GENERAL MECHANICAL EXAMINATION

1. What is NACE MR0175?

Ans. National Association of Corrosion Engineers
NACE MR0175: Standard Material Requirement-Sulfide stress cracking resistant metallic material for oilfield equipment.

2. What is the meaning of CSD?

Ans. Consulting Services Department

3. What is RTR?
Ans. Reinforce thermosetting resin

4. What is AWWA?
Ans. American Water Works Association

5. AWS D1.1 structural, dont need to qualify for WPS? (True or false)
Ans. False

6. What is the vision of an inspector?

Ans. Jaeger 1

7. What electrode used for overhead position?

Ans. 6010, 6020

8. Does the 6010 can apply over the 7018 vertical position?
Ans. No

9. Stud welding is based on AWS D1.1? (True or false)

Ans. True

10. Lack of fusion can detect by?

Ans. Ultrasonic test (UT)

11. Which one will be a shielding?

Ans. Flux

12. What is the purpose of shielding?

Ans. To prevent atmospheric contamination during welding

13. What is the Carbon Equivalent? Why it is important?

Ans. To determine the material capabilities

14. How to measure raised faced finish?

Ans. Surface comparator gauge
15. What is thermal expansion?
Ans. The increase of material due to increase of temperature

16. PWHT is required to apply on 1 thickness? (True or false)

Ans. True

17. In overhead position, what kind of electrode is acceptable?

Ans. 6010, 6020

18. What other American code required for testing pipeline and welder qualification?
Ans. ASME IX (Welding & Brazing Qualification)

19. Is hardness test, can be use to determine tensile strength?

Ans. No

20. Preheat is needed in tack welding in thick materials?

Ans. Yes
21. What are the types of joint?
Ans. Butt, lap, tee, corner, fillet joints

22. Which is harder, steel containing 0.1% or 0.5% carbon?

Ans. 0.5% carbon

23. What grooves use for SAW process? When to use this preparation(groove)?
Ans. U, V & Square grooves

24. What is GMAW mode of transfer?

Ans. Globular, spray, pulse, short circuiting

25. Type of RTR joints?

Ans. Bell & spigot, socket, flange joint

26. Basic instrument use to measure preheat temperature?

Ans. Tempil stick, contact pyrometer

27. Circumferential seam, weld first than longitudinal seam? (True or false)
Ans. False

28. Is 6010 electrode design to apply to 7018 electrode on vertical position? (True or false)
Ans. False

29. How to repair too close root gap?

Ans. By means of grinding

30. What you will do if you found welder doing wrong?

Ans. ask the welding foreman

31. What American standard for structural welding?

Ans. AWS D1.1

32. Why 316L has low carbon content in stainless steel?

Ans. L- is represent low carbon content

33. What is a good attitude of an inspector?

Ans. Quality minded knowledgeable, experience, impartial, informed etc.

34. Type of joint category?

Ans. Category A, B, C, D base on UW 3, table UW 13

35. Hardness test is one requirement of NACE MR0175, what the other requirements?
Ans. Nickel content shall be less than 1%

36. Ferromagnetic materials can be detected by?

Ans. (MT) Magnetic particle test

37. Code of quality inspection standard?

Ans. ISO

38. Difference between DCRP & DCEP?

Ans. No difference

39. What is ASME sec. V?

Ans. Non-destructive examination (NDE)

40. Where to apply preheat?

Ans. On weld joint plus 50mm both side of the joint

41. Where to measure preheat?

 Ans. at both side of the joint (parent metal)

42. for non-magnetic materials, what kind of NDT to be used?

Ans. Penetrant test (PT)

43. Give two kinds of material that direct current (DC) welding machine can be used?
Ans. P1, P5 materials

44. Describe 3G position?

Ans. Vertical position

45. Radiographic test is the most effective to detect lack of sidewall fusion? (True or false)
Ans. False, UT is the most
46. Why preheat is needed for alloy materials?
Ans. To avoid cracking

47. What 5G position in ASME sec IX is qualified?

Ans. Flat, overhead, vertical position

48. What filler metal to be used on 304 to SA 516 GR70 material first layer?
Ans. ER309L

49. What P number for SA 516 GR70?

Ans. P1

50. As an inspector, do you reject if the NDE results have a discontinuity?

Ans. Yes, if it is exceed the limit in acceptance criteria of relevant code

51. In 100circumferential, how much @ 45 degree?

Ans. 1 feet

52. Lamination defect can detect by?

Ans. Ultrasonic test (UT)

53. How many minutes in 1 degree?

Ans. 60 minutes

54. What 6G position?

Ans. All position

55. What is the minimum tensile strength of 7018 electrode?

Ans. 70,000 psi

56. What is MILS?

Ans. Thousand of an inch

57. Give at least 3 essential variables of WPS?

Ans. Electrode, preheat, volt/amp, position, base metal

58. What is WPS?

Ans. Welding Procedure Specification- a prepared welding procedure which serve as guidance of the welders

