PARTICIPANT

PEW105.03

SAUDI ARAMCO SURFACE PREPARATION INSPECTION OF NEWLY APPLIED COATING

WARNING : The training materials contained in this manual are the property of the Saudi Arabian Oil Company (Saudi Aramco) and are intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training courses. Any material contained in this manual which is not already in the public domain may not be copied reproduced sold given or disclosed to third parties or otherwise used in whole or in part for the purposes other than the use in Saudi

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PEW105.03

Aramco!s "rofessional #ngineering and Technical $evelopment courses without the prior written permission of the Chief #ngineer of Saudi Aramco

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PEW105.03

DATE 12/11/99

REVISION DESCRIPTION GRAMMAR ONLY

PAGE(S) AFFECTED ALL

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CONTENTS

MODULE COMPONENT

PAGE

OBJECTIVES

INFORMATION SHEETS

EXERCISE SHEET

WORK AID

GLOSSARY

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OBJECTIVES

TERMINAL OBJECTIVES Upon completion of this module the Participant will be able to inspect a prepared substrate surface prior to new coating application in accordance with SSPC Standards and SAES-H-100, 101, 101V, 102 and SAEP-316. The participant will perform this inspection using the Swedish Photographic Standards, SSPC-VIS-1, NACE RP0178, and Testing/Measuring Instruments. ENABLING OBJECTIVES In order to accomplish the Terminal Objective the Participant will be able to do the following: Describe surface preparation conditions and methods. Perform a surface preparation inspection using the proper tools, instruments, methods and procedures. Inspect abrasive blasting operations using the proper equipment, materials, safety requirements and the appropriate checklist. Verify the certification of critical coating personnel using the appropriate checklist. Verify that the correct types of scaffolding and staging are properly installed and safely used by personnel. Use the appropriate checklist to perform this inspection.

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INFORMATION SHEET

INTRODUCTION The purpose of a Surface Preparation Inspection is to verify the quality of the surface preparations prior to the application of a coating and to ensure the safety of personnel during a coating job. The cleanliness and degree to which the surface will accept the coating is as important to successful coating adhesion as the coating application itself.

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INFORMATION SHEET

SURFACE PREPARATION Surface preparation requirements depend on the findings of a prior surface condition inspection. All defects found must be corrected and cleaned prior to surface preparation. The extent of the preparation required depends on the extent of deterioration and contamination of a given surface. There are a number of surface preparation methods available to meet these conditions. Adequate surface preparation for minor contamination might only require cleaning the surface with solvent or detergent. However, preparation to remove scale or corrosion might require abrasive blasting of the surface to white (bare) metal. Evaluating Degree of Surface Preparation SSPC-VIS-1 provides a visual representation that allows the Inspector to evaluate the degree of surface cleanliness. These visuals are numbered for easy identification. The number for a given visual indicates the rust grade, the preparation grade and the degree of cleaning required. The SSPC Paint Manual, SSPC Guide to Vis-1-89, (Addendum Page 1) shows four grades of preparation for a panel that has a "C" Rust Grade. The "C" represents the rust grade or extent of rusting which is 100% with no pitting. The letters SP represents the grade of the surface quality by abrasive blasting. The last number in the series indicates the degree of cleanliness.

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INFORMATION SHEET

SURFACE PREPARATION (Cont'd) Safety Factors for Surface Preparation SSPC-SP-1 requires some surfaces to be solvent cleaned. This method is for removing all visible oil, grease, soil and other contaminants from surfaces. Solvents can be a health hazard if breathed over long periods of time. Health hazards increase for workers who breathe solvents indoors where the vapors are concentrated. There are standards for the length of time that workers can remain in contaminated areas given certain concentrations of contaminants. These times are called the Threshold Limit Values (TLV). TLVs are based on the amount of contamination present in the air as measured in parts per million or milligrams per cubic meter. A worker must not stay in a contaminated area for a period of time longer than is specified for the TLV of a given measurement of contaminants in the air. Table 10 in the SSPC Paint Manual, Vol. 2 (Addendum Page 13 ) shows the TLVs of many solvent products. Notice that acetone has the highest TLV which means that it produces the most harmful vapors. The first column, (labeled TWATLV) are values based on long-term factors while the second column, (labeled STEL-TLV) are values based on short-term exposure. Read the footnotes carefully.

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INFORMATION SHEET

SURFACE PREPARATION Safety Factors in Surface Preparation (Cont'd) Some solvents are dangerous to the skin. Any solvent may cause some irritation and should be washed off the skin immediately with soap and water. Saudi Aramco prohibits workers from using solvent to wash with. Showers and eyewash facilities must be furnished at the work site for workers. The inspector should check that these safety devices are installed and functioning properly before proceeding with his surface preparation inspection. Aromatic or coal-tar solvents may be used to remove heavy grease film where greater solvency is required, but these solvents are very toxic and they have low flash points which can cause fire and explosion hazards. Xylol and toluline types of solvents may be used when the toxic concentration of fumes in the air does not exceed safe limits. Fresh air masks or airline hoods should be worn anytime toxic concentrations exceed the safe limits. These solvents also have a low flash point. All electrical equipment and lighting used near solvents and paints must be explosion proof to meet the National Electric Code as stated in the Saudi Aramco Engineering Standards (SAES). All equipment must be properly grounded to prevent fire and explosion from sparks.

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INFORMATION SHEET

SURFACE PREPARATION Safety Factors In Surface Preparation (Cont'd)

Ventilation

Proper ventilation and breathing air are extremely important in interior work. Ventilation requirements for workers are outlined in Table 4-1 of SAES-H-102, (Addendum Page 48 ) Saudi Aramco requires forced mechanical ventilation during any work in confined spaces when abrasive blasting, solvent cleaning and/or painting is performed. The forced air will continue until the coating is fully cured because the curing process itself emits harmful hydrocarbon vapors. The inspector must ensure that ventilation is uniform throughout the space and that no pockets of still air exist. The fresh air inlets must be at the top of the space and the discharge openings at the bottom. Fans may be used in low places or other spaces where the air will not move. Workers must wear airline hoods or airfed respirators to perform abrasive blasting or spray painting indoors, or to perform solvent cleaning in a space of less than 16 cubic meters. These hoods and masks have a fresh-air supply that allows the worker to breathe without ingesting the contaminants present in the work environment. The inspector must ensure that the air supply is free of contaminants and that carbon monoxide alarms are installed at the air source.
Personal Protective Equipment

All personnel must have proper protective equipment as outlined in Table 4-2 of SAES-H-102 (Addendum Page 49 & 50). This table gives the protective requirements for several different work conditions for both confined spaces (inside) in the columns labeled C and outdoors as indicated under column 0. Note that the table covers two pages and has two sections, SURFACE PREPARATION and PAINT APPLICATION.

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INFORMATION SHEET

SURFACE PREPARATION (Cont'd) Methods of Surface Preparation Surface preparation methods are standardized by the SSPC. These methods are also outlined in the SSPC Paint Manual and SSPC-VIS-1-89. The SSPC Guide to Vis-1 (Addendum Page 3 - 18) lists the surface preparation methods. The inspector will be most concerned with the cleaning methods explained in the following paragraphs.
SSPC-SP-1, "SOLVENT CLEANING"

This specification includes simple solvent wiping, immersion in solvent, solvent spray, vapor de-greasing, steam cleaning with a solvent additive, emulsion cleaning, chemical paint stripping, and alkaline cleaners. The purpose is usually to remove oil, grease, dirt, and organic products. A pH test should always be performed after cleaning with alkaline cleaners to ensure there is no residue. Final wash should always be a clean wash. In the case of solvent, it should be a clean solvent rinse. Alkaline cleaners should be rinsed with rinse water that has a neutral pH.
SSPC-SP-2, "HAND TOOL CLEANING"

Hand tool cleaning is an acceptable method in maintenance coating and in normal atmospheric conditions. This method is used very little in Saudi Aramco because of the extreme atmospheric conditions in Saudi Arabia. It is generally used only when power operated equipment is unavailable, where the work is inaccessible to power tools or where the job is too small to justify the use of power tools. Tools used in hand cleaning include wire brushes, scrapers, chisels, knives, chipping hammers and sandpaper. The coatings in these cases need to have good wetting characteristics. Hand tool cleaning will not clean all residue, rust, or hard mill scale. For cleaning small areas prior to maintenance priming, hand tool cleaning is acceptable. One problem with this standard is determining what is "loose" rust and what is "adherent" rust. The specification considers the rust adherent if it cannot be lifted with a dull putty knife. It is a subjective test but will give some guidance to the Inspector.

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INFORMATION SHEET

SURFACE PREPARATION Methods of Surface Preparation. (Cont'd)

SSPC-SP-3, "POWER TOOL CLEANING"

Power tool cleaning provides a better foundation for priming paint than hand tool cleaning. Power tool cleaning, like hand tool cleaning, requires that the surface be cleaned first with solvent. Power tool cleaning is better and faster than hand tool cleaning. It removes weld spatter and other defects much better. It is necessary that these defects be removed and smoothed to prevent coating failure. All loose material must be removed prior to coating. The most common power tools are rotary wire brush, impact tools, grinders and sanders. After power tool cleaning is complete, ensure that dust and debris is blown off the surface with oil-free compressed air. Ensure that the operator exercises care not to roughen the surface excessively. This will cause gouges, burrs or ridges. These defects will cause paint failure because the sharp edges do not accept the proper thickness of paint. Check to ensure that power tool cleaning does not cause a smooth or polished surface. Paint will not adhere to a polished surface.
SSPC-SP-5, "WHITE METAL BLAST CLEANING"

This method is used for very corrosive and immersible atmosphere applications. Saudi Aramco requires white metal blast cleaning for all new and critical coatings. It results in a high degree of coating adhesion success because this method removes all rust, mill scale and detrimental material from the surface. Equipment and piping surfaces that have been cleaned by this method are extremely susceptible to rust bloom or rust back. The Inspector must ensure that the coating applicator controls the environmental factors and applies the coating to the surface immediately to prevent rusting. Coating must take place immediately after cleaning with this method.

