CIP 1 Day 1 and 2 Flashcards
(109 cards)
1
Q
_________ is the deterioration of a material, usually a metal, that results from a reaction with its environment.
A
Corrosion
2
Q
___________is a reduction of the anodic reaction rate of an electrode involved in corrosion.
A
Passivation
3
Q
What term describes the complete electrochemical system required for corrosion, consisting of an anode, cathode, electrolyte, and metallic pathway?
A
Corrosion Cell
Anode, Cathode, Metallic Pathway, Electrolyte
4
Q
The electrolyte is a medium that conducts _____ current.
A
Ionic
5
Q
The _______ is the more noble region on the electrode (metal surface, or in the battery analogy the carbon rod) where the electrons are consumed.
A
Cathode
6
Q
The ______ ____ connects the anode and the cathode and allows passage of electrons, generated at the anode, to the cathode.
A
Return Path
7
Q
An __________ is a medium that conducts ionic (rather than electronic) current
A
Electrolyte
8
Q
____ _____ is the oxide layer formed during hot fabrication or heat treatment of metals. A blue-black layer of iron/iron-oxide; cathodic relative to substrate; Generally removed prior to painting
A
Mill Scale
9
Q
The ________ ______ is a list of materials in order of their corrosion potentials; with the most easily corroded, or most active, at the top and the least active at the bottom.
A
Galvanic Series
10
Q
Corrosion occuring uniformly across a surface is called _______ _________.
A
Generalized Corrosion
11
Q
_________ _________ occurs at discrete sites on the metal surface.
A
Localized Corrosion
12
Q
_______ corrosion does not proceed uniformly but primarily occurs at distinct spots where deep ____ are formed.
A
Pitting
The bottoms of pits are anodes in a small, localized corrosion cell, often aggravated by a large cathode-to-anode ratio.
13
Q
_______ _________ occurs on a metal surface that is shielded from full exposure to the environment because of the close proximity of another material that forms a narrow gap between them.
A
Crevice Corrosion
14
Q
Substance that, when added to an environment, prevents or decreases the rate of corrosion.
A
Corrosion Inhibitor
15
Q
A technique to reduce the corrosion of a metal surface by making the surface the cathode of an electrochemical cell. Uses sacrificial anodes, magnesium, zinc or aluminum, that will corrode in preference to the steel structure they are connected to.
A
Cathodic Protection
16
Q
A reduction of the anodic reaction rate of an electrode involved in corrosion
A
Passivation
17
Q
What are the elements of a corrosion cell?
A
- Anode
- Cathode
- Metallic path
- Electrolyte
18
Q
Different concentrations of oxygen on the same metal that usually occurs in immersion conditions is called an ______ _____________ ____.
A
Oxygen Concentration Cell
19
Q
________ _____ increase the rate of corrosion by increasing the efficiency (conductivity) of the electrolyte.
A
Chemical Salts / Chloride
20
Q
Plants and refineries are known to have highly corrosive environments due to the presence of _____, _________, and ____ ________ all of which can stimulate corrosion.
A
- Gases
- Chemicals
- High humidity
21
Q
Highly corrosive environment because of the gases, chemicals and high humidity all of which can stimulate corrosion
A
Chemical with High Humidity
Chemical plants and Mills
22
Q
An environment that provides an active electrolyte because of the moisture and the salt particles.
A
Marine with High Humidity
23
Q
What type of environment can still cause corrosion due to reactive gases, even when moisture levels are low?
A
Chemical with Low Humidity
24
Q
Least corrosive environment due to clean air, few pollutants and low moisture.
A
Rural Environments
25
What occurs at the anode?
Metal deterioration
## Footnote
Metal ions enter into the solution and corrosion usually occurs at this location, generates the electrons
26
What is the function of the electrolyte?
Transport ions between the anode and the cathode
| closes the loop in a corrosion cell
27
______ ____(________ _______) connects the anode and the cathode and allows passage of electrons, generated at the anode, to the cathode.
Return Path (metallic pathway)
28
5 Factors that affect the rate of corrosion
* Oxygen
* Temperature
* Chemical salts
* Humidity and pollutants
* Acid gases
29
Common tools used to control corrosion?
