Upgrading of IMM Blaster & Painter and Coating Inspector ...
Transcript of Upgrading of IMM Blaster & Painter and Coating Inspector ...
Protective Coatings Technician – 1999 to today
• PETRONAS and IMM initiated the IMM Blaster & Painter Certification
& IMM Coating Inspector Certification Programs to improve the skills of
the blasters & painters
• The scheme is aimed at improving the quality of workmanship thereby
reducing overall costs.
• In the Malaysian EP industry, the total cost from rework, in service repair
and total recoating is estimated at a staggering RM45m annually.
• In the offshore, associated costs like scaffolding and work boat/barge hire
costs 3 times as much (~Rm 150 million annually) to support these
operations
• The lesson learnt by all asset operators/owners is premature failures not
matching the system’s lifespan capability are often encountered. Root
cause analysis by manufacturers and industry research attributed up to
70% of it to surface preparation and application weakness.
PETRONAS REQUESTS IMM TO REVAMP THE PROTECTIVE COATINGS TECHNICIAN
TRAINING PROGRAM
Protective Coatings Technician – 1999 to today (contd..)
• Much of the coating rework was attributed directly or indirectly to…
– Poor QA/QA practices (~30%)
– Poor workmanship (including poor surface preparation) due to inexperience, unprofessional and
uncertified applicators (~60%)
– Paint failure due to poor paint performance (~5%)
– Others (~5%)
• An in depth analysis of IMM certification revealed that the older certification had
gaps which needed to be addressed, especially in the following areas…
– Change certification duration from an indefinite period to 5 years recertification
– Update and expand teaching material to incorporate new technologies and industry best practices
– Put in additional levels of qualification to help differentiate between various levels of skills and
experience
– Add thermal spray and other specialist application to the curricula
– Bring workmanship quality up to international standards
– Added emphasis on HSE, QA/QC, and workmanship
– Added Bahasa Malaysia as a language of delivery for those weak in English
– Added checks and balance to examination & qualification process
COATINGS COMMITTEE RENEWED FOCUS ON BLASTER PAINTER TRAINING
- Emergency Committee Meeting Appointed New Chairman, Vice Chairman & Committee Members On April 10th 2015
- Blaster Painter Sub- Committee Formed July 10th
2015
- Thermal Spray Coatings (TSC) Sub-Committee Formed July 10th 2015
INTRODUCING THE REVISED
PROTECTIVE COATINGS TECHNICIAN
TRAINING PROGRAM
Proposed New Protective Coatings
Technician Program Overview
• Blaster and Painter • Replaces Blaster Level 1, Painter Level 1
• Pre-requisite 12 months relevant experience – familiarity with the equipment
• Language proficiency (written & oral) Bahasa Malaysia or English
• 4 days draining & 1 day assessment
• Blaster and Painter, Lead • Replaces Blaster Painter Supervisor
• Pre-requisite –Blaster and Painter with 5 years experience
• 2 days training & 1 day assessment
• Blaster and Painter, Supervisor• Pre-requisite – Lead Blaster Painter with minimum 10 years experience
• 1 day theory & 1 day assessment
• Thermal Spray Applicator• Blaster painter lead certification
• 2 days practical and 2 days practical training
Proposed New Coatings Inspector
Program Overview
• Level 1 – Assistant Coatings Inspector
• Level 2 – Coatings Inspector
BLASTER AND PAINTER TECHNICIAN
TRAINING COURSE
Blaster & Painter Training & Assessment Schedule
Day 1 – Theory Training (Blasting)
Day 2 – Practical Training (Blasting)
Day 3 – Theory Training (Painting)
Day 4 – Practical Training (Painting)
Day 5 – Theory & Practical Assessment
(Blasting & Painting)
Blaster and Painter Training Program
Surface Preparation1.IMM Introduction
2.The importance of Corrosion Control
3.Basic Corrosion Science Explained
4.The Standards
5.The Substrates
6.Methods of Surface Preparation
7.Dry Air Abrasive Blasting in Depth
8.Abrasives
9.Recycling of Expendable Abrasives
10.Common misconceptions and mistakes Q&A
Coating1. Paint Technology
2. Paint Application
3. Application Technique
4. Coating Breakdown
5. Quality Control
6. Safety & Health
TRANSITION PLAN
(Blaster Painter ‘Go Live’ September 2016)
• Exiting Certified Blaster Painter has to certify under new blaster painter program by 31st December 2017
• Blaster painter refresher every 5 years, recertification every 10 years
• Blaster Painter Lead, Blaster Painter Supervisor, TSA to be advised in due course