Contentcorrosionshortcourse.com/2017 slides/2017 UCSC Purdue/05... · 2017-03-17 · Swedish Rust...

Chris Beninati Outside Sales Manager

Elcometer

Pipeline Coatings Course

Introduction

Surface Profile

Environmental Conditions

Coating Thickness

Porosity Detection

Conclusions

Content

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Introduction Blast cleaning is used to remove rust and other contamination from steel substrates prior to applying protective coatings

Mill scale and Rust Oil and grease

Soluble salts Anchor pattern to increase adhesion of paint coating

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Surface Profile Measurement Methods

Visual Assessment of Cleanliness

Swedish Rust Standard ISO 8501 – 1 SSPC VIS 1, VIS 3 , VIS 5

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Profile Assessment

Profile Rating

Peak to Valley Height Measurement

Roughness

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Surface Profile Measurement Methods ASTM D4417 – 03, “Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel”.

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ASTM D4417 Method A Surface Comparator

ISO 8503-1 Grit Shot

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ASTM D4417 Method B Dial Depth Gauge

Digital Gauge with Memory &

Bluetooth®

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Digital Gauge with Convex Surface Probe

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Method of Use:

Set zero on flat surface (Glass slide)

Take maximum of 10 readings in area diameter 3” (75 mm)

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ASTM D4417 Method C Replica Tape

ISO 8503 - 5

4 Grades:

Course Minus – 0.5 to 1.0 mil (12 to 25 um)

Coarse – 0.8 to 2.0 mil (20 to 50 µm)

X-Coarse – 1.5 to 4.5 mil (38 to 114 µm)

X-Coarse Plus – 4.5 to 5.8 mil (115 to 152 µm) 12



Replica Tape Kit Mechanical ‘Snap’ Gauge

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Method of Use 14



New measurement method:

Coarse tape reading between 1.5 & 2.5 mil (38 to 64 µm) repeat with X-Coarse tape.

Add both results & divide by 2

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Original Measurement by Focusing Microscope or Stylus Scan of master

Verify by visual inspection

Re-measurement not economically viable


Verification

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Calibration against matched sets of gauge blocks

Verify by visual inspection of tip

Field check using measured ceramic shims with hole for tip


Verification

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Calibration of snap gauge only

Verify snap gauge by measuring shims of known thickness (e.g. coating thickness gauge standards)


Verification

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Common Conditions

Air Temperature Relative Humidity Dew Point Temperature Surface Temperature The difference between the surface and dew point temperatures

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Common Instruments

Sling Psychrometer (ASTM E337) Magnetic Surface Temperature Electronic Psychrometers

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Using Sling Psychrometers

Wet Wick Whirl in increments (3 or 4x) 1 ½ minutes until wet bulb stabilizes Record wet & dry bulb temperatures Psychrometric tables use to calculate RH & dew point

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Relative Humidity Air Temperature Dewpoint Temperature Surface Temperature TΔ (the difference between surface temperature and dewpoint)

Rule of Thumb – surface temperature must be 5° F above dewpoint temperature

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Cure conditions

Data logging Interval readings Statistics

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Dry Film Thickness

Destructive

Nondestructive

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Dry Film Thickness

Tooke Gauges

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Dry Film Thickness ASTM D7091 and SSPC-PA 2

3 steps to ensure accurate measurements

Calibration Verification of Accuracy Adjustment

Required to be complete before coating thickness data acquisition to determine conformance to a specification

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Dry Film Thickness

Type 1 Pull Off Gauges

Mechanical gauges Base Metal Reading – BMR

Measure Record Deduct from coating thickness

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Dry Film Thickness

Type 2 Electronic Gauges

Readings Speed Statistical Analysis Limits Data Storage Probe Options

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Verification

Calibration 2 Electronic Gauges

Verify thickness gauge by measuring shims of known thickness Use high level shim Bare substrate

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Pin Hole Detection

ASTM 5162-1

Wet Sponge Locates discontinuity in coatings 0-20 mils of non-conductive coating Wet sponge 1ft per second

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Holiday Detection

ASTM 5162-1

High Voltage Locates discontinuity

in coatings 20-300 mils of coating Electrical current

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Verification

ASTM 5162-1

Touch sponge to grounding clamp and bare area of the substrate Volt meter

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CONCLUSIONS

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Surface Comparators

Simple and quick

Profile rating

Subjective

.

Conclusions

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Replica Tape

Simple

Maximum profile measurement

Confirmation of correct range of tape

.

Conclusions

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Digital Depth Gauge

Simple and quick

Statistics & Data Transfer

Paperless QC

.

Conclusions

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Mechanical Climate Instrumentation

Multiple equipment

Time consuming

.

Conclusions

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Digital Climate Gauge

Simple and quick


Accurate

Paperless QC

.

Conclusions

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Mechanical Thickness Gauge

Simple

Fairly Accurate

Intrinsically Safe

.

Conclusions

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Digital Thickness Gauge

Simple and quick


Accurate

Paperless QC

.

Conclusions

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.

Conclusions

Digital Inspection Gauges

Wireless data transfer

Cloud File Exchange

Data Management Software

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Questions?

Thank You

.

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