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INFORMATION SHEET

SURFACE PREPARATION Methods of Surface Preparation. (Cont'd)

SSPC-SP-6, "COMMERCIAL BLAST CLEANING"

Commercial blast cleaning is used where a high but not perfect degree of cleaning is required. It will remove all rust and mill scale but will allow a great amount of stain. The surface will not be uniform in color or cleanliness. If this type of cleaning is likely to produce a surface that is unsatisfactory for severe service requirements, the "Near-White" or "White Metal Blast Cleaning" method should be used. In maintenance coating, it is not necessary that all old paint be removed; just the loose and scaling paint. However, if the old paint is thick, inflexible and incompatible with the new coating system, it must be removed. Compatibility of coatings will be covered later.

SSPC-SP-7, "BRUSH-OFF BLAST CLEANING"

This type of surface preparation is usually used when the environment is mild enough to allow tight mill scale, paint and minor amounts of tight rust to remain on the surface. This method is used extensively in maintaining existing coatings, which will be covered later. Check to ensure the surface is free of all loose mill scale and rust. The rust remaining should be a part of the surface. The remaining material should be tightly adhered and the surface should be abraded to provide a good anchor pattern to which the new coating can adhere to. Because of the high rate of cleaning, this method is inexpensive compared to other types of blast cleaning methods. It is usually used to supplement power tool cleaning and to provide the proper profile.

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INFORMATION SHEET

SURFACE PREPARATION Methods of Surface Preparation. (Cont'd)

SSPC-SP-10, "NEAR-WHITE METAL BLAST CLEANING"

This type of surface preparation method is used in areas with combinations of high humidity, chemical atmosphere, and marine environments where there are many corrosive elements including saltwater. It allows for some streaks and shadows and is less expensive than "White Metal Blast Cleaning". It can cost 10 to 35 percent less. It requires that 95% of the surface to be free of all rust and mill scale, but slight discolorations may remain.
SSPC-SP-11, POWER TOOL CLEANING TO BARE METAL

This type of surface preparation is to be used when a completely clean uncontaminated surface is required. A profile is required when using this type of power tool cleaning. Its advantage over SP-3, is for use on small confined surfaces that must be coated with a sophisticated or complex coating system. Cleanliness after Surface Preparation Cleanliness after surface preparation is very important. Residual traces of abrasive must be blown away before any primer coating is applied. Cleanliness can be checked in several ways. The primary method is to visually inspect the surface to determine if abrasive dust or grease needs to be removed. An ultraviolet light can be used to illuminate the surface to reveal traces of grease. Only approved ultraviolet lamps should be used.

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INFORMATION SHEET

INSPECTING SURFACE PREPARATIONS Surface Profile Inspection Surface Preparation Inspections are required to ensure that the proper profile and cleanliness has been obtained. The inspection ensures that all dust and debris from blasting has been removed by cleaning /vacuuming and the surface has a uniform textured profile.
Surface Profile

Paint will adhere much better to a surface that is rough. Abrasive blasting is an excellent way to roughen the surface. Hand Tool and Power Tool cleaning sometimes leave smooth surfaces that will not allow the coating to stick to the surface. When these methods are used, it is sometimes necessary to etch the repaired areas with abrasive blasting to prepare the surface for coating. Blasting the surface will provide a surface profile. The surface profile is made up of the ridges and valleys or points to which the coating can attach. That is why a profile is also called an anchor pattern. It is also called anchor profile, blast profile and surface profile. It is the pattern that achieves the best anchor for the coating to adhere to. A profile is the average peak to valley depth (height) caused by the impact of the abrasive material upon the substrate (steel). It is the average distance from the bottom of the valleys of the surface to the top of the ridges. This profile is intentionally placed upon the surface by the abrasive or power tool. Each type of abrasive material has a predetermined profile capability as shown in the SSPC Paint Manual, Vol. 2, Table 8, (Addendum Page 9 ). The type of blast cleaning does not specify the profile. Both White Metal and Commercial Blast Cleaning can have the same profile. The exact profile and the abrasive material to use to obtain the required profile must be specified. The profile required for coatings may be found in SAES-H-101, Saudi Aramco Data Sheet for the particular coating being applied. A specification for anchor profile should be stated as a range, for example, 60 150 microns.

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INFORMATION SHEET

INSPECTING SURFACE PREPARATIONS

Surface Profile Inspection

Surface Profile (Cont'd)

Each coating has a specified profile for best success as shown in SAES-H-101, APCS-1A, (Addendum Page 34). Both the profile requirements and the type of abrasive material to be used for the specified profile and cleanliness are listed. This will be covered later in this module. Profile depth is measured in micrometers or mils. Most job specifications in Saudi Aramco are written in micrometers (microns) or mils. A simple way to convert microns to mils is to remember that 25 microns is equal to 1 mil. One mil is equal to .001 of an inch.

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INFORMATION SHEET

INSPECTING SURFACE PREPARATIONS (Cont'd) Measuring Profile The inspector must measure the profile of any blasting job prior to the application of any coatings.There are many instruments the inspector can use to measure the profile of the surface. The ones used in Saudi Aramco are: Comparators (ASTM D 4417 Method A ) Profile gauge (ASTM D 4417 Method B ) Replica tape. ( ASTM D 4417 Method C )

The Profile Comparator

The profile comparator is a set of instruments containing a lighted magnifying glass and metal disc for visual reference. See ASTM D-4417 Method A, (Addendum page 35 - 37). One of the comparator kits in Saudi Aramco is the Keane-Tater Surface Profile Comparator. It contains the following items. 1. 2. 3. Note: Three discs, one for each type of abrasive used; sand, grit, and steel shot. Lighted magnifying glass (5x). Protective pouches.

The discs should always be kept in the protective pouch when not being used. This keeps the surface from being worn and scratched. This would cause a distorted profile and give a false picture.

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INFORMATION SHEET

INSPECTING SURFACE PREPARATIONS Measuring Profile

The Profile Comparator (Cont'd)

Each disc contained in the Comparator Kit is labeled with a set of numbers and letters. The numbers stamped on the discs look like this: 1S70. The numbers and letters represent the following The 1 is a profile of 1 mil. The S means sand. The disc is a visual reference for any surface prepared by blasting using sand as the abrasive material. The number 70 is the year in which the disc was made.

Each disc has five leaves. The disc is inserted in the magnifier and placed next to the surface. The surface is compared to the reference disc until a match is achieved. That match is the profile depth that is printed on the leaf. Sometimes an exact match is not possible. The profile will be between the two profile numbers stamped on the leaves of the disc. In this case, a number half way between the two numbers will be chosen. This is called Interpolation. If the profile is sufficient, work can proceed. If the profile is unacceptable, further blasting is necessary. Remember, this type of profile examination is subjective and the disc closes to the desired profile is acceptable.

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INFORMATION SHEET

INSPECTING SURFACE PREPARATIONS Measuring Profile (Cont'd)

Surface Profile Coupon

The surface profile coupons are small metal pieces that have been prepared in the laboratory to represent predetermined types of abrasive blasting and profiles. The most common one in Saudi Aramco is the Clemtex Profile Kit. It contains six profile coupons and a 5X magnifying glass. The profile is stamped on the coupons. The process of using the coupons is the same as for the comparator discs. The numbers stamped on the coupons are in mils. The numbers range from 1/2 to 3 in increments of 1/2 mil.
Dial Surface Profile Gauge

The Dial Surface Profile Gauge is an instrument that displays the profile depth on a gauge. See ASTM D 4417, Method B, ( Addendum page 35 - 37). The gauge is calibrated to zero on a flat surface. The base of the gauge is then placed on the surface. A pen in the base of the gauge extends downward into the valley of the profile, thus measuring the depth of the profile. The number is read off of the gauge at the pointer. Ten such readings should be taken and an average reading obtained. The dial gauge is in Mils. Caution: Lift the instrument off the surface each time you move it. Do not drag the gauge across the surface. This action will wear down the pin and make the instrument inaccurate and unusable.

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INFORMATION SHEET

INSPECTING SURFACE PREPARATIONS Measuring Profile (Cont'd)

Replica Tape

Replica tape is a tape with a mylar film surface on one side and an emulsion on the opposite side. See ASTM D 4417, Method C, ( Addendum page 35 - 37). The most common used in Saudi Aramco is the Testex "Press-o-Film". All types of replica tape are basically the same. The tape is placed on the surface to be measured with the emulsion side next to the surface. It is rubbed with a burnishing tool to force the emulsion side deep into the valleys and smash the emulsion at the peaks of the profile. The tape is then removed and measured with a spring micrometer to obtain the profile height. The depth of the profile is registered on the gauge. The tape may be retained in the file as a permanent part of the record. This method or the surface profile gauge method must be used when profiles are greater than those measured with the comparators.

