrons flow from anode to cathode?
Yes. ELECTRONS FLOW FROM ANODE TO CATHOD E via metallic path
7 Which gas is released at the cathode when the electrolyte is water?
Hydrogen
8 Which is the more noble metal, steel or aluminum?
Steel
9 Which is more electronegative, steel or aluminum?
Aluminum
10 If steel and copper were in contact in an electrolyte which would corrode?
Steel
11 Name two common hygroscopic salts.
Iron Sulphates, Iron Chlorides
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12 Name three metals used as sacrificial anodes on a steel pipeline.

Zinc, aluminum, Magnesium
13 What is the approximate thickness of mill scale?
From 25 to 100 Microns
14 Which of the two metals would corrode if steel and zinc were coupled?
Zinc
15 Which are other names relate to the galvanic list?
Electromotive Forces Series, Electrochemical Series
16 In which environment are you likely to encounter chloride salts?
Marine environment
17 Which three compounds together form mill scale?
Hematite, Wustite, Magnetite
18 If magnesium was coupled with zinc, which would corrode?
Magnesium
19 In which environment would sulphate salts be found?
Industrial (Power stations etc.) and agricultural areas
20 What is an osmotic blister?
Tiny, pinhead-sized, water-filled blisters caused by hygroscopic salt contamination. (Iron sulphates/iron
Chlorides)
21 What is an ion?
A positively or negatively charged particle or atom. Unstable atom.
22 What is meant by polarization?
The polarity (negative or positive) of an atom
23 Is an anode positive or negative?
Positive
24 Can corrosion occur without an electrolyte?
No
25 Name a sub atomic particle.
Proton, Neutron, Electron
26 What is mill scale and when and where does it occur?
Compound of compressed oxides formed during steel rolling manufacturing operations at 580 °c, thickness 25
to 100 µm.
27 Name three factors, which can accelerate corrosion reactions.
Temperature, Bacteria, Acids & Alkalines, Oxygen, Bi-metallic corrosion (galvanic list location), Hygroscopic
salts.
28 Why is it considered essential to remove mill scale prior to painting?
It prevents Bi-metallic corrosion (mill scale is more noble than the steel) and improves adhesion & cleanliness.
29 Why does an un-coated steel plate corrode?
Steel is heterogeneous, as it exists as both a cathode and an anode simultaneously. Electrons enter at every
available point of the substrate. Iron reacts readily with oxygen to form iron oxide (rust).
30 If corrosion occurs at anodic areas, why does steel corrode evenly all over the surface?
Trace alloying elements in the steel ( Nickel, Carbon, Aluminum etc.) provides millions of anodic and cathodic
areas, (Bi- metallic contact) so the steel surface will corrode (as it is both an anode and a cathode).
Surface preparation - Monday
1 Which British standard would be used in determining the size of copper slag abrasive?
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BS410
2 Which British standard would be used in determining the size of metallic abrasives?
BS410
3 Which regulation prohibit the use of sand for steel blasting?
COSHH (MSDS or data sheets) & SI 1657
4 What is meant by term “Key”?
To improve adhesion to the surface
5 Why is it important to have good surface preparation?
to improve adhesion & remove contamination.
6 What is meant by term "sliver"?
A surface breaking lamination
7 What is a hackle?
A sliver, which has been deformed upright after blasting.
8 Name two other terms that could be used for “anchor pattern” ?
Peak to trough, key, surface profile, amplitude
9 What are the main advantages of using “Testex papers” for measuring profiles?
It provides a permanent record, and it can be used on curved surfaces
10 What is meant by the term grade, relating to a blast finish?
Degree of surface cleanliness
11 What are the main factors governing the grade of a blast finish?
Time spent, abrasive size, abrasive density, material density, shape of particle, hardness of the abrasive, initial
rust grade
12 Can the grade of a blast finish be determined by using the surface comparators to BS 7079 Pt. C3?
No, only surface roughness
13 What profile range can be measured using X coarse Testex?
37- 115 microns
14 What profile range can be measured using 'coarse' grade Testex?
20 - 50 microns
15 What are the two theories of adhesion?
Molecular Interference, Molecular Attraction
16 Briefly describe the mechanisms of the two theories of adhesion.
Physical (e.g. Velcro) Chemical (e.g. Magnet)
17 How many microns are in thou?
25.4
18 Give three different names for the cross section of a blast.
Surface profile, anchor pattern, key, peak to trough, amplitude
19 What is the approximate speed of abrasives leaving a venture nozzle?
450 mph
20 What is the most common cause of flash rusting on a blasted substrate?
Moisture
21 What would be considered to be an ideal shot grit mix?
70-80% shot I 20 -30% grit
22 What is the purpose of mixing shot and grit?
Grit cuts the profile & shot controls the peaks, to give a uniform profile .
23 Which abrasive would have the effect of work hardening a substrate?
Metallic shot or steel shot
24 Name three methods of measuring or assessing a profile.
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Comparator, Visual, Touch (tactile), Surface Profile Needle Gauge, Dial micrometer & replica tape
25 What is the most common cause of rogue peaks on a substrate?
Concentrated blasting in one area for too long
26 In what situation would it be better to use steel grit in preference to copper slag abrasives?
Enclosed blast cabinets or 'wheelabrator'
27 If Cracks or laminations are found on a substrate after blasting what steps should be taken?
Stop the blasting operation, mark the area, and report it to the Site Engineer (Ultrasonic lamination Checks
would normally follow)
28 Using comparators to ISO 8503, what are the three main profile assessments?
Fine, Medium, Coarse
29 What are the other two assessments when the above three are not appropriate?
Finer than fine, Coarser than coarse
30 What would be size of copper slag needed to give a profile of 50 to 75 µm?
G16 (J Blast Supa is most common)
SURFACE PREPARATION - TUESDAY
1 What is the title of the BS 7079?
Preparation of steel substrates before application of paints and related products
2 What are the four characteristics of an abrasive?
Size, hardness, density, shape
3 Why are blast hoses carbon impregnated?
Static electricity discharge
4 Name the gauge used for measuring pressure at the blast nozzle?
Hypodermic needle gauge
5 Name four advantages of centrifugal blasting over open blasting.
Recyclable abrasives, operator safety, quality control, no operator fatigue
6 According to BS 7079 is it possible to blast clean to an A Sa1?
No
7 Is there any difference between an A Sa1 and B Sa1?
Yes
8 Could you tell the difference between rust grades A and B blasted to Sa3?
No
9 Could you tell the difference between rust grades C and D blasted to Sa3?
Yes, possible heavy pitting
10 What would be a typical speed of abrasives leaving a wheel abrator?
220mph
11 What is considered to be the most efficient blasting pressure?
100 psi
12 What is meant by the term burnishing?
Polishing or shining of the material surface
13 What would be the equivalent to St2 in the SA grades?
Sa 2 1/2
14 What is the neutral figure on the pH scale?
Seven (7)
15 What is the meaning of pH and how is it measured?
Potential Hydrogen (level of acidity or alkalinity) using litmus papers or pH indicators
16 Why are inhibitors sometimes added to water in wet blasting?
To prevent flash rusting (immediate oxidation)
17 Name two typical areas where needle guns might be used?
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Rivets, bolts, weld cap profiles, plate overlap