59. What is WPQ?

Ans. Welders Performance Qualification- is the performance testing of the welder capability to do the weld in accordance
with approved WPS

60. What is PQR?

Ans. Procedure Qualification Record- a record of welding data used to weld a test coupon

61. What is PMI?

Ans. Positive material Identification- a process use to determine the constituents of a materials
62. What is HAZ?
Ans. Heat affected zone- a portion of base metal that was not melted during welding process but whose microstructure &
properties were altered by heat

63. What is PWHT, its purpose?

Ans. Post weld heat treatment- to relieve internal stress that has trapped inside the weld during welding process

64. What is purpose of preheat?

Ans. To slow down the cooling rate, to reduce hardness of the weld, to avoid cracking & brittleness

65. What is interpass temperature?

Ans. A highest temperature in the weld were immediately perform prior to welding or in the case of multiple pass weld

66. What essential variables in WPS?

Ans. A change in welding condition which will affect the mechanical properties of the weldment

67. Why maintenance temperature is very important for austhenetic materials?

Ans. To reduce integranual corrosion near the weld

68. What is hardness in accordance with NACE MR0175?

Ans. 22 HRC maximum @ 620 degree (Rockwell C hardness)

69. Type of toughness test?

Ans. Charpy V-notch, IZOD, CTOD (crack tip opening displacement)

70. Type of hardness test?

Ans. Rockwell, Vickers, Brinell

71. What mechanical test is an additional requirement for materials in low service temperature?
Ans. Impact test

72. What toe cracks is?

Ans. Generally cold cracks a results of thermal shrinkage stress acting on the weld HAZ

73. Differentiate between discontinuity & defects?

Ans.
Defects- a discontinuity which exceed the permissible limit in relevant code
Discontinuity- irregularity in the normal pattern of the weld metal not necessary a defects

74. Prevention before using low hydrogen electrode?

Ans. Electrode shall be dried at 260 degree ~ 430 degree for 2 hrs. and shall stored continuously in the oven at 120 degree

75. What is GMAW?

Ans. Gas Metal Arc Welding- often called MIG (Metal Inert Gas) welding. Widely use as semi-automatic joining process w/c
coalescence of metal is produce by heat from an electric arc that is maintained between the tip of a consumable bare wire
electrode and surface of the base metal in the weld joint

76. What is FCAW?

Ans. Flux Cored Arc Welding- its similar to GMAW, FCAW have the highest deposition rate & semi-automatic welding
process w/c coalescence of metal is produced by heat from an electric arc & maintain between the tip of consumable flux filled
wire electrode & surface of the base metal in the weld joint

77. What is SAW?

Ans. Submerged Arc Welding- Referred to as (Submerged) because electric arc is actually submerged under the granular flux,
currently use for thick metals & heavy steel fabrication

78. What is the acronym GTAW, describe the process?

Ans. Gas Tungsten Arc Welding- which often called TIG (Tungsten Inert Gas) welding, can be manual joining process in w/c
coalescence of metal is produced by heat from an electric arc that is maintain between the tip of a tungsten electrode (non
consumable) & the surface of base metal in the weld joint
79. What is SMAW?
Ans. Shielded Metal Arc Welding- its commonly called stick welding, widely use arc welding process w/c coalescence of
metal is produced by heat from an electric arc that is maintain between the tip of a covered electrode & surface of base metal in
the weld joint

80. What is a straight face in a size of 3mm in Bevel?

Ans. Root Face

81. It is need to qualify the welder, if the WPS is pre-qualified in the same project?
Ans. No

82. What NDT which use illumination for testing? (RT not included in the choices)
Ans. Magnetic Particle Test (MT)

83. Give at least 3 attributes that could result form tension test.
Ans. Ultimate tensile strength, yield strength, and percent elongation

84. Enumerate at least 5 essential attributes in material test report (MTR).

Ans. Material specification/grade, mechanical properties, chemical properties, heat number, name of
manufacturers

85. Why there is a need to specify maximum interpass temperature for austhenitic stainless steel?
Ans. To avoid excessive heat input

86. Why is it 3mm root face (in groove preparation) is important in most weld joint?
Ans. To avoid melt through weld

87. What is the minimum mechanical test required to qualify a welder?

Ans. Bend Test

PRESSURE VESSEL EXAMINATION (SAUDI ARAMCO)

1. DESCRIBE NACE MR0175.

National Association of Corrosion Engineers. Standard material requirements for Sulphide Stress Cracking
Resistance of metallic material for Oil Field Equipments.

2. HARDNESS (22HRC=235BHN) IS ONE REQUIREMENT FOR NACE

MR0175, WHAT ARE THE OTHER REQUIREMENTS?
Nickel content shall be less than 1.0%.

3. WHAT IS THE MEANING OF MDMT?

Minimum Design Metal Temperature.