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INFORMATION SHEET

INSPECTING ABRASIVE BLASTING OPERATIONS The inspector must ensure that the abrasive blast cleaning operation is monitored very carefully. Monitoring starts with testing the ambient conditions prior to the start of work and obtaining the long range forecast to ensure an adequate weather window. It includes checking the abrasive material to ensure that it meets the job specifications in the Saudi Aramco Data Sheet. When all these things are adequate, the inspector must turn his attention to the actual operation. Abrasive Blasting Machines The inspector must ensure that all the equipment used in abrasive blasting is working properly and is large enough to handle the job. All the air requirements of the job must be calculated. Compressors and blast machines must be large enough to supply the required amount of compressed air and breathing air if required. The supply of air must be clean and free of water or oil for the blasting operation. Water in the blasting air will cause rust and possibly contaminate the substrate. Oil in the air stream can contaminate the surface with oil. There are three common types of abrasive blast machines: Pressure type Suction type Vacuum type

The type indicates how the abrasive is carried into the hose or recirculated.

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INFORMATION SHEET

INSPECTING ABRASIVE BLASTING OPERATIONS Abrasive Blasting Machines (Cont'd)

Pressure Type

The type of Abrasive Blasting machines most used in the field is the Pressure Type. It is the most efficient of all the portable/movable types. In the pressuretype abrasive blasting system, the abrasive machine operates at the same pressure as the rest of the air system. The compressor, the abrasive machine, the air line, the abrasive blast hose and blast nozzle are all operated at the recommended pressure of 90 to 100 pounds per square inch (psi). This type uses an abrasive machine or "pot" into which the abrasives are loaded. The system is pressurized and draws the abrasives into the abrasive blast hose. The efficiency is based largely upon the nozzle orifice size. The orifice determines the size of the opening in the nozzle. The larger the orifice, the more abrasive it uses and the greater the production. The Inspector must ensure that all elements of the abrasive blast operation are serviceable and large enough to do the job. See Figure 7.

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INFORMATION SHEET

FIGURE 7

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INSPECTING ABRASIVE BLASTING OPERATIONS Abrasive Blasting Machines (Cont'd)

Suction Type

Another type of blasting machine is the suction type. It is about 1/3 less efficient than the pressure type. It is limited to touch-up and spot cleaning jobs.

Vacuum Type

The third type of blasting machine is the vacuum type. In this type, the air and the abrasive are captured by a rubber enclosure. The abrasive material and the contaminated particles are separated and the abrasive is recycled and returned to the abrasive container, which is called a pot. This type of blasting machine is used when a dust-free atmosphere must be maintained. Cleaning speed of the vacuum-type machine is not as fast as the pressure -type machine because the operator cannot see the surface being blasted. This technique is limited to recycled abrasives, which are more expensive.

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INFORMATION SHEET

INSPECTING ABRASIVE BLASTING OPERATION (Cont'd) Elements Of A Successful Blasting Operation The equipment and resources required for a successful abrasive blasting operation are illustrated in Figure 10, and by the corresponding numbers below. 1. Large compressor. The compressor capacity should be one size larger that the capacity required to operate all attached equipment and personnel protective suits. Large air hose and couplings. The air hose should be three or four times the size of the nozzle. Portable high production sandblast machine. The machine must always have a deadman shut-off. Large abrasive blast hose with external couplings. Hose should be three to four times larger than the nozzle. Large orifice venturi nozzle. The venturi nozzle gives much better blasting stream. Remote control valves. Moisture/oil separators located on the air receiver. High nozzle air pressure. A nozzle pressure of 90 to 100 psi is required for efficient blasting operation. Proper abrasive material selected from Saudi Aramco Data Sheet. Air-fed safety helmet. The requirements for use are listed in Table 4-2 of SAES-H- 102. Trained and Certified operators. Requirements listed in SAEP-316. Air Receiver. In Saudi Aramco, an Air Receiver/Exchanger is used to ensure that supply is steady and that oil and water cannot get into the lines.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

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INSPECTING ABRASIVE BLASTING OPERATION (Cont'd) Commercial Systems Operational Diagram Figure 11 shows an operational diagram of a commercial air blasting system used in Saudi Aramco. The parts are located at the corresponding numbers indicated below: 1. 2. 3. 4. Air flow from compressor Exhaust valve Self-cleaning abrasive trap. The screen is cleaned by air when the system air is turned on. Inlet valve. When the system is activated, air pressure opens this valve which is normally closed. This allows the compressor to pressurize the tank and begin blasting Choke valve. This valve is used to clear clogged abrasive lines. Trigger with deadman shut-off. This connects to the air supply inlet valve to shut off air automatically if it is dropped. Sand flow adjustment valve (metering valve). This valve adjusts the rate of flow of abrasives. Pop-up valve. This valve stops the flow of abrasive as part of the safety shut-down system (deadman shut-off.)

5. 6. 7. 8.

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OPERATIONAL DIAGRAM OF AIR BLAST MACHINE

3 1

7 6

FIGURE 11

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INSPECTING ABRASIVE BLASTING OPERATIONS Components of Air-Blast Equipment (Cont'd)

Air Supply

The inspector must test the air supply to ensure that it is free of oil and water. As a minimum, the inspector shall check and approve the air quality at the start of work, every four hours thereafter and if the compressor is shut off and restarted. Oil will remain on the blasted surface and cause coating failure. Water will cause rust to develop. The blotter test is performed to ensure there is no water or oil in the air supply. This test uses a clean surface such as blotter paper or a white cloth. Any contaminants or water will show up on the white surface. See ASTM D 4285, (Addendum page 38 ). The inspector must also check the air supply to ensure that the pressure is adequate for production. A needle gauge is used to measure the air pressure at the nozzle. Production air should be at 690 kPa (100 psi), but may range between 620-690 kPa (90 to 100 psi). SAES-H-100, Paragraph 5.4.2,( Addendum page 39 - 41), states the minimum pressure for blasting shall be 620 kPa (90 psi).

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INSPECTING ABRASIVE BLASTING OPERATION Components of Air-Blast Equipment

Air Supply (Cont'd)

The needle is injected into the hose just behind the nozzle to give a gauge reading. The test is performed while the abrasive is flowing and all the supporting equipment is running. A low pressure gauge reading alone is no reason to reject the unit. Low pressure simply will not allow the blasters to be as productive. It will take much longer to do the job. However, the profile may be affected and an improper profile is reason for the inspector to reject the job. The inspector must ensure that adequate breathing air is available for air-fed hoods. The air consumption requirements of each individual must be considered which is 20 cubic feet per minute (cfm). These requirements may be increased if ventilators are used which require 120 cfm for each ventilator. The air consumption requirements for blasting depend upon the size of the nozzle orifice being used. This requirement is listed in the SSPC Table # 1, ( Addendum page 23). The compressor size should be one size larger than required. A separate air source is required for air-fed hoods unless a carbon monoxide detector is installed on the air system. All equipment must be in good working order to produce air that is free of carbon monoxide. The inspector must be sure that worn units are removed from service. The first sign of a bad unit is excessive smoke and fumes from the exhaust pipe.

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INSPECTING ABRASIVE BLASTING OPERATION Components of Air-Blast Equipment (Cont'd)

Air Hoses And Couplings

The inspector must check the hoses to ensure that they are in good condition with no cracks or breaks and that when in operation they have no kinks and short bends. The size of the air hose should be three to four times the size of the nozzle orifice to reduce the possibility of rupture; no smaller than 1-1/4 is recommended. If the line is over 100 feet long, the hose should be at a minimum of four times the size of the nozzle orifice. Sometimes the hose has to be joined with a coupling. The inside diameter (I.D.) of the coupling has to be considered because the coupling may decrease the air flow to some degree. The size of the compressor manifold outlet and inlet valves may be a problem. Some air compressor units are supplied with a 1-inch manifold outlet and valves. These are usually not sufficient. Ensure that these manifolds are replaced with 1-1/2 to 2 -inch outlets to match the air supply hose size as shown. All couplings should be of the external-fitting type and couplings should be safety wired, or pinned, to prevent accidents in case they accidentally disconnect. Plastic clips (tie wraps) should never be used.

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INSPECTING ABRASIVE BLASTING OPERATION Components of Air-Blast Equipment (Cont'd)

Abrasive Blast Hose and Couplings

There are two types of abrasive blast hose: 4-ply is used when the hose is subject to heavy duty external use 2-ply is a lighter hose, preferred by some workers because of its greater flexibility

Abrasive material flowing through the abrasive blasting hose produces friction, which causes a loss of pressure of the abrasive. The hose size is the same as recommended for the air hose; 3 to 4 times the size of the nozzle orifice except at the nozzle end. All hoses should have capped ends to allow for coupling and to prevent any moisture or compressed air from working its way through the braid or ply of the hose. The size and length of blast hoses are related to their efficiency. A short piece of smaller hose about 10 feet long, and to 1 inch I.D., is used at the nozzle end of the hose to make it easier for the operator to handle. This smaller hose is called a "tail line" or a "whip hose".

Note: Couplings should be exterior type and should be fastened with a small screw through the coupling into the cover ply tube. xterior couplings do not reduce the flow due to friction loss. There is a normal drop of ! psi over a distance of !" feet with a #$% orifice. &t is important to use large hose as short as possible. 'll couplings should be wired shut to assure safe connections. Note. (sing a hose that is too large for the selected no))le is unproductive. The use of a hose that is too large such as a *+ inch hose on a small no))le such as a #$*,- no))le orifice may cause an uneven flow of abrasive material and be unproductive. 'll hoses should be grounded.