18 What is the duplex process of surface preparation?
Pickling followed by passivation (Footners-Duplex system)
19 Which pH range covers acid and which range covers alkalis?
0 to 7 acids, 7 to 14 alkaline
20 Name two areas on a structure where flame cleaning cannot be done.
Areas of fastenings under tension (bolts, rivets, screws etc.)
21 Which three basic operations are performed during flame cleaning?
Expansion, Dehydration, Heat Penetration
22 How does BS 7079 define flame cleaning standards?
AFL, BFL, CFL, and DFL
23 What is a Jason's Hammer?
A pneumatic caulking chisel, a type of needle gun
24 What is meant by St2 and St3?
Thorough hand & power tool cleaning, Very thorough hand & power tool cleaning
25 Two alloys are used to render wire brushes spark free, what are they?
Phosphor Bronze I Beryllium Bronze
26 Why should burnishing be avoided?
Polished surface gives poor adhesion
27 Name two major disadvantages of using a needle gun.
Work hardening, operator fatigue, very coarse surface profile, Health and safety issue due to vibration white
finger.
28 After phosphating, what would be a typical pH requirement prior to coating?
4.5 to 7.0
29 What is understood by the term knock out pot?
A small vessel with a drain tap, to remove oil and water vapor from the compressed air stream
If an operator was blasting with a nozzle pressure of 80 psi. What would be his approximate
30
efficiency?
70% (80 psi = 20 x 1.5 efficiency drop = 30%)
31 Which solvents are commonly used for degreasing?
Xylene
32 What is a 'dead man’s handle'?
Safety cut-off trigger controlling the abrasive stream, which must be under the direct control of the blasting
operator
33 How is abrasive cleansed in a wheelabrator system?
Air wash separator
34 What is the main disadvantage of high pressure jetting compared to other systems?
Safety, huge volumes of water, slurry, no profile, flash rusting
35 Name five methods of wet blasting.
Steam, Air blasting plus water·, high pressure, high pressure plus abrasive, low pressure plus abrasive

36 What are the typical temperatures and concentration of sulphuric acid in the pickling process?
5 - I 0% at 65 to 70 degrees
37 Describe the duplex process.
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Degrease using Xylene. Check with Ultraviolet light. Immerse in 5-10% Sulphuric acid for 5-25 mins at 65-70 c.
Rinse with clean warm water. Immerse in 1-2% Phosphoric or Chromic acid, at 80 ℃ for 1-2 mins, with
addition of 0.5% iron fillings. Rinse with clean warm water. Check pH level, to be between 4.5 and 7.0.
38 What would be a maximum pressure for high pressure water jetting?
30,000 psi (above this is said to be Ultra High Pressure)
39 What are the disadvantages of wet blasting over dry basting?
Cuts no profile, large amounts of slurry, large volume of water, flash rusting
40 What would be considered to be advantages of wet blasting over dry blasting?
Spark-free operation, removal of toxic detritus, removes hygroscopic salts
41 Why is the phosphating or chromatlng of steel done?
Give limited protection against corrosion & help to prevent flash rusting.
42 What would be an acceptable remedy for burnished areas?
Emery cloth or Emery paper
43 Would burnishing be expected on areas of St2 preparation?
No
44 How many photographs of blast cleaning standards are shown In BS 7079 Pt A?
14 (blast cleaning standards!!)
45 Do the plates shown in BS 7079 Pt. A relate to grit blasting or shot blasting?
It refers to all types of abrasives
Paint technology (1)- Wednesday
1 Name a third type of paint other than solvent free and solvent borne.
Powder
2 An epoxy resin would use which solvent?
Acetone
3 Name four or more advantages of chlorinated rubber paints.
Durability, Flameproof, Resistant to algae I mould growth, not reliant upon surface profile, waterproof.
4 What are the three main disadvantages of chlorinated rubber paint?
Poor resistance to HC solvents, cannot be made water-borne, low Temperature tolerance
5 Which solvent could be used with a phenolic resin?
White Spirit
6 Chlorinated rubber paint would contain which solvent?
Xylene
7 Would It be good practice to apply chlorinated rubber over alkyd resin?
No
8 Which solvent would be used with an alkyd resin?
White Spirit
9 How was the word alkyd derived?
It is derived from an Alcohol I Acid reaction
10 What is meant by opaque?
Hiding or covering power. The ability to hide an underlying layer
11 What Is meant by vehicle?
Binder, Film former, Non-Volatile
12 Would it be acceptable practice to apply an alkyd over chlorinated rubber?
Yes
13 Would it be acceptable practice to apply chlorinated rubber over phenolic?
No
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14 Would it be acceptable practice to apply phenolic resin over chlorinated rubber?