1. Design
2. Inhibitors
3. Material selection
4. Cathodic protection
5. Protective coatings
6. Alteration of the environment
30
The general duties of an inspector are:
1. Review Specifications
2. Observe and Monitor Work
3. Perform Inspections and Tests
4. Document Results
5. Report Non-Conformances
6. Maintain Objectivity and Ethics
31
A coating inspector should be able to use simple________ ___________.
Inspection equipment
32
While on a job site, Inspectors should observe:
1. **Surface Preparation Activities**
2. **Coating Application Procedures**
3. **Environmental Conditions**
4. **Use and Calibration of Instruments**
5. **Safety Practices**
6. **Workmanship**
33
Corrosion is the _________ of a material usually a_______, because of a________ with its environment
Deterioration, metal, reaction
34
Name the four elements of a corrosion cell.
1. Anode
2. Cathode
3. Metallic path
4. Electrolyte
35
The anode __________ in the electrolyte.
Dissolves
36
The two broad classifications for curing mechanisms are
* Non-convertible
* Convertible
37
Types of adhesion
1. Chemical
2. Mechanical
3. Polar
4. A combination of all three
38
List two nonconvertible coating types
1. Vinyl
2. Latex
## Footnote
Nonconvertible coatings cure by evaporation of the solvent.
39
**Convertible coatings** cure by one of several *polymerization* mechanisms even when solvent evaporation is also involved.
1. Oxidation
2. Co-reaction
3. Hydrolysis
4. Fusion
40
Characteristics of ***oxidation cure*** coatings
1. Cannot withstand an alkaline environment due to the reaction of akaline materials with the oil portion of the resin (saponification)
2. Excessive film build up may stop curing of the lower portion of the coating film
3. Unsuitable for merchant service
4. Cures by reaction with atmospheric oxygen
41
Co-reaction coatings cure by **polymerization** reactions between two chemical entities. Examples of co-reaction coatings include:
1. Epoxy
2. Polyurethanes
3. Polyurea
4. Polysoxanes
5. Polyaspartics
42
Induction time
The amount of time after mixing two parts before applying paint to give the time for reaction
43
What is the main requirement for **hydrolysis** coating to cure?
Some amount of water to complete the cure
44
Oil based coating applied over alkaline surfaces may result in
Saponification
45
Formal sections usually contained in a good specification
1. Scope of the work
2. Terms and definitions
3. Reference standards and codes
4. Safety
4. Pre Job conference
5. Surface preparation
6. Coating materials including the coating schedule
7. Sampling coatings
8. Workmanship
9. Application
10. Work schedule
11. Repairs and remedial coating work
12. Inspection
13. Documentation
46
Components of a coating added in small amounts to perform a specific function are called _________.
Additives
47
Process in which the similar molecules cling together due to attractive forces
Adhesion
48
A coating that has a high resistance to permeation of liquids and or gases or is applied over previously coated surface to prevent damage to the underlying coating during subsequent handling
Barrier coatings
49
Nonvolatile portion of the vehicle of a formulated coating material
Binder
50
A ***pigment*** that passivates the metal surface by forming a thin, tightly adherent film or by reinforcing and plugging defects in the natural air formed film
Inhibitive pigment
51
Coatings who's binders are made from nonliving things, most commonly based on either silicone or silicates are said to be _________.
Inorganic
52
Coatings who's binders are made from living or once living things
Organic coatings
53
A _______ is a discrete particulate solid used to impart specific properties to the coating in the liquid and solid state.
Pigment
54
Why is pigment added
1. Impart color
2. Protect binder from weathering
3. Provide inhibitor protection
4. Control water resistance
5. Provide a form of cathodic protection
6. Modify mechanical or electrical properties
55
A ___________ coating uses a metal that is anodic to steel and which corrodes preferentially.
Sacrificial
56
________ are added to coatings to liquefy the binder and allow for application in a productive manner
Solvents
57
_______ ___ are primarily polymeric derivatives of ***acrylic*** and methacrylic acid.
Acrylic resins
## Footnote
Acrylic coatings have excellent weathering and UV resistance and in some cases resistance to splash and spill of certain acids.
58
The coating specification tells the contractor ....
What to do and where to do it but does not tell how to do it.