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INSPECTING ABRASIVE BLASTING OPERATION Components of Air-Blast Equipment (Cont'd)

Nozzles and Orifices

There are several items concerning abrasive blast nozzles: materials of nozzle linings size of nozzle orifice interior design of the nozzle

The inspector may see many types of nozzles. The material used to make the interior of the nozzle determines nozzle life. The materials described refer to the nozzle linings, the area in contact with the abrasive. Nozzles made of tungsten carbide have a 300 hour life. Ceramic and cast iron have a short life of about 2-4 hours of constant use. Silicon carbide provides the most durable lining, with a 750-1000 hour life. It can be used with all abrasives. The inspector should always inspect the nozzle for cracks and for size. If cracks occur, the nozzle should be discarded. If the nozzle breaks during operation, damage may occur. As the nozzle is used, the abrasives wear down the lining, increasing the diameter of the throat of the nozzle and decreasing its efficiency. The nozzle size is checked with a orifice gauge. The nozzle size is etched on the side of the nozzle housing. Nozzles are made in sizes of 1/16-inch increments. A number 1 is 1/16 of an inch in size. An number 8 is 1/2 inch in size (8/16 = 1/2). When performing this test, a mark is made on the orifice gauge using a grease pencil, at the approximate size of the nozzle. The gauge is inserted into the nozzle and twisted. The gauge is then withdrawn and the black mark examined. The I.D. of the nozzle is indicated by where the grease mark is on the nozzle. If the nozzle gauge indicates the nozzle is worn by 25% of its inside diameter (I.D.) the inspector should suggest that it be replaced.

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INSPECTING ABRASIVE BLASTING OPERATION Components of Air-Blast Equipment

Nozzles and Orifices (Cont'd)

There are two basic types of nozzles. For many years, all nozzles had a straight bore and a small throat opening. In 1954, the Venturi shape was developed. See Figure 14. The conventional nozzle is shown at (A) and the venturi nozzle is shown at (B). The conventional nozzle has a high impact in the center of the blasting pattern but the force is greatly reduced at the outer edges of the blasting pattern. The straight nozzle has an outlet abrasive velocity of about 217 miles per hour. This pattern is not as productive because it takes more passes or strokes to clean the same size area. The force of air and abrasive is not being utilized on the outer edge of the pattern. The Venturi shape has a large entrance throat, tapers gradually into a straight short section and then flares at the outlet end. This shape allows for an abrasive velocity up to 450 miles per hour. The venturi opening spreads the air and material more evenly on the outer edge of the blasting pattern which is more efficient. The pattern is wider and the cleaning blast more powerful and productive as shown at the close-up view in ( C).

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INSPECTING ABRASIVE BLASTING OPERATION Components of Air-Blast Equipment (Cont'd)

Control Valves

There are two types of control valves on the blasting machine: flow control valves and safety shut-off valves. Figure 15 shows an illustration of a pressure abrasive blasting machine. It has an inlet valve at ( 1), an outlet valve at (2), a choke valve at (3), an abrasive metering valve at ( 4), and a pressure safety valve built into the unit at (5). The choke valve is used only to clear clogged abrasive lines. The choke valve is closed momentarily to force all the pressure into the machine so that lines will unclog. This takes about 10 seconds. Check to make sure the lines are clear. The abrasive metering valve controls the abrasive/air mixture and meters the proper balance of abrasive to the nozzle size. Check to see that this valve is in good condition. Once it is set, it does not require continual monitoring.

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1 4

FIGURE 15

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INSPECTING ABRASIVE BLASTING OPERATION Components of Air-Blast Equipment (Cont'd)

Oil and Moisture Separators

The compressor may accumulate moisture in a high humidity area such as Saudi Arabia. There is also a possibility of oil mist forming from lubricants in the compressor. The oil and moisture separators on the compressor are designed to eliminate these problems. They remove oil, water and other contaminants through centrifugal force. They are installed at the most distant place between the compressor and the blast machine. The drain valves must be drained to prevent moisture and oil from getting into the air supply . The inspector must check these. They must eliminate 95% of all contaminants. If not, the valves must be removed, cleaned with solvent and replaced. If they still do not work properly after cleaning, they must be discarded and replaced. Centrifugal Wheel Blast Cleaning Centrifugal wheel blast cleaning is used in a wide variety of cleaning operations. In Saudi Aramco, the inspector will generally see this process in shop operations. Some general advantages are: Containment of blasting dust Ease of recycling abrasives Air equipment not required for the actual wheel blast operation

Some general disadvantages are: Complete cleaning of complex shapes is difficult Contaminants can be driven into the workpiece, especially when using steel shot Equipment is mechanically complex

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INSPECTING ABRASIVE BLASTING OPERATION (Cont'd) Centrifugal Wheel Blast Cleaning (Cont) Details of wheel design may vary with individual manufacturers. The following statements are general statements concerning wheel blast units: The motor driven bladed wheel hurls the abrasive by centrifugal force at the workpiece An impeller rotates with the wheel and carries the abrasive to an opening where it is discharged onto the wheel blades

The machines use one or more wheels, that are positioned so the abrasive reaches the entire surface. The number of wheels is determined by the size and shape of the object.

Personal Safety Equipment During Blasting Operation Personal equipment required while sandblasting in Saudi Aramco is outlined in Table 4-2 of SAES-H-102 (Addendum page 49 - 50 ). Ventilation requirements are listed in Table 4-1 (Addendum page 48 ) of the same standard. The purpose of this equipment is as follows: To provide safe respirable air to the user at a low noise level To protect the user from flying objects To provide clear vision

The inspector must follow the guidelines set out by SAES-H-102, ( Addendum page 42-50) and GI 6.021 (Addendum page 51 - 55). Blast Pot Safety Efficient use of the blast pot can save time and money in both manhours and abrasives. The blast pot should be emptied daily and kept dry to avoid

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contamination of the abrasive. The pot should be inspected annually and hydrotested to 1-1/2 times the design pressure.

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INSPECTING ABRASIVE BLASTING OPERATION (Cont'd) Abrasive Material Many types and sizes of abrasives are used in abrasive blasting. Each has a specific use and provides a special etch to the surface. Each type will give a different appearance to the surface. The coating to be used will determine the type of abrasive. This information is contained in SAES-H-101, Saudi Aramco Data Sheets. Each coating also requires a different surface profile or anchor pattern. The abrasive material is selected to give the specified profile. SSPC Vol. 2, Table 8, (Addendum page 9), shows the types of abrasives and the profile they produce. SSPC Vol. 2, Tables 3 & 6, ( Addendum page 6 & 8) shows aspects of different abrasives.
Testing Abrasives

Abrasives must be tested periodically to ensure that they are usable. Abrasives used more than one time are called "recirculated" abrasives. Recirculated abrasives may pick up contamination. The Floatation Test, is a simple test to determine if there is oil, dirt or contamination in an abrasive material. Place a small sample of the abrasive in a jar containing distilled water and shake for about two minutes. Allow it to stand for an hour undisturbed. If an oily film appears on the water or if the water appears to be clouded with dirt, you know the abrasive is contaminated. Litmus and pH paper will indicate the presence of any chemical salts. If the red litmus paper turns blue you know the solution is basic. If the blue litmus paper turns red you have an acidic solution. If the litmus paper does not change color, you do not know that there are any souble chemical salts present. Some chemical salts, including sodium chloride (common table salt) form a neutral solution. This test should be done before the job starts an every 4 hours thereafter.

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INSPECTING ABRASIVE BLASTING OPERATION Abrasive Material

Testing Abrasives (Cont'd)

If the inspector suspects that there are other types of contaminants present in the abrasive material, he takes a sample and sends it to the laboratory. The inspector must be specific about what he wants the lab to test. The lab will test only what the inspector indicates he wants tested. Be sure to fill out the Analysis Request Form.
Lab Test

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INSPECTING ABRASIVE BLASTING OPERATION Abrasive Material (Cont'd)

Characteristics of Abrasives

Blast abrasives are classified by the following characteristics.:

Size-

New abrasives consist of a narrow range of shot or grit sizes. Abrasive manufacturers supply shot or grit screened to SAE specifications. As abrasives are repeatedly used, the pellets will fracture into smaller pieces. The operating mix is maintained automatically by the machine as long as relatively small quantities of new abrasives are added regularly to the machine. When in doubt whether an abrasive is the correct size, a sieve test may be performed. A sieve is a wire screen with a specified opening in the mesh. This mesh opening is the sieve size. Most are measured in U.S. Sieve Size xample: *, . /" mesh is actually ."*,! inches by ."/,0 inches. This mesh corresponds to the National 1ureau of 2tandards 2i)e 3N124.

The required equipment is a balance scale and a set of NIST screens. A quantity (1000 grams) of abrasive is weighed and then poured into the nest of screens. The screens are nested with the coarsest is on the top, graded down to the finest on the bottom. The screens are shaken for a specific period of time. The amount of material on each screen is weighed. The percentage of material on each screen is then calculated. If 238 grams is retained on a certain screen, using 1000 grams for our original sample, 23.8% was retained on the screen.
Shape-

Indicates whether the abrasive is round, sharp or irregular. Different

The hardness scale is called the Moh's Hardness Scale.

shapes will produce different surface patterns and etches.