Yes
15 Would it be acceptable practice to apply epoxy over linseed oil base?
No
16 Would it be acceptable practice to apply chlorinated rubber over epoxy?
Yes
17 Would it be acceptable practice to apply epoxy resin over alkyd resin?
No
18 What is another name for an un-pigmented paint?
Varnish or Lacquer
19 What are the natural properties of a resin?
Brittle & fast drying
20 What are the natural properties of oil?
Slow drying and elastic
21 How does paint using the barrier principle work?
Physically prevents the electrolyte from making contact with the substrate
22 How does paint using the passivation principle work?
Phosphates & Chromates react with iron, to create a layer of rust inhibitive 'Passivating' salts
23 How does paint using cathodic protection principle work?
By incorporating a metallic pigment of a lower nobility than the steel into the paint (zinc & aluminum)
24 Give another name for solvent free two packs.
Multi- Component Liquid or 'MCL'.
25 Name six properties of a binder.
Resistance to abrasion I acid & alkaline I water I electrons, keep the Pigments in suspension,
cohesive/adhesive strength/change from liquid into a solid
26 Name the natural resins used in paints.
Copals, Dammars, coumarones, Amber, Laq
27 Name five natural oils used In paints.
Olive, Palm, Castor, Coconut, Linseed, Soya
28 What does oleo resinous mean?
A mixture of Oil and Resin
29 Name an in-organic high temperature service binder.
Silicates and Silicones
30 Name two pigments likely to be used for high temperature service.
Zinc & Aluminum
Paint technology (2)- Wednesday
1 By what name would you call the basic unit of a polymer?
Mer, Molecule, atom
2 What is polymerisation?
"The joining together of a string or structure of repeated units"
3 Name three types of polymers.
Linear, Branched, Cross-linked
4 What would be the characteristics of a short oil paint?
Less than 45% Oil to Resin, faster drying, suitable for steelwork.
5 What would be the characteristics of a long oil paint?
More than 60% Oil to Resin, slower drying, mainly Decorative applications
6 What is meant by the term opaque pigment?
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Pigment with excellent "light scattering" properties, or "Hiding ability”. It is said to have "covering power".
7 What is a typical size of a pigment particle?
0.1 to 1.0 micron
Briefly describe the difference between saturated and unsaturated when referring to oils or
8
polymers.
Unsaturated oils will react with oxygen and solidify, saturated oils will not, so they are classed as non-drying
oils.
9 Name two drying oils, which are unsaturated.
Linseed, Tung, Soya, Safflower, China Wood
10 What is the main difference between a dye and a pigment?
A pigment must remain solid within the binder. (A dye will dissolve)
11 What are the sources of pigments?
Animal, Mineral, Synthetic, Vegetable
12 If titanium dioxide was used In paint, what would be the colour?
White
13 Name three rust Inhibitive pigments considered to be toxic.
Red Lead, Coal Tar, Zinc Chromate, Calcium Plumbate
14 Name four commonly occurring minerals used as extender pigments.
Talc, Chalk, Slate Flour, China Clay
15 Name three laminar pigments.
MIO, Glass Flake, Graphite, Mica
16 If pigment was added way below the CPVC, how would it affect the film?
Low Opacity, Blistering, Low Cohesive Strength, High Gloss.
17 The abbreviation CPVC means what?
Critical Pigment Volume Concentration
18 Why are thixotropes added to a paint formulation?
Anti-Settling agent, Thickener, Storage aid
19 If carbon was used as a pigment what would be the paint colour?
Black
20 Name four properties that a binder contributes to a paint film.
Adhesion, ease of application, Dielectric strength, Cohesive strength, Liquid to solid, Will keep the pigments in
suspension, impermeability.
21 Describe how a basic inhibitor works.
A basic inhibitor reacts with the substrate to create rust inhibitive salts (phosphates & Chromates), to
"passivate" the surface and make it less reactive to oxidation and corrosion.
22 Which of the common extenders could not be used In whites and pastels?
Slate Flour
23 How would the film be affected if pigment was added above the CPVC?
Permeable/Porous, Low Cohesive strength, Low Gloss, Low Adhesion
24 Which of the rust inhibitive pigments is the most common?
Zinc Phosphate
25 Why are extenders used in paint formulation?
Add thickness and bulk at low cost, increase intercoat adhesion
26 If chromium was used as a pigment, what colour would the paint be?
Green, Orange, Yellow
27 Why are plasticisers added to paint?
Increases flexibility, reduces brittleness. Modifies the film properties.
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28 Two metals are commonly used as galvanic pigmentation, name them.

Zinc, Aluminium
29 Why are driers added to oil based paint?
To ensure even through thickness drying. (Prevent wrinkling & rivelling)
30 What is meant by the term thixotropic?
Thickener, Anti-Settling agent, aid to storage.
31 What is meant by the term aggregate when referring to paint?
Loosely adhering cluster of pigments and particles
32 If an antioxidant was added to paint, what would it do?
Anti-Skinning agent. Prevents paint from forming a skin in the tin.
33 Give the names of two plasticisers.
Castor Oil, Coconut Oil
34 What is meant by the term solution?
The resultant liquid after dissolving a solute in a solvent.
35 Give two examples of a solution.
Salt and water, sugar and water
36 What is meant by the term dispersion?
A solid or liquid mixed in another liquid, where there is no solubility.
37 There are two types of dispersion, what are they?
Suspension, Emulsion
38 If paint cures by chemical reaction Is it reversible or convertible?
Convertible
39 What type of polymerisation occurs In chemically curing paint?
Crosslinked
40 Name a paint, which dries solely by solvent evaporation.
Any linear polymer paints. (Chlorinated Rubber, Vinyls, Emulsions)
41 What is meant by non-convertible?
Reversible. Can be returned to its original state if solvent is re-introduced or re-applied.
42 What is meant by non-reversible?
Convertible. It is permanently altered to a new state after undergoing a chemical change.
43 Name four drying mechanisms.
Solvent Evaporation, Chemical Curing, Coalescence, Oxidation
44 In a coating, which dries by solvent evaporation,what type of polymerisation occurs?
Linear
45 What is another term for fineness of grind?
Degree of dispersion
46 Which generic types of paint dry by solvent evaporation followed by oxidation?
Natural Oils and Resins
47 What type of polymer forms during oxidation?
Branched
48 What term applies to paint drying at ambient temperatures?
Air Drying
49 What is meant by the term coalescence?
To physically join together
50 What is meant by the term pot life?
The time after opening and mixing, in which the contents of the container must be used.
51 Name three curing agents used In epoxies?
Amides, Amines, Isocyanates
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52 Is Paint a solution or dispersion. Qualify?