59
Inspector Responsibility - Coating materials
* Only specified materials are used
* Ensure proper storage conditions
* Observe and record pot life and induction/sweat-in times
* Know volume of solids
* Ensure and record wet and dry-film thickness and allowable tolerances
* Know dry and recoat times
* Know proper cure time.
60
Inspectors Responsibility - Job Site
* Walk-through to become familiar with the surroundings
* Identify items to be coated or left un-coated
* Obtain maps or drawings that would be helpful
61
Inspectors Responsibility - Safety
1. You are responseible for your own safety first
2. Safety enforcement is NOT my job
3. Be knowledgeable enough to recognize safety violations
4. Report all safety violations immediately to the proper personnel
5. Be aware of any hazardous substances associated with the job site
62
Inspectors Responsibility - Pre-job Conference
* Study the specification before the meeting
* Have a crystal clear understanding of specification
* Be aware of any modifications or waivers
* What is your AUTHORITY on the job.
63
Inspectors Responsibility - Sampling of Coatings
Select samples at random, ensure coatings are thoroughly mixed, proper sample amount, label the sample container as specified (preprinted or know who to send them to directly).... dry or wet (clarify at pre-job meeting)
64
Inspectors Responsibility - Workmanship
* Have the latest copy of manufacturers instructions
* Clarify performance expectations at pre-job meeting
* Document and report unacceptable work.
65
Inspectors Responsibility - Work Schedule
* Understand the work schedule (which item first, etc)
* Ensure job is done in the manner outlined by the contractor and approved by the owner
* Inspect at the specified intervals
* Prepare and submit the reports as specified
66
Inspectors Responsibility - Repair work
* Ensure areas to be repaired are clearly marked and the coating surface properly prepared (clarify what will be used to mark repairs)
* Monitor the number of repair coats applied
* Observe re-coat times and check the WFT and DFT as specified
Document the work
67
What is an SDS?
A document that provides safety, handling, and emergency information about materials.
## Footnote
SDS stands for Safety Data Sheet.
68
What does HazCom stand for?
Hazard Communication Standard; requires communication of chemical hazards in the workplace.
## Footnote
HazCom is crucial for workplace safety.
69
Define Confined Space.
An enclosed space with limited entry/exit that can pose hazards; requires special precautions.
## Footnote
Confined spaces can include tanks, silos, or pipelines.
70
What is an Inspection Plan?
A document outlining inspection scope, hold/verification points, and responsibilities.
## Footnote
It helps ensure that inspections are thorough and organized.
71
What is a Hold Point?
A mandatory inspection point where work stops until the inspector approves it.
## Footnote
Hold points are critical for maintaining quality control.
72
What is a Verification Point?
An optional inspection point; work may continue while inspection occurs.
## Footnote
Verification points allow for ongoing work while ensuring compliance.
73
What does a Specification document describe?
Detailed document describing coating requirements, procedures, and materials.
## Footnote
Specifications are essential for consistent application.
74
What is a Product Data Sheet?
Manufacturer's technical sheet with coating properties, application, and curing data.
## Footnote
It provides essential information for correct usage of coatings.
75
Define Corrosion.
Electrochemical process where metal deteriorates due to environmental exposure.
## Footnote
Corrosion can lead to significant structural damage.
76
What is an Anode?
Part of a corrosion cell where oxidation occurs and metal loss begins.
## Footnote
The anode is critical in the corrosion process.
77
What is a Cathode?
Part of a corrosion cell where reduction occurs; it is protected from corrosion.
## Footnote
The cathode helps mitigate overall corrosion damage.
78
What is a Metallic Pathway?
Conductive connection that allows electron flow between anode and cathode.
## Footnote
This pathway is essential for the electrochemical process.
79
Define Electrolyte.
A medium (e.g., water with salts) that enables ion movement between anode and cathode.
## Footnote
Electrolytes are crucial in the corrosion mechanism.
80
What is Pitting Corrosion?
Localized form of corrosion leading to small but deep holes in the metal.
## Footnote
Pitting can be particularly damaging to structural integrity.
81
What is Galvanic Corrosion?
Corrosion between dissimilar metals in electrical contact within an electrolyte.
## Footnote
This type of corrosion can be mitigated by proper material selection.