HardnessColor-

Ranges from light to dark. The lighter colored abrasive material reflects light and gives restricted visibility. Darker abrasives absorb the light and gives better visibility. This is important particularly on internal tanks and vessels.

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INSPECTING ABRASIVE BLASTING OPERATION Abrasive Material

Characteristics of Abrasives (Cont'd) Chemical Components-

Abrasives should be free of harmful materials such as clays that discolor the surface and remain on the surface of the blasted area. The abrasives should not contain any harmful chemicals such as sulfates and chlorides and should be pH neutral; that is the abrasive should have a pH range of 7.0. Saltwater washed abrasives should not be used. The pH factor was explained in the module on Surface Condition/Pre-Preparation.
Weight-

Heavy abrasives clean faster and the impact is greater than light-weight abrasives. Lightweight abrasives are used mainly for polishing.
Availability and Cost -

Abrasives are often selected on the basis of cost, (particularly transportation cost.) This is a very important factor in Saudi Arabia. On maintenance coating projects, regular ungraded sand is used because it is too expensive and time consuming to ship a huge supply of other abrasives.

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INSPECTING ABRASIVE BLASTING OPERATION Abrasive Material (Cont'd)

Types of Abrasives

There are many types of abrasives. Abrasives are classified into the five categories listed below:
Metallic-

Metallic Abrasives includes steel, iron, or grit. Grit is crushed steel or iron shot. Metallic abrasives have a longer useful life than sand or non-metallic abrasives. This useful life is 50 to 200 times longer than other types. Metallic abrasives have greater impact and clean faster. It also gives much better visibility and is most essential for interior tank and vessel surface preparation. Metallic abrasives do not imbed into the surface being prepared like softer materials. These materials are found naturally in the earth or may be manufactured. They are often used for special purposes, such as aluminum oxide , which is used to clean stainless steel.
OxidesSand-

There are two basic groups; silica and non-silica and many different types including sand and staurolite. They range from sharply angular in shape to round. Sand is cost effective and can be used in non-critical and maintenance work. Non-silica sand is called "heavy mineral" sand and is stronger and finer grained than silica sand. These are effective on new steel but are not recommended for maintenance jobs.
Vegetable-

This group includes corn cobs, walnut shells, peach pits and other farm by-products. Walnut shells and peach pits are very dense and work well to remove paint and fine scale for a steel surface without changing the substrate. They are also good for removing contaminants as are corncobs.
Slag or conglomerated (mixed) -

By-products of some type of manufacturing or power generating operation. They are excellent for blasting because of their uniform quality and sharply angular shape. They can be used for all jobs such as new steel, corrosion and maintenance blasting.

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CERTIFYING COATING PERSONNEL

Certification SAEP-316, (Addendum page 56 - 75), requires that all personnel involved with industrial/pipeline coatings go through a certification process designed to test their knowledge and skill at their job and to certify that they can perform their specific job assignment. Inspectors are also required to have certain experience and training, as outlined in Table 1 of SAEP-316. They are also required to go through specific training courses and be certified. The training and performance of the personnel involved is recorded on the "Coating Inspector Qualification Report", SAEP-316 Attachment C for inspectors and the "Coatings Applicator Qualification Report", SAEP-316 Attachment A for the applicators. All personnel involved must have a current certification form on file. All personnel must have current cards certifying they can perform the job. This must be accomplished prior to the start of work. This card must be on the person or present at the job site. The card format is shown in SAEP-316 Attachment D for inspectors and SAEP-316 Attachment B for applicators.

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CERTIFYING COATING PERSONNEL

Certification (Cont'd) Contractors may be allowed to administer their own Quality Control program but this program must meet Saudi Aramco standards. The Saudi Aramco Scope of Work, outlines the Quality Control specifications of the coatings portion of projects. Inspectors on coating jobs must ensure that all personnel are qualified to perform their task and that they have been certified. Personnel involved in coatings must be certified for the particular job they perform such as inspector, crew supervisor, abrasive blaster, and coating applicator. The certification must be signed by the proper person and the date must be current. The certification is good until the expiration date; the cardholder no longer works for the company indicated on the card; or, fails to retest before the expiration date. Individuals can be required to recertify any time their work becomes unsatisfactory to the Certified Coatings Inspector, Level 2, or higher authority. The inspector must always check the cards of individuals involved in coatings. If there is a question, check the Qualification Report . There are two levels of inspector for coatings and the requirements for each are contained in Table 1 of SAEP-316. The Level 1 inspector is the least qualified level and works directly for a Level 2 inspector. The Level 2 inspector has more experience and training than the Level 1 inspector. Requirements for each level are listed in SAEP-316.

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INSPECTING SCAFFOLDING AND STAGING There are numerous devices to assist the abrasive blast operators and painters to work in areas above their normal reach. All of these involve safety hazards and must be used with great care and must be set up properly. There are two general types: ground support and aerial support. Ground Supports Ground supports are those supports that set upon the ground and are not suspended by some mechanical device. These include the following devices:
Ladders

There are three types of ladders; stepladders, straight ladders and extension ladders. These devices have two legs and set upon the ground. They have to be moved periodically. This process is time consuming. Planks can be placed between two stepladders to form a platform but great care must be exercised because the platform is very narrow. Strong planks of at least two inches thick must be used and the length should be short. There are also devices to attach to ladders such as ladder platforms, which make them more effective. Ladders may be made out of wood, metal or fiberglass. Metal ladders should never be used around electrical sources. They will also corrode easily. Wood is heavy and will eventually rot in a damp environment. The preferred type is fiberglass which is light, will not rot and will not conduct electricity.

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INSPECTING SCAFFOLDING AND STAGING Ground Supports (Cont'd)

Scaffolds

Built-up or portable scaffolds are safer than ladders. They make the work easier and faster. Some have wheels called casters. The casters make them portable because they can be rolled from place to place. Scaffolds should always be used on larger jobs if possible instead of ladders.
Stationary Scaffolds

These scaffolds are put up for a particular job or phase of a job and then taken down and moved to the next phase or the next job. Many now are lightweight tubular steel, which are easy to install. The metal ones are dangerous around electrical sources.
Portable Support Systems

These may be used on special jobs and are easy to move and handle. The two major ones are boom lifts and scissor lifts

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INSPECTING SCAFFOLDING AND STAGING (Cont'd) Aerial Support Aerial supports include all types of supports that are suspended above the ground. These are generally called rigging. The different types are discussed below.
Cable-Supported Scaffolds

These are scaffolds that are suspended from above, such as from the roof of the structure being worked on. They are suspended on cables with motors and winches that can be operated from the platform to move the scaffold up and down.
Swinging Scaffold -

This scaffold is usually supported by two or four cables and can be as large as 40 feet long and 28 inches wide.
Bosuns Chair-

These are used for a one-man operation above the ground. One person is strapped in a canvas chair and can operate the lift from the chair. The equipment is strapped to the chair also.

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INSPECTING SCAFFOLDING AND STAGING (Cont'd) Scaffolding And Staging Safety Any time personnel are working above ground level, there are safety factors to consider. The inspector should observe while the equipment is being set up and should inspect all scaffolding and staging to ensure they meet safety requirements prior to the use of such devices
Stationary Supports

Stationary supports are supports that do not move up and down. Once they are put in place, the work is performed at that level until the staging area is moved and a new staging area is established. They may be on rollers and moved from place to place, but not up and down, by a mechanical device. All stationary supports should be inspected to ensure there are no safety hazards. Inspect to ensure that: All materials are strong and in good condition. There should be no large rusted areas. If there are, these materials should be rejected. The materials should meet all specifications for strength, width, height and load limits. Staging material must be strong enough to hold at least twice its weight. Scaffolding should be dry and free of oil and debris, so no one will trip over it. All joining parts are strong and free of rust. The units should be stable in every direction. Check to be sure support members are on firm bases and are perfectly upright. Scaffolds must be anchored to structures or have guy wires attached every 25 feet horizontally and 15 feet vertically. The scaffold should be about 1 1/2 feet from the surface to be blasted or coated. The planking must be a minimum of 18 inches wide.

INSPECTING SCAFFOLDING AND STAGING (Cont'd)

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Safety devices should be checked to ensure they are installed and working properly. Guard rails must be installed 42 inches above the staging (floor) of the scaffold. These guard rails must be on the sides and ends of the scaffold. There must be intermediate rails 20 inches above the staging and toe rails 6 inches high. These rails must be tubular fittings, not cable or rope. These rails will prevent the worker from falling or getting his foot broken from falling objects. Access ladders must be provided to all work areas. Electrical power sources must not be located within 10 feet of scaffolding. Working on a scaffolding is always dangerous. Do not allow personnel to climb on the braces. Do not allow personnel to reach over the edge. The scaffold should be moved to get to other locations, which are out of reach of the worker Be sure that movable scaffolds have casters that have brakes and are at least 6 inches in diameter. This allows them to be stopped and maneuvered easily. Be sure there are enough personnel available to move them before the moving starts. Once rolling, it may require a lot of manpower to stop (at least one person on each wheel brake.)