Dispersion, as the pigments must remain solid within the binder
53 What is an exothermic reaction?
A chemical reaction, which is giving off heat.
54 What is meant by the term 'induction period'?
The time after mixing, in which the paint should stand prior to use, to allow polymerisation (crosslinking) to
begin, and thorough wetting of the pigment particles to take place.
55 What is the difference between 'thermoplastic' and 'thermosetting'?

Thermosetting coatings will cure if heat is applied, and Thermoplastic coatings will deform if heat is applied.

56 With a chemically curing paint, what type of polymerization occurs?

Crosslinking
57 Two other terms relate to induction period, what are they?
Stand time and Lead time
58 Does a phenolic resin have an induction period?
No (Phenolic resin paints are not chemically curing)
Which of the following binders are reversible?
59 a) Epoxy d) Urethane g) Cellulose b) Phenolic e) Chlorinated Rubber h) Silicone c) Vinyl f)
Alkyd
Chlorinated Rubber, Vinyl, Cellulose (C, E, and G)
60 Is an epoxy powder paint thermoplastic or thermosetting?
Thermosetting
61 If a coating is permeable, what does it mean?
It will allow the passage of moisture or electrolyte
62 What is meant by cross-linking, give two binders as an example?
Multi-directional polymerisation, e.g. Epoxy, Urethane
63 What is the opposite to exothermic?
Endothermic
64 What is the term used for paints needing temperatures in excess of 65oc to cure?
Stove Drying
65 What would be a typical induction period for Chlorinated Rubber paint?
None (Chlorinated Rubber is not chemically curing)
66 Name a material used as a dryer in paint formulation.
Heavy metal salts (such as Octoates and Napthanates of Cobalt, Manganese and Zirconium)
67 Why would bentonite or wax be used in paint formulation?
Thickeners, thixotropic agents, Anti settling agents, Non-drip
68 Name two materials used as plasticisers.
Coconut Oil, Palm Oil, Castor Oil
69 What generic type of paints would use anti-oxidants?
Natural Oils & Resins
70 How does a single pack, epoxy ester paint dry?
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Solvent evaporation followed by Oxidation

71 How is Dew point defined?
The temperature at which moisture, in the form of water vapour in the air will condense
72 How is Relative Humidity defined?
The amount of water vapour present in the air, expressed as a percentage of the water vapour, which
"could be" in the air at that same temperature.
73 When using a whirling hygrometer which bulb should be read first and why?
The wet bulb should be read first, as it is artificially reduced and the temperature will gradually rise back to
ambient.
74 At what speed should the thermometer bulbs pass through the air?
Four metres per second (4 m/s), or as fast as possible.
75 What should be used when wetting the wick on whirling hygrometer?
De-Ionised or distilled water.
76 By what other name can we refer to a whirling hygrometer?
Aspirated psychrometer
77 When the air temperature rises does the air's capacity to hold water increase or decrease?
Increases
78 What is the stated criterion for acceptance, prior to calculations, on a whirling hygrometer?
2 Consecutive identical readings (within 0.2 degrees)
79 Name two pieces of equipment used for taking steel temperature.
Limpet gauge (magnetic thermometer), touch pyrometer
80 Is it possible for a wet bulb temperature to be higher than the dry bulb?
No, never.
Paint Testing - Thursday
1 Define viscosity.
A Fluids resistance to flow
2 What is meant by high viscosity?
Very thick, and resist ing flow
3 Approximately, what is the viscosity of water?
1 centipoise, or 1 dyne sec/cm 2
4 Name the cgs and SI units of dynamic viscosity.
cgs = poise, Sl = N sec/m2
5 Name three different flow cups.
Ford, Zahn, Frikmar, ISO, ASTM
6 When using a flow cup which unit of viscosity would be used?
Seconds
7 In Ford Flow Cup No 4 what does 4 relates to?
Diameter of the flow hole
8 Give the names of three different rotational viscometers.
Krebs Stormer, Ford Flow cup, Zahn, Rotational Viscometer
9 Give a reason for performing a viscosity test on site.
Test to determine the addition of thinners, and mix ratio of multi packs
10 Which viscometer would not be used on thixotropic paint?
Flow cup
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11 Why is temperature very important when doing viscosity tests?