82
What is the Dew Point?
Temperature at which moisture in air begins to condense on a cooler surface.
## Footnote
Understanding dew point is important for coating applications.
83
What is a Sling Psychrometer?
Device used to measure wet and dry bulb temperatures to calculate RH and dew point.
## Footnote
It is essential for assessing environmental conditions.
84
What does an Electronic Hygrometer measure?
Digital instrument to measure relative humidity and calculate dew point.
## Footnote
Accurate humidity measurement is vital for coating applications.
85
What is a Surface Thermometer used for?
Tool used to measure surface temperature of substrates.
## Footnote
Surface temperature affects coating adhesion and curing.
86
What is SSPC-SP1?
Solvent cleaning standard.
## Footnote
This standard is the first step in surface preparation.
87
What does SSPC-SP2 refer to?
Hand tool cleaning standard.
## Footnote
Hand tools are often used for small areas or detailed work.
88
What is SSPC-SP3?
Power tool cleaning standard.
## Footnote
Power tools increase efficiency in surface preparation.
89
What does SSPC-SP5 represent?
White metal blast cleaning standard.
## Footnote
This standard is for achieving the highest level of cleanliness.
90
What is SSPC-SP6?
Commercial blast cleaning standard.
## Footnote
This standard is widely used in industrial applications.
91
What does SSPC-SP10 refer to?
Near-white metal blast cleaning standard.
## Footnote
It is a step below white metal cleaning.
92
What is Replica Tape used for?
Used to measure surface profile depth after abrasive blasting.
## Footnote
Surface profile affects coating adhesion.
93
What is an ISO Comparator?
Standardized reference plate to visually and tactilely compare surface profiles.
## Footnote
It helps ensure the proper surface preparation.
94
What is the Soluble Salt Test?
Method (e.g., Bresle patch) to detect salts like chlorides on cleaned steel surfaces.
## Footnote
Salts can negatively impact coating adhesion.
95
What does a DFT Gauge (Type I) measure?
Magnetic pull-off gauge used to measure dry film thickness.
## Footnote
Accurate DFT measurements are crucial for coating quality.
96
What is a DFT Gauge (Type II)?
Electronic constant-pressure probe used for accurate dry film thickness readings.
## Footnote
It offers improved precision over Type I gauges.
97
What is a WFT Gauge?
Comb gauge used to measure wet film thickness immediately after application.
## Footnote
Wet film thickness is critical for ensuring proper application.
98
What is a Holiday Detector?
Device used to detect discontinuities in coating; high-voltage or low-voltage types.
## Footnote
It is essential for ensuring coating integrity.
99
What are Coating Components?
Include resins, pigments, solvents, and additives.
## Footnote
Each component plays a specific role in the performance of the coating.
100
What are Curing Mechanisms?
Include air drying, chemical reaction (catalytic), heat curing, etc.
## Footnote
Different mechanisms affect the final properties of the coating.
101
What is a Stripe Coat?
Extra coating applied to edges and hard-to-coat areas before full coating.
## Footnote
Stripe coating helps ensure uniform coverage.
102
What is Brush Application?
Manual method suitable for small or detailed areas.
## Footnote
It allows for precision in application.
103
What is Airless Spray?
High-pressure spray method producing atomized coating without air.
## Footnote
Airless spraying is efficient for large areas.
104
What is a Daily Report?
Inspector's documentation of work, testing, and observations for each day.
## Footnote
It provides a record of progress and issues.
105
What is a Nonconformance Report (NCR)?
Formal report identifying deviations from project specifications.
## Footnote
NCRs are essential for ensuring compliance.
106
What does SSPC-PA 2 standardize?
Standard for measuring and evaluating dry film thickness on metal substrates.
## Footnote
This standard is critical for quality assurance.
107
What does NACE SP0178 address?
Standard for weld surface preparation and visual criteria.
## Footnote
Proper weld preparation is crucial for coating adhesion.
108
What is the Code of Ethics?
AMPP’s guideline to ensure inspector integrity and impartiality.
## Footnote
Adhering to the code is essential for professional conduct.
109
What is Team Collaboration?
The process of inspectors and other project members working together effectively.
## Footnote
Effective collaboration enhances project outcomes.