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INSPECTING SCAFFOLDING AND STAGING Scaffolding And Staging Safety(Cont'd)

Portable Supports

Portable supports are those that may be moved from place to place. They can also move vertically and horizontally by boom or hydraulic action such as scissor lifts. The following safety factors apply to booms and scissor lifts.
Operation-

Be sure that only authorized personnel operate this equipment. In Saudi Aramco, such personnel must be certified and licensed. Be sure the equipment operates properly. Never use faulty or improperly operating equipment. Never allow contractors to operate such equipment below or in close proximity to power supplies. Do not allow contractors to use the boom as a crane to lift material with. Do not allow contractors to operate the boom above the rated capacity. Do not allow contractors to operate when vision is limited. Require contractors to use a spotter to help the operator particularly on the return swing. Do not allow any personnel to walk under a boom. Be sure operators always keep their attention on the boom travel. Do not shout at or allow contractors to shout at the operator while boom is in operation. The operator must keep his mind and his eyes on the operation and travel of the boom. Use standard hand signals if required. Do not allow contractors to do any maintenance on the equipment until the power source has been disabled.
Movement-

Do not allow equipment to be moved unless scissors or booms are down and locked in place. Be sure all outriggers and jacks are removed. Do not tip the machine or operate on uneven ground. Be sure the equipment is set on the base pads on level ground. Do not allow the equipment to be operated until the jacks and outriggers have been extended and are on solid ground. Use concrete pads for shoring if necessary. Be sure all obstructions and personnel are clear of the extending boom or moving equipment.
Set-up-

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INSPECTING SCAFFOLDING AND STAGING Scaffolding And Staging Safety

Portable Supports Use of Platform -

Keep the platform clean and free of oil or other slippery material. Do not allow it to get cluttered. Check the surface before the workers occupy it. Do not allow anyone to walk or climb on the boom or the scissor. Use caution when entering and leaving platform. Make sure personnel use the gate to enter and leave. Be sure no cables are attached to the platform. Be sure safety belts and lifelines are used at all times when personnel are on the platform. Never allow anyone to use a ladder on the platform to reach higher that the platform limit. Be sure everyone keeps both feet flat on the platform deck.
Rigging

Rigging is the cable and winches that move the swinging and suspended platforms. The following precautions apply to cable-operated rigging. Always read all instructions applicable to cable rigging. Be sure it is strong, free of rust and in good operating order. Check the cable by applying twice the rated load at a height of one foot above the ground. This will ensure that if it does fail, it will cause little damage at that height. Always be sure the combined weight of the load and the operators are below the rated capacity.
CablingEquipment-

This includes motors, pulleys and drivers. This equipment should have free-fall safety devices and manual controls. The machine should have worm gears and should be able to be moved by power in both directions. Check the equipment to ensure that it will not move when the power is off. In addition to normal brakes, the power-driven units must have emergency brakes that operate automatically when the normal descent speed is exceeded.

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INSPECTING SCAFFOLDING AND STAGING Scaffolding And Staging Safety

Rigging (Cont'd)

Scaffolds may sway and move in the wind. To prevent this the scaffold must be guyed and braced. Suspended scaffolds must have guardrails 42 inches high all around, intermediate guardrails and toe rails as already specified. Safety belts and fall prevention devices must be used and attached to a lifeline. The lifeline must be tied so that if the worker falls, they will not reach the ground. No more than two workers should occupy the stage of a scaffold if it is rated at 500 pounds and no more than three persons if the scaffold is rated at 750 pounds. Do not allow workers to reach over the side of the rigging.
Safety devices Suspended Scaffolds

Suspended scaffolds are those that are suspended from above on a device that runs on a track or similar device. Basically the same safety factors apply for suspended scaffolds as for other scaffolds.

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EXERCISE

EXERCISE 1

PERFORM INSPECTION OF ABRASIVE BLASTING OPERATION.

Refer to Work Aid 4 and the Addendum Pages, Information Sheet and peers to answer the questions below: Write the answer in the space provided. There are three abrasive blast operators on a project, One is using a 3/8" nozzle One is using a 7/16" nozzle One is using a 1/2" nozzle

1.

At 100 psi, what is the combined air consumption of the three workers for one hour at 100 psi.

Each worker in Question 1 requires an air-fed hood and each requires an airdriven ventilator. 2. What is the air consumption for all the hoods and air ventilator?

3.

What is the total air consumption in problems 1 and 2?

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EXERCISE

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EXERCISE

EXERCISE 1 (Cont'd) 4. What would the minimum diameter size of the air-supply hose be for each worker in Question 1 if the hose is over 100 feet long?

5.

What is the working pressure required at the blasting machine?

6.

What is the maximum hose length for a suction blasting machine?

7.

What is the minimum abrasive blasting hose diameter requirements for each of the workers in Question 1?

8.

What aspect of grounding the equipment does the Inspector need to verify?

9.

What does the Inspector need to verify about the hose couplings?

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EXERCISE

EXERCISE 2

PERFORM SURFACE PROFILE TEST

The Instructor will provide a sample of a steel surface that has been previously prepared. Use one of the four types of instrument/test and one of the Work Aids of the same title to determine the surface profile. You may use the Information Sheet and peers within your group to obtain the correct profile. 1. Use the Keane-Tator Surface Profile Comparator and Work Aid 6 to determine the surface profile of sample 1

2.

Use the Dial Surface Profile Gauge and Work Aid 7 to determine the surface profile of sample 2.

3.

Use the Testex Press-O-Film Replica Tape and Work Aid 8 to determine the surface profile of sample 3.

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EXERCISE 3

USE CHART AND VERBAL DESCRIPTION TO DETERMINE SURFACE PREPARATION GRADE AND QUALITY REQUIRED

This Exercise is designed to give the Participant practice in how to find information in the SSPC Manuals. Refer to Addendum Pages, Information Sheet and peers In the questions below, a verbal description of the required surface preparation quality and rust grade are given. In the blanks provided, write the surface preparation quality grade, the SSPC Specification number and method. 1. Blast clean to pure metal, remove all visible rust and millscale. C

Rust grade SSPC Specification/Method Surface Preparation Grade. 2.

Remove all oil, grease and dirt with solvent.. None

Rust grade SSPC Specification/Method. Surface Preparation Grade

3.

Remove all loose rust by hand chipping, sanding or scraping. B

Rust grade SSPC Specification/Method. Surface Preparation Grade

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EXERCISE

EXERCISE 3 (Cont'd) 4. Light blast cleaning of all except tightly adhering residues of rust. Rust grade SSPC Specification/Method Surface Preparation Grade 5. Very thorough blast cleaning to nearly white metal. Rust grade SSPC Specification/Method. Surface Preparation Grade. D C

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EXERCISE 4

VERIFY THAT SCAFFOLDING IS PROPERLY INSTALLED.

Below are facts about the scaffolding that has been set-up at the work site for sandblasting and coating. Refer to Information Sheet and peers to obtain the correct answer. Read the listed facts. If the statement is correct about the safety requirements for scaffolding, place a "YES" in the blank. Place a "NO" in the blank if the statement about scaffolding is not correct about the safety requirements. Facts: You are the Inspector on a job. You arrive at the job. The scaffolding is set up and ready for inspection. The inspection reveals the following about the stationary supports. Statements: 1. 2. 3. 4. 5. 6. 7. The tubular material is 2 -1/2 inches in diameter. The scaffolding is 6 inches from the structure to be prepared. The scaffold is guyed every 25 feet horizontally but not vertically. Guard rails are installed 42 inches above the floor of the scaffold. Planking is 18 inches wide. An electrical wire is just behind the scaffolding. Casters are 4 inches in diameter.

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EXERCISE

EXERCISE 5

FILL OUT IN-PROCESS INSPECTION FORM ASSOCIATED WITH SURFACE PREPARATION

This Exercise will be continuous throughout the first series of modules. Instructions will be given to fill out various parts of the forms used in coating inspections. Follow the steps below: 1. 2. Fill out the first part of the In-process Inspection Sheet Fill in the Abrasive Blasting section in the Surface Preparation section using information in the Work Aid, Addendum and Information Sheet. Fill out the form provided by the Instructor during the field trip. Keep this In-Process Inspection sheet. entered into this form in later modules. Additional information will be

3.

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WORKAID

WORK AID 1

PERFORM BLOTTER TEST ON ABRASIVE BLASTING AIR SUPPLY

This Work Aid will assist the Participant in determining if the abrasive blasting air supply is clean. 1. 2. 3. 5. 6. 8. 9. Procure a piece of white blotter paper or a white cloth. Start the air compressor and allow it to warm up. Adjust the cloth or paper on a clipboard for stability. Aim air nozzle at clipboard held 18 inches from nozzle. Engage air trigger and allow to run for 2 minutes. If water or oil is detected, stop operation and verify that the contractor performs maintenance on the system. Verify that the contractor checks and replaces filters and drains traps if necessary.

10. Retest after traps and filters have been checked and or replaced. 11. If changing filters and traps does not solve the problem, verify that the contractor takes the unit out of service and replaces the unit. 12. Verify that the area contaminated by oil is washed down with solvent and reblasted.

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WORKAID

WORK AID 2

USE HYPODERMIC NEEDLE AIR GAUGE TO TEST AIR SUPPLY PRESSURE

This Work Aid will assist the Participant in determining if abrasive blasting airnozzle orifice and pressure meets specifications. 1. 2. 3. Start the air compressor and allow it to warm up. Bring the air pressure up until the specified level is shown on compressor gauge. Insert the hypodermic needle of the air gauge into the sandblast hose as close to the nozzle as possible. The needle should be pointing downstream from the air supply. Read the pressure on the gauge while the nozzle is engaged and the abrasive flowing. If the air supply is inadequate to meet the specifications, adjust as required. If the adjustments fail to bring the pressure into limits, replace the air unit if possible. 5ood working no))le pressure is 0" to *"" psig. Low pressure is not a reason to re6ect work. Low pressure slows down work and improper pressure may not give the specified profile. &mproper profile is reason to re6ect the work.