Viscosity will reduce at raised temperatures
12 What is the main difference between the rotothinner and Krebs Stormer?
Rota thinner is d dynamic viscosity, Krebs Stormer is kinematic
13 Describe how to use a Ford Flow Cup.
100 cc of paint, level @ 20 °C, scrape excess, allow to flow, measure in seconds until first break in
continuous flow.
14 Give another name for a Fineness of grind gauge.
Hegman Grind gauge
15 Is a low flash point safer than a high flash point?
No
16 How and for what is a Hegman grind gauge used?
To measure the degree of dispersion or fineness of grind
17 Briefly describe how to do the volatile, non-volatile test to BS 3900 Pt. B2.
Weigh glass rod & plate, add 2g of paint, weigh again, stir and place in oven to evaporate solvent. Removeand
weigh again.
18 Name the equipment used to determine the flash point of a solvent.
Abel Cup
19 What colour should the flame be at the flash point?
Blue
20 What formula is used to calculate the density?
D=W/V
21 What formula is used to calculate specific gravity?
Density of product /Density of distilled water
22 What is relative density?
Density compared to that of distilled water
23 What are the other names for a density cup?
Pyknometer, weight per litre cu p, density cup, SG cup, weight per gallon.
24 What is a stoke, the unit for?
Kinematic viscosity
25 Which test is used to determine abrasion resistance?
Erichson, Taber, Gardner
26 Which equipment would be used to determine flexibility?
conical mandrel
27 Which equipment would be used to measure impact resistance?
Tubular Impact tester
28 For what reason would the Koenig Albert apparatus be used?
Hardness of paint film
29 For which two reasons could a density cup be used on site?
Check addition of thinners, correct mixing ratio
30 Name four accelerated test boxes.
Humidity ca binet, Salt spray cabi net, Temperature cycling, Prohesion test, Water soak test
31 Why would a tropical box be used?
To test a paints ability to withstand accel erated tropical conditions
32 Would a paint be higher or lower density than water?
Higher
33 How would the density be affected if solvent was added to paint?
Weight Desity would be reduced
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34 What is the capacity of a density cup?

100 cc
35 What difference is there between SG and density?
Densi ty has a unit(g/cc) SG is the measure ofthe density of the product/100
36 What information could be obtained from a water soak test?
Water absorption
37 What information could be obtained from a temperature cycling test?
Contraction a nd expansion cracking
38 What information could be obtained from a cold check test?
Contraction cracking
39 Name four drying and curing tests.
Ballotini, BK stylus, mechanical thum b test, Wolff-wil borne pencil scratch
40 What stage of the BK test would be recorded as the drying time?
When no scratch is evident whatsoever
41 Name three methods of determining opacity.
Pfund cryptometer, Hiding power charts plus adjustable applicator, Black/White fused plates
42 What effects the opacity of a paint film?
Hiding ability is affected by CPVC
43 Why would a Pfund cryptometer be used?
To determine the minimum DFT required to provide covering of the underlying substrate
44 Give one reason why an inspector would use a PIG gauge?
Check DFT and correct coating sequence. Check DFT over ferrous materials MIO Or to check DFT on Non
Ferrous su bstrates.
45 Why are wet paint film thicknesses needed?
To calculate the DFT if volu me solids is known, ensure correct DFT.
46 Name two methods of measuring WFTs
Eccentric wheel , comb gauge, biscuit gauge
47 What is the reason for taking WFTs immediately after application?
Prior to immediate solvent evaporation, to ensure correct calculation of DFT
Where could an inspector find information to determine If a two-pack paint was mixed in the correct
48
proportions, using a density cup?

Manufacturers data sheets

49 Can a banana gauge be used on non-ferromagnetic substrate?

No
50 Could an eddy-current gauge be used on ferromagnetic substrates?
No ( Electromagnetic induct ion is used for ferrous)
51 Can a horseshoe gauge be used on non-ferromagnetic substrates?
No
52 As part of which test would a bar applicator be used?
Hiding power charts and bar applicator (Opacity)
53 Which instruments would be used to measure reflectivity?
Glossmeter
54 How does a gloss meter work?
Measures the amount of received light from a known light source, at a given angle
55 Which factors in paint govern the degree of gloss?
CPVC, Binder type, Solvent ty pe, refractive index, Degree of dispersion
56 In a primer/mid coat what would be the expected degree of grind?
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40 microns
57 In a gloss paint what would be a typical degree of grind?
Occasionally 10 microns, but mainly 20 microns
58 What percentage reading would be expected when measuring gloss on a glass pan,!l?
100%
59 Using a gloss meter a reading of 25% would signify what?
Matt
If an aggregate size of 35µm was present in a paint of 30µm DFT, what would be a likely result when
60
using a gloss meter?
Matt finish
61 Name three common tests for determining adhesion of a paint film?
Cross cut, Dolly, HATE, V cut tests
62 Which adhesion tests are quantitative?
Dolly, HATE
63 Intercoat adhesion and primer to substrate adhesion are two adhesion faults name the third?
Cohesive failure
64 What chemical solution is used to conduct a cathodic disbondment test?
3% Saltwater
65 Which gas evolved at the cathode causes disbondment?
Hydrogen
66 What criterion is used when assessing a cathodic disbondment test panel?
No more than 5mm damage outside of 6mm diameter hole, after 28 days
67 Name the two methods of applying cathodic protection.
Sacrificial anode, Impressed current
68 What is used to determine the potential of a pipeline?
Copper/Copper sulphate, half cell reference electrode
69 Would it be advisable to refill a pipe trench with carbonaceous backfill?
No, as the CP system would be nullified
70 Does a cathodic protection system eliminate corrosion?
It controls the " location " and the rate of corrosion
71 Can the external surface of a tank be protected?
No
72 Could a crude oil tank be fully protected internally?
No. Onl y to the level of the tank contents
73 What voltage would be used on a 250 µm thick paint using a sponge type pinhole detector?
9 volts
74 What voltage would be used on a 450µm thick coating with a sponge type pinhole detector?
67.5 volts
75 When using a wet sponge, what other liquid is added to the water?
Detergent
76 What function does the above additive perform?
Reduce surface tension, water softener
77 Would it be advisable to do wet sponge detection on galvanising?
No because Zinc is conductive
78 Why work upwards on a vertical surface with a wet sponge?
To avoid incorrect or erroneous flaw locations owing to water seepage
79 Does a sponge detector work on AC or DC current?
DC
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Other than the wet sponge,which other equipment could be used to determine the presence of
80
pinholes/holidays?
High voltage holiday detector using wire brushes. (NOT SPRINGS)
Revision Questions - Friday
1 Name two categories of paint mill.
Direct Charge Mill, Premix mill, Let down mill
2 What is the main reason for processing paint in a mill?
Correct mix proportionate with requirements, fineness of grind.
3 Briefly describe how a ball mill works.
Steel balls tumbled in a horizontal rotating drum, grinding the mill base.
4 Briefly describe how an attritor mill works.
Vertical drum with motorised paddles driving the steel balls
5 When would steel balls not be used In a ball mill?
When producing lighter coloured paints
6 A bead mill is sometimes called by whicllother names?
Sand Mill, Pearl Mill
7 How does a colloid mill work?
High speed stone discs bottom one rotating at 3600rpm , top disc stationary.
8 Name eight items of information listed on a materials data sheet.
Pot life, shelf life, SG, drying time, application temperatures, flash point, VS%, Induction period, mix ratio,
application method and rate, orifice/nozzle size, safety, Brand name and description, batch number, Solvent
ty pe, colour, coverage, storage conditions, binder type, recommended surface preparation, overcoating time.
9 What do you understand from the term halogenated hydrocarbon?
Iodine, Fluorine, Chlorine
10 How can we determine the viscosity of a high viscosity paint?
Krebs-Stormer Viscometer
11 Briefly describe the principles of CP.
It controls the location and rate of corrosion by means of an impressed current
12 What function does a primer have in a paint system?
Protects the substrate by means of anti-corrosive or sacrificial pigments
13 In a mordant primer what is the main working constituent?
Phosphoric acid
14 What advantages do electrostatic application methods provide?
Good edge cover, good transfer, low waste, uniform thickness
15 Which is the most expensive type of brush filling?
Natural hair
16 What is cohesive failure in paint, give the main cause?
Solvent entrapment, incorrect mixing ratio, too high CPVC
17 Why does a zinc rich paint need a strong binder?
Good cohesive strength is required with zinc, to provide sacrificial protection
18 Why are etch primers not spray applied?
Toxic, acid, and environmentally unsafe
19 What do you understand by the term over spray?
Accidental spray on undesirable areas. (nameplates, instrumentation etc.)
20 Name four methods of determining DFTs.
WFT plus calc, PIG, electronic gauges, banana gauge, horseshoe gauge, tinsley pencil
21 What is a psychrometer used for?
Classification: Internal Use #