4. 5.

Note

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WORKAID

WORK AID 3 1. 2

USE NOZZLE ORIFICE GAUGE TO TEST NOZZLE SIZE

Inspect the nozzle for cracks and wear. Reject any defective nozzles. Locate the number etched on the nozzle housing. This number indicates the size of the nozzle in sixteenths of an inch when new. A number 8 nozzle is 1/2-inch in diameter (1/16 X 8.) Insert the nozzle orifice gauge into the orifice. Read the gauge. Determine if the nozzle is worn beyond usable limits. Reject nozzles worn more than 25% of the inside diameter (I.D.)

3.

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WORKAID

WORK AID 4

PERFORM INSPECTION OF ABRASIVE BLASTING OPERATION

This Work Aid will assist the Participant in determining if the recirculated abrasive blasting operation is safe and functioning properly. Material pertinent to this Work Aid will also be located in the Addendum. A. AIR SUPPLY: 1. 2. 3. 4. 5. Check pressure and volume. Check orifice nozzle size(s) to determine air consumption. Use the Table in the Addendum to determine requirements. Check the number of units in use. Check number of air-fed hoods required (20 cfm each) Check number of air-driven ventilators (120 cfm each) ' separate air supply is re8uired for air+fed hoods if carbon monoxide detectors are not installed on e8uipment

7arning:

B. AIR HOSE AND COUPLINGS 6. Check the size of the air supply hose to ensure it is at least three times the size of the nozzle orifice. Ensure that hoses greater than 100 feet in length, are four times the size of the nozzle orifice. Check the inside diameter (I.D.) of all couplings to ensure that air is not restricted. Check the compressor manifold, valves and outlets. They should not be smaller than the air hose requirements.

7. 8.

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WORK AID 4 (Cont'd) ABRASIVE BLAST MACHINE 9. Check the pressure at the machine (125 psi working pressure.)

10. Verify that the abrasive metering valve is operating 11. Check the pressurizing and de-pressurizing valve of the pressure tank. 12. For suction machines, ensure that the hose distance is less than 25 feet. D. ABRASIVE BLAST HOSE AND COUPLINGS: 13. Verify that the hose is three to four times the size of the nozzle orifice except at the end near the nozzle 14. Check the whip hose to ensure an adequate flow 15. Verify that the hose is properly grounded if it is not the anti-static type 16. Verify that in areas of high volatility, additional grounding of the hose is performed. 17. Verify that the parts being blasted are also grounded. 18. Verify that all couplings are the exterior type. 19. Verify that all couplings are wired or pinned at the connections. 20. Verify that the nozzle is working properly . Check for excessive wear. E. CONTROL VALVES 21. Check the automatic shut-off valve (deadman.) 22. Verify that the choke valve is unblocked. 23. Check the abrasive metering valve for proper operation.

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WORKAID

WORK AID # 4 (Cont'd) F. OIL AND MOISTURE SEPARATORS 24. Verify that the oil/moisture separators are installed at the most distant point from the compressor. Drain all moisture from the traps 25. Check all moisture and oil separators. Clean or replace as necessary.

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WORKAID

WORK AID 5

PERFORM TEST FOR CLEANLINESS OF ABRASIVE BLASTING MATERIAL

This Work Aid will assist the Participant in determining if recirculated abrasive blasting material meets specifications for cleanliness. Note: 1. 2. 3. 4. 5. 6. 7. 8. 9. Test is re8uired only for recirculated abrasive blasting material.

Take a small sample of abrasive material. One cup is adequate. Place the sample in a quart jar or beaker of sweetwater. Shake the contents for 2 minutes. Allow to set undisturbed for 1 hour. Visually examine the contents of the jar or beaker. If oil is present on top of the water, verify that the contractor stops work. Reject all the area blasted since the last test. Verify that new abrasives are delivered prior to restarting work. Test the abrasive prior to continuing work as indicated in steps 1 through 5 above. Verify that the contractor solvent cleans the area contaminated in accordance with SSPC-SP-1, "Solvent Cleaning".

10. Verify that the contractor re-blasts the area after solvent cleaning to remove any oil or rust bloom.

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WORKAID

WORK AID 6

USE KEANE-TATOR SURFACE PROFILE COMPARATOR TO PERFORM SURFACE PROFILE TEST

This Work Aid will assist the Participant in determining if the surface profile meets specifications. 1. 2. 3. 4. 5. Check the profile immediately after surface preparation. Verify the profile required by specifications or the Manufacturer's Data Sheet. Procure the comparator kit from Inspection Section. Mark off an area with a greaseless marker. Open the kit and select one of the three comparator discs for the type of material used as abrasive (S for sand, G/S for metallic grit or steel, and SH for steel shot). This information is stamped on the comparator leaves along with the depth profile in mils. The depth profile is the first number in the series of numbers and letters. Remove the 5X magnifying glass for the case. Turn on the light. Attach the selected comparator disc to the magnet on the base of the magnifying glass. Place the magnifying glass with disc attached next to the surface of the substrate. Examine the surface and compare it to each of the five leaves on the disc one at a time until a match is found. The match between the surface and the comparator may be between two leaves. &f so9 interpolate to the *$: position. ' surface that appeared between : and # mils. would be : *$: mils.

Note

6. 7. 8.

Note

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WORKAID

WORK AID 6 (Cont'd) 9. Repeat step 8 several times. Log the results each time. Find the average of the readings. Compare the average you obtained with the profile required. If the profile is satisfactory, no action is necessary.

10. If the profile is unsatisfactory, work cannot continue. Notify the engineer and verify that the contractor corrects the discrepancy.

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WORKAID

WORK AID 7

USE THE DIAL SURFACE PROFILE GAUGE TO PERFORM SURFACE PROFILE TEST

This Work Aid will assist the Participant in determining if the surface profile meets specifications. 1. Remove the depth micrometer from the case 1e careful. Do not drop or throw the instrument. &t is delicate and may break. &t is very expensive to replace.

Caution:

CALIBRATE 2. Place the base of the gauge on a mirror or plate glass. A conical shaped pin will protrude from the base of the instrument. Be sure the point of the pin is visible to you. Turn the entire scale ring until the pointer is aligned on the "0"(zero) mark. At this point, the pin should just be touching the surface of the glass. If the pin does not touch the glass surface when the scale is at zero, the pin end has been worn and the instrument is no longer usable. Replace worn or faulty instruments.

3.

4.

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WORKAID

WORK AID 7 (Cont'd) OPERATE 5. 6. Place the instrument firmly but gently on the surface to be evaluated. Take a reading of the gauge. Repeat step 4 and 5 several times at different locations on the surface. ;rofile 5auge will not be *""< accurate on pitted steel. The number of readings taken should be increased. Lift the instrument from the surface each time a new reading is taken. Dragging the instrument across the surface will wear the point of the pin and cause severe error.

Note:

Caution

7.

Log the various readings. When several readings have been obtained, compute the average by adding the samples together and dividing by the number of samples. Compare the average you obtained with the profile required. If the profile is satisfactory, no action is necessary. If the profile is unsatisfactory, work cannot continue. Notify the engineer and verify that the contractor corrects the discrepancy.

8. 9.

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WORKAID

WORK AID 8

USE THE TESTEX "PRESS-O-FILM" REPLICA TAPE TO PERFORM SURFACE PROFILE TEST

This Work Aid will assist the Participant in determining if surface profile meets specifications. 1. Procure the following items from the inspection section. 2. Replica tape kit. Burnishing tool Spring micrometer

Open the replica tape package and select one piece of tape of the proper size for the specified profile. There are two thickness of tape. Coarse is " to :.! mils thick and xtra Coarse is :.! to /.! mils thick.

Note:

3. 4. 5. 6. 7. 8. 9.

Place the tape on the surface to be measured with the emulsion side next to the surface. Rub the mylar film side vigorously with a burnishing tool. Remove the tape. Place the tape between the jaws of the micrometer while the spring is depressed. The gauge will read zero. Release the spring Measure the areas of the tape that are not depressed. These areas are the depth of the profile. This value will be the figure at the pointer on the dial. Subtract 2 mils (the thickness of the mylar) from the dial reading. This is the profile depth. Compare this reading with the specified depth profile. satisfactory, no action is necessary. If the profile is

If the profile is unsatisfactory, work cannot continue. Notify the engineer and verify that the contractor corrects the discrepancy.

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WORKAID

WORK AID 9

SAFETY CHECKLIST FOR SURFACE PREPARATION

This Work Aid will assist the Participant to ensure that safety procedures are followed during the surface preparation phase of the coating job. This is a checklist to help the participant organize applicable safety requirements into a logical sequence. Caution: This checklist does not take the place of 2'(D& '='>C? and &ndustry published safety instructions. &t is only a guide. @ollow the steps below:

1.

Procure the following safety standards. SAES-H-100 SAES-H-101 SAES-H-101V SAES-H-102 G.I. 6.021

Note::

2'(D& '='>C? Data 2heets 32' 2+A+*"*B4 contain the specifications for storage of the material approved for 2'(D& '='>C? use. @ollow all safety and storage re8uirements.

2. 3.