To measure wet bulb and dry bulb temperatures.

22 What colour should a galvanised surface be after application of T- wash?
Black
23 How soon can a T washed substrate be coated?
As soon as it is dry
24 Other than pigment, base and curing agent name two other constituents of FBE powder paint.
Anti foaming agent, wetting agent
25 Give the main differences between airless and conventional spray.
Conventional gives better atomisation, more accuracy, better finish, easier cleaning, specialised container
required, Airless gives higher deposition rate, less waste, faster, larger area coverage
26 Brush application has advantages over spray application, what are they?
Small area, environmental friendly, cheaper, works paint into substrate, accessibility, thicker application, very
low waste, prevents pinholes, accuracy, no overspray
27 What is the main consideration when selecting a metallic pigment for a sacrificial paint?
Its position in the galvanic list
28 What is meant by sheradising?
Items are tumbled in zinc dust at a temp just below melting point
29 Name thre types of paint feed for a conventional spray.
Suction, gravity, remote pressure
30 What is the calorising process?
Coating with aluminium
31 Why would a sealer be applied to aluminium metal spray?
Yes, for high temperature service, to prolong protection
32 What is the BS 2015 term for skipped or missed areas?
Holidays
33 Colour has three properties, what are they?
Hue, Brightness and Saturation
34 Why would paint be applied by hot spray?
To reduce viscosity
35 On an airless spray tip how are blockages cleared?
Twist the nozzle
36 How is atomisation achieved using conventional sprays?
Airstream convergence outside of the nozzle
37 How is atomisation achieved using alrless sprays?
Explosive force of high pressure paint meeting low pressure air
38 What is dip coating?
Dipping the item in a tank of paint, allowing to dry
39 What do you understand from the term ropiness?
Brushmarks
40 What is efflorescence and how does it occur?
Soluble salts, normally deposited on concrete and mortar work
41 Name two ways of melting aluminium to enable it to be sprayed.
Electric arc,Wire & pistol
42 What is flocculation?
Loosely clustered particles or aggregates often found in out-of-date paint
43 What could be the cause of bittlness in a paint film?
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Foreign bodies in the paint (grit, dust etc)