Verify that all personnel involved in abrasive blasting operation wear personal protective equipment as outlined in Table 4-2 of SAES-H-102. Verify that all breathing apparatuses and filters are OSHA approved.

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WORKAID

WORK AID 9 (Cont'd) 4. 5. 6. 7. 8. Verify that ventilation requirements are maintained during abrasive blasting in accordance with Table 4-1 of SAES-H-102 and paragraph 4.2. Verify that breathing air supply meets specifications of paragraph 4 of G.I. 6.021 Verify that abrasive blast equipment meets the requirements of SAES-H102 paragraph 4.4.2. and paragraph 6 of G.I. 6.021 Verify that compressors, which are oil lubricated meet specifications of G.I. 6.021, paragraph 4.3. Verify that all equipment grounding requirements are complied with in accordance with Paragraph 4.4.2 of SAES-H-102 and paragraph 6 of G.I. 6.021. Verify that blasting hoses couplings are of the proper type and are pinned or safety wired at each connection.

9.

10. Verify that noise suppression equipment is used in accordance with Paragraph 4.4.1.3. of SAES-H-102 and paragraph 7 of G.I. 6.021. 11. Verify that power tools are operated safely as prescribe by Paragraph 4.4.1. of SAES-H-102. 12. Verify that health hazards do not exist as outlined in Paragraph 4.3.of SAES-H-102 and paragraph 3 of G.I. 6.021.

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WORKAID

WORK AID 9 (Cont'd) 13. Verify that all personnel involved in critical coating projects are qualified and certified in accordance with SAEP 316 (Complete Work Aid # 14). Note: &nspection items on this checklists follow the ma6or headings in the inspection plan. This is the 2econd in a series of checklist that have been developed for this course. Ceep this checklist. 1y the end of the course9 all of these checklists together provide the &nspector a complete coating checklist covering every phase of the 6ob.

Note:

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WORKAID

WORK AID 10

CHECKLIST FOR VERIFYING QUALIFICATION AND CERTIFICATION OF COATING PERSONNEL

This Work Aid will assist the Participant in verifying that requirements established by Saudi Aramco for Certified Coating Personnel are complied with. Follow the steps below: 1. 2. 3. Verify that all certified coating personnel are qualified prior to the start of work Verify that all certified coating personnel are in possession of a Certification Card. Verify the following items on the Certification Card: 4 Proper signature on front by Inspector Supervisor. Proper signature on back by Certified Coating Inspector Level 2. Expiration date has not been exceeded Card holder is still employed by company indicated on card. Qualification checked for the job being performed. Person possessing card is the person the card was issued to (check the picture to verify).

If doubt arises on the capability of the individual, check the Coating Qualification Report to ensure proper training and certification.

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GLOSSARY

abrasion abrasion resistance abrasive

Wearing away of a surface by friction due to rubbing, blasting, scraping or erosion. The ability of a coating to withstand wearing as a result of friction. A material used to blast clean a surface. Some of these are sand steel grit, steel shot and metallic oxide particles. Cleaning or preparing a surface for coating by hitting the surface with abrasive products using an abrasive blast machine. A cleaning method for surface preparation using acid which makes the surface rough. The depth of surface roughness after abrasive blasting. It is measured from the depth of the depression to the top of the peak. (Also anchor profile and blast profile.) The depth of surface roughness after abrasive blasting. It is measured from the depth of the depression to the top of the peak. (Also anchor pattern and blast profile.) A method of surface preparation using abrasives propelled through a nozzle or centrifugal wheel. The depth of surface roughness after abrasive blasting. It is measured from the depth of the depression to the top of the peak. (Also anchor pattern and anchor profile.) Cubic feet per minute.

abrasive blasting

acid etch anchor pattern

anchor profile

blast cleaning blast profile

cfm

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GLOSSARY

comparator "deadman" control

A device or tool to determine surface profile. A remote control device that stops the blasting machine automatically if the operator should drop the trigger mechanism. To remove grease and fatty substances from a surface by using solvents or detergents or a combination of both. To reduce the quantity of water vapor in an area that is usually confined. Separation of one coat or layer of paint or coating from another coat or layer. Determine a value that is somewhere between two stated values; it is greater than one value but less than the other. A device on an air system to take the oil and water out of the stream of air. These are also known as moisture traps and oil/moisture traps. The roughness of a prepared surface. It is a measure of the anchor pattern or anchor profile. The average depth between the high and low points of the anchor profile. A value obtained by looking at the pointer on a gauge or rule. Wires, cables and rope that make up the suspension devices for scaffolding. Immediate rusting of a newly-blasted surface due to excess moisture either in the atmosphere or in the abrasive blasting air. Any device used to attain a greater height other than ladders. The platform on a scaffold. An area to work upon.

de-grease

dehumidify delamination interpolate

oil/moisture separator

profile profile depth reading(noun) rigging rust bloom

scaffold staging

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GLOSSARY

substrate

The surface of steel, concrete, or wood

surface profile

The depth of surface roughness after abrasive blasting. It is measured from the depth of the depression to the top of the peak. (Also anchor pattern, blast profile and anchor profile.) Manufactured grit. (TLV) A value for evaluating a workers exposure to toxic material. The values are used to determine the health of personnel exposed to airborne toxic material. The gaseous state of a substance which is normally solid or liquid. Heat or burning causes vapor to form. Many materials give off harmful vapors that cause health problems when inhaled for long periods of time.

synthetic abrasive Threshold Limit Values

vapor

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EVALUATION

Write short answers to the following questions in the blank space provided. Extra space is not required. 1. What are the two purposes of the surface preparation inspection?

2.

The presence of oil and moisture in compressed air: a) Should be checked with a white blotter paper or cloth b) Is completely removed by the oil and moisture separators c) Is not important during cleaning operations d) Should be checked with a needle gage Use an orifice gage to check the: a) the O.D. of the blast nozzle b) the length of the blast nozzle c) the I.D. of the nozzle d) all of the above Steel surface completely covered with adherent mill scale: little or no rust visible is rust grade: a) B b) E c) A d) D Abrasive blast hose couplings must be: a) externally fitted b) wired shut to assure safe connections c) grounded d) all of the above

3.

4.

5.

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EVALUATION

6.

Anchor profile is: a) the degree of surface cleanliness b) the measured average peak to valley depth c) the visual surface condition d) none of the above On a sieve the larger the sieve number the finer the screen: a) true b) false The air hose should be: a) no greater than !"# b) $ times the no%%le orifice si%e c) $&' greater than the no%%le orifice si%e d) ( to " times the no%%le orifice si%e A special tape used to measure surface profile is: a) masking tape b) transparent tape c) replica tape d) anchor tape The air pressure should be checked *ith the abrasive flo*ing and all supporting e+uipment running a) true b) false The standard for measuring surface profile is: a) ,,-./0is/ b) A,T1 2 "" 7 c) 3A.4 5-& 78 d) 6,O 8$& /8) An e8ample of a metallic abrasive *ould be: a) garnet b) silica c) steel shot d) slag The label of surface comparator disc 7,7& stands for:

7. 8.

).

&.

7.

(.

14.

If the initial rust grade is C and the surface prep is commercial blast it is: a) CSP5 b) BSP10

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EVALUATION

c) CSP6 d) none of the above

15.

What is the abrasive consumption rate per hour of the following listed nozzle sizes? 3/16"= 5/16'=

16.

What is the air requirement in CFM (cubic feet per minute) at 100 PSI (pounds per square inch) for the following size nozzle? 3/16"= 5/16"=

17.

When in doubt if the abrasive is the correct size: a) a blotter test is performed b) a hypodermic needle test is performed c) a surface comparator is used d) a sieve test is performed In dry abrasive air blasting, the blast pot: a) is where the compressed air and abrasive are mixed b) should be emptied daily c) should be inspected annually and hydrotested d) all of the above A number 12 blast nozzle is what size ? a) 1/2 b) 5/8 c) 3/4 d) 1 A choke valve on a blast pot is used to: a) meter the amount of abrasive and air b) shut off the air in an emergency c) clear the clogged abrasive lines d) control the air pressure

18.

19.

20.

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EVALUATION

21.

The test for contaminated abrasives is: a) Chloride test b) Sieve test c) Floatation test d) Ferrous ions test Measuring the surface profile with a dial surface profile gage is: a) method C b) method A c) method D d) method B The larger the nozzle orifice size the more abrasive it uses and the less production: a) true b) false 3 workers are blasting, all are using an air fed hood and a ventilator, what is the air requirement for 8 hours, for all 3 men ?

22.

23.

24.

25.

Inspection for surface cleanliness should take place: a) before any surface preparation activities b) after surface preparation, before coating begins c) between each coat application d) all of the above e) b and c only

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EVALUATION

31. Of the materials listed in questions 25-30, which would complete a job the fastest?

What is the consumption rate in lbs./sq. ft. for the following abrasives? 32. 33. 34. 35. 36. 37. 38. Silica Sand 16/40 Mesh= Aluminum Oxide 36 Grit= G40 Steel Grit= Staurolite 50/100 Mesh= Coal Slag 16/40 Mesh= Copper Slag 16/40 Mesh= When abrasive blasting a 100 sq. ft. surface, without recycling the abrasive material, which of the materials in question 32-37 would last the longest?

39. What size diameter is required for a 100 feet long abrasive blasting hose if using a 1/2-inch nozzle?

40. What is a "deadman" shutoff valve?

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