44 What is a tie coat?
A coat of paint applied to an area adjoining two incompatible coating systems
45 How many depressions of the bellows are needed for the Drager test?
Varies according to the relevant crystals required for the solvent under test
46 What are the hazard signs for Toxic, Very Toxic, Harmful and corrosive?
Blank-------Answer not available
47 What is saponification?
The production of ' lead soaps', when using basic primer with Natural Oil paints
48 What units are used for measuring toxicity?
PPM (parts per million)
49 Which material would have to be used on a perpetually damp surface?
Moisture curing Polyurethane
50 What is padding?
Use of a pad, coated in fine natural hair, to apply paint
51 What air inlet pressure Is needed to give 2500 psi delivery with 35:1 pump?
71 Psi
52 What causes lifting of a paint film?
Non-observance of overcoating time, applying strong solvent over weak binder
53 What is cissing and how is it caused?
Oil or grease contamination of the substrate, causing a local lack of adhesion
54 What is meant by the abbreviations: OES, OEL, MEL, UEL, LELand RAQ?
Occupational Exposure Standard, Occupational Exposure Limit, Maximum Exposure Limit, Upper explosive
Limit, Lower Explosive Limit, Required Air Quantity
55 Why would a paint Inspector use potassium hexacyonoferrate?
Check for hygroscopic salt contamination
56 What would be an average thickness for galvanising?
100µm
57 How can you tell the difference between blooming and chalking?
No
58 What could be the reasons for inter coat adhesive failure?
Incompatibility, contamination
59 How would you determine quality of added thinners in thixotropic paint?
Rotational Viscometer
60 Why are manufacturers developing solvent free, water borne and powders?
Environmental impact, cost
61 What would be the cause of grinning on a paint film?
Poor opacity, Low CPVC
62 How can bleeding be avoided?
Total removal of Bitumen I Coal Tar coatings prior to painting
63 In less than 30 words, explain the duties of a painting Inspector.
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Visually inspect paint finish, Measure & report wet bulb dry bulb, DP, RH.Control storage of paint and
abrasives, Monitor against re-use of abrasives. Monitor compliant materials. Check surface condition &
preparation. Record Weather conditions & compliance with specification. Measure and record surface
profiles. Prepare inspection reports. Check adherence to Pot life & Induction period. Measure & record DFT,
WFT, Report any non-conformance to Engineer. Check operation of blaasting equipment (vapour traps earth
cable, whiplash cables, external couplings etc), Should have Site plan and documentation. Monitor intercoat
time, painting sequence, Monitor addition of thinners, Preparation of Q panels or test plates. Administering
adhesion tests.
64 Name five documents, which a painting inspector might need on a contract.
Contract specification, Inspection reports, Operator qualifications, COSHH
65 What Information should be given on a daily report sheet?
WFT, DFT, Dew point, wet bulb, dry bulb, time, RH, operators name, paint system, Steel Temp, Air Temp,
Weather Conditions. Wind Speed, Measured surface profile, paint batch number, paint manufacturer, colour
code. Application date, expiry or shelf life date, Induction period (if applicable) Client, Contract, report
number, location, inspectors name and qualification, specification,Standard, abrasive type, abrasive size,
abrasive supplier, overcoating time, method of cleaning, blast grade, rust grade, location.
66 Curtains, sags, runs and tears are a result of what?
Excessive paint deposition
67 Some binders can be modified to use water as a solvent, name four.
Vinyls, acrylics, emulsions, Alkyds, Bitumens
68 What is meant by the term stripe coat?
Brush applying a coat of paint where spray application may be inaccessible
69 How many cm3 are there in 4.5 litres?
4500
70 A paint data sheet provides a wealth of information, name eight items.
Flash Point, density, VS%, Health & Safety, Batch numbers, recommended thinners, Drying time at 20 ℃,
recommended WFT, Application method, Contents, Solvent type.
Revision questions PA 10 specific
1 What is the specified course of action for grit inclusions?
Re-blast and re-coat
2 The term long term protection refers to what?
Protection lasting typically 10 years
3 What is the difference between new and weathered galvanising?
Weathered surface provides its own key, and requires only stiff bristled brush for preparation
4 What criterion determines which paint system should be used?
The compatibility with the existing coating system, and must be in accordance with PA 10
5 What is the total DFT of the compliant epoxy system?
265 microns minimum
6 What is the total DFT of the water borne system?
225 microns minimum
7 When can ladders and other means of access be removed?
When all operations (including final acceptance) have been completed
8 Two materials are specified for used on damp surfaces, what are they?
Moisture Curing Polyurethane, and Solvent Free Epoxy
9 After removal of a non-drying paint, which type of primer is recommended?
A White spirit BASED PRIMER 32.6 NUMBER 5
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10 Some non-ferrous substrates are painted for aesthetics only, name four.
Stainless Steel, Concrete, Fibre Glass, Aluminium
11 Which three non-ferrous substrates are painted for anti-corrosion purposes?
new Galvanised, weathered galvanised, previously painted galvanising
12 According to PA 10 in which situations would T wash be used?
New Galvanised Steel, where sweep blasting or hand abrasion is inadvisable or impractical
13 How many coats of primer are specified on surfaces at 100-149°C?
As many as required
14 Give preferential order of coating systems for surface 150-340°C.
TSA, IZS, PIC
15 Is it mandatory for a contractor to produce a test area?
Not mandatory, but generally upon request
16 List four items needing masking off prior to blasting and painting.
Name plates, instrumentation, vents, monitoring panels
17 Which aluminium substrate would not be sweep blasted?
Thin Aluminium plate
18 Which three paint systems are specified for use on aluminium?
Water-Borne Acrylic, High Build Epoxy, Alkyd or modified Alkyd
What differences are there In new and maintenance painting specifications for substrates below
19
100°C?
Existing coating type (compatibility), surface preparation (new=blasting I maintenance painting = hand and
power tools. Environmental conditions. Access to area, application methods, overlap with maintenance
painting 100mm onto sound coating (feathering onto sound coating)
Toxic coatings need special considerations for removal from substrates,name two methods
20
which comply.
needle gun, water jetting, water plus abrasive
21 In which situations is a permit to work required?
All BGas installations (live sites)
22 Which primers are specified for non-weathered galvanising?
Wash Primers, such as T-Wash
23 Which primers are specified for weathered galvanising?
Primer not required, initial coat MIO
24 According to PA10 is flame cleaning allowed?
No, not on live Gas sites
25 According to PA10 is thinning of paint allowed?
Yes, but only in accordance with the manufacturers data sheets
26 What temperature range is covered by 'hot duty service'?
Above 100 °C
27 Does PA10 cover internal coatings on pipes?
No, BGC/PS/PA8 covers this
28 What is the specified overlap on repair areas?
100mm onto sound coating
29 What would be the specified surface preparation and coating system for aluminium cladding?
Blast cleaning to Sa3 (check for millscale) profile 75µm MAX
30 What would be the procedure for removal of algae and mould?
Treat with a biocidal agent for 24 hours, then scrub with stiff bristle brush and water power washing
31 What would be the procedure for degreasing prior to surface preparation?
Classification: Internal Use #

Degrease using a non aliphatic solvent (xylene) and then scrub with a detergent.
32 What would be the procedure for degreasing after to surface preparation?
USING A SMALLER SIZE ABBRASIVE OR USING HAND AND POWER TOOLS
33 When blast cleaning on an AGI what precautions are taken?
All blast cleaning done in accordance to IGE SR 21 and ensure that a permit to work is in place and also a hot
work permit
34 Is it permissible to prepare paint by stirring?
only if the volume of the paint is less than 5L otherwise use a mechanical agitator.
35 What would be the surface preparation method for new galvanising?
Sweep blast (Sa 1)
36 When would it be necessary to apply a sealer to Inorganic zinc silicate?
When long term protection is required
37 How could areas of a paint breakdown be prepared for repainting?
sweep blasting, emery paper
38 What information should be on a paint can label for BG?
Hazard warning symbol, batch number, paint type, colour
39 When measuring DFTs over galvanising what allowances are made?
Deduct the thickness of the zinc, generally 100 microns
40 What is the first coat applied to galvanised substrates and why?
MIO, primer is not required because the zinc acts as a sacrificial primer much like the aluminium primer.
41 Properties and Performances of paint are covered In which BG specification?
BGC /PS I PA9
42 What are the considerations when selecting a paint system?
Existing coating if any (compatibility), surface temperature, environment, lifetime expectancy, cost, cleaning
methods available, specification requirements
43 According to PA 10 which two coats are applied at works?
Primer and MIO
44 Give the criterion for when and when not, painting can take place.
Max. 90% Relative Humidity, Steel & Air Temperature to be 3 °C above Dew Point
45 What should be the substrate reaction when T wash Is applied to a newly galvanised substrate?
The substrate turns black
46 Which two materials are specified for use on damp surfaces?
Moisture Curing Polyurethane, Solvent-free epoxies
47 What is the maximum time lapse from surface preparation to coating?
4 Hours
48 Which is the most common pigment used in high temperature paints?
Silicone
49 What would be the result of over thick application of zinc silicate?
Mud Cracking
50 According to PA10 is roller application permissible?
PA 10 states that Roller application is NOT RECOMMENDED.

B Gas 3.2 Maths Exercises

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WFT (Wet Film Thickness) calculations (Related to Chapter 11)

1 What WFT would need to be applied to give a DFT of 45µm using a paint of 56% VS?

2 What WFT would need to be applied to give a DFT of 60µm using a paint of 40% VS?

3 A paint of 38% VS was used to give a DFT of 45µm what would be the WFT?

4 A DFT of 55µm was obtained from a paint of 55% VS, what was the WFT applied?

5 What WFT would be applied to leave DFT of 65µm using a paint of 49% VS?
Classification: Internal Use #

DFT (Dry Film Thickness) calculations (Related to Chapter 11)

1 What would be the DFT if 20 litres of paint, 45%VS covered an area of 9m x12m?

What would be the resulting DFT? 25Ltr of paint, 65%VS was used to cover a circular area of 10m
2
diameter.
Classification: Internal Use #

3 What DFT would be obtained If a paint VS content of 42% was applied at a WFT of 84µm?

4 With a WFT of 130µm, using a paint containing 83% VS, what would be the resulting DFT?

5 A paint, 65%VS was applied at a WFT of 130µm, what would be the resulting DFT?
Classification: Internal Use #

VS (Volume Solids) calculations (Related to Chapter 11)

1 A DFT of 53µm was obtained from a WFT of 110 µm, what was the %VS of the paint?

2 A paint was applied at 120µm WFT. The resulting DFT was 65µm, what was the %VS?

What would be the %VS of a paint if it was applied with a WFT of 120µm and a DFT of 68µm was
3
obtained?

4 What was the %VS of a paint with a DFT of 36µm, when the WFT was108µm?

A DFT of 62µm was measured, from a WFT application of 100µm, what would be the %VS of the
5
paint used?
Classification: Internal Use #

Volume calculations (Related to Chapter 11)

What volume of paint would be required to cover an area of 300 square metres, to a specified DFT of 65µm,
1
using a paint of 45% VS?
Classification: Internal Use #

How much paint would be required to coat a tank, roof and side sheets to a DFT of 100 µm? The
2
tank is 5 metres diameter and 6 metres high. The paint to be used Is solvent free.

How much paint would be needed to cover a circular area of 10 metres diameter, using a paint 65%
3
VS to a DFT of 60µm?
Classification: Internal Use #

A circular area of 7 metres radius is to be coated to a DFT of 45µm. What volume of paint would be
4
required if the VS content was 48%?
Classification: Internal Use #

5 How much paint would be needed, at 55% VS, to coat an area of 250 square meters to a DFT of 60µm?

Density and SG exercise

1 What would be the weight of 16.5 litres of paint with a SG of 1.45?

Classification: Internal Use #

2 What is the density of a paint if 7.5 litres weighs 9.75kg?

3 What would be the relative density of paint in question above?

4 If the weight of 25 litres of paint is 37.5kg, what would be the SG?

A two-pack epoxy should be mixed at one part base to one part activator, the base has a density of
5
1.4gm/cc and the activator 0.9gm/cc. What would be the density of the mixed components?
Classification: Internal Use #

A two-pack paint is mixed at a ratio of six parts pack A (density 1.3gm/cc) to one part pack B
6
(density 0.9gm/cc). What would be the density of the combined parts?

A mixed two-pack paint has a density of 1.35gm/cc. The density of the base was l.5gm/cc and the
7
activator 0.9gm/cc. The mixing ratio was 3:1. Has the paint been mixed correctly?
Classification: Internal Use #

A mixed two-pack paint has a density of 1.35gm/cc. Mixed at a ratio of 6:1, base density 1.45gm/cc,
8
activator density 0.95gm/cc. Has the paint been mixed correctly?

The End