4. WHAT IS THE DIFFERENCE BET. CERTIFICATE OF COMPLIANCE (COC)

AND CERTIFICATE OF MATERIAL TRACEABILITY REPORT (CMTR)?
COC certifies the whole product issued after completion of the product or
materials.
CMTR certifies the raw materials used before start of fabrication.

5. WHAT IS JOINT EFFICIENCY?

Stated how much percent of radiographic testing are required on the joint.
ASME VIII Div.1 UW-12.

6. WHAT IS JOINT CATEGORY?

ASME VIII Div.1 Fig.UW-3; location of a joint in a vessel.
A Longitudinal joint in shell, nozzle neck, head petal to petal,
petal to crown and shell to hemispherical head joint.
B Circumferential weld joints on shell and nozzle neck.
C Flange to shell and flange to nozzle neck joints.
 D Nozzle to shell, nozzle to heads and boot to shell joints.

7. WHAT IS P Number OF SA516-GR70?

P1.

8. WHAT IS THE CRITICAL POINT WHEN YOU ARE CONDUCTING PRESSURE

TEST FOR AUSTHENITIC STAINLESS STEEL AGAINST CARBON
Water used for SS= 50 ppm max.chloride content of water; carbon steel is
potable water.

9. WHAT IS RT1 IN A NAME PLATE?

100% radiographically tested.

10. DOES THE UCS-193 IS INTENDED FOR HYDROSTATIC TEST?

No! UG-99 is intended for hydrostatic test.

11. DIFFERENCE BET. ASME SECTION VIII Div.1 and ASME SECTIONVIII Div.2?
ASME VIII Div.1 Rules for construction of Pressure Vessels.
ASME VIII Div.2 - Alternative Rules for construction of Pressure Vessels.

12. DOES THE UCS-56 IS INTENDED FOR PWHT?

Yes.

13. WHAT CERTIFICATION OF THE COMPANY QUALIFIED FOR FABRICA-

TION OF PRESSURE VESSELS?
U stamp.

14. WHAT NDE APPLIED IN CLADDED PLATE AFTER REMOVING OF STAIN-

LESS TO CARBON STEEL?
Acid Test.

15. WHAT IS ASME VIII Div.1?

Rules for construction of Pressure Vessels.

16. WHAT IS ASME VIII Div.2?

Alternative Rules for construction of Pressure Vessels.

17. WHAT IS ASME IX?

Boiler and Pressure Vessel Code. (Welding and Brazing Qualifications).

18. WHAT IS ASME V?

None Destructive Examination.

19. IN PRESSURE VESSEL HEAD F & D STANDS FOR WHAT?

F Flange; D dish.
20. WHAT IS THE MEANING OF CSD?
Consulting Services Department.

21. WHAT IS THE REQUIREMENT OR DOCUMENTS NEEDED FOR TWO PIECE

DISH HEAD SUPPLIED OR SUB- CONTRACTED BY OTHER COMPANY?
Form U-2 and U-2A. Manufacturers Data Report.

22. GIVE AT LEAST 8 CHECKPOINTS TO CHECK OUT FIT-UP OF LARGE DIA-

TER NOZZLE TO THE VESSEL.
Material identification, flange rating, orientation, elevation, projection,
rotation/ straddleness of flange bolt holes to centreline, root gap,
groove angle/ face, longitudinal seam orientation of nozzle neck.

23. WHAT IS THE LIST OF REQUIREMENTS OF HYDROSTATIC TESTING

AS PER UG-99?
 All fabrication has been completed; all examinations have been performed.

24. WHAT IS MAWP?

ASME VIII Div.1 UG-98 Maximum Allowable Working Pressure.
It is the max. pressure permissible at the top of the vessel.

25. IS PEENING ACCEPTABLE OR PERMITTED IN THE CONSTRUCTION

OF PRESSURE VESSELS?
ASME VIII Div.1, UW-39 Peening is allowed when it is deemed necessary.

26. WHAT IS THE ALLOWABLE OUT OF ROUNDNESS IN PRESSURE VESSELS?

ASME VIII Div.1, UG-80 Difference bet. max. and min. inside dia. at any
cross section shall not exceed 1% of the nominal diameter at the cross
section.

27. IN WHAT SECTION CAN WE REFER THE LIST OF HEAT TREATMENT

REQUIREMENTS?
ASME VIII Div.1, UCS-56.

28. WHAT IS AUTOGENOUS WELD?

Autogenous weld is a fusion weld made without the addition
of a filler metal.

29. WHAT IS THE ACCEPTABLE DISTANCE OF WELD ENCROACHMENT TO

WELD?
20mm toe to toe of the weld.

30. WHAT IS PREHEATING?

Preheating is the application of heat to the base metal immediately before a
welding or cutting operation. Is to removed surface moisture or wet or
condensation on the weld joint.

31. WHAT IS THE HYDROSTATIC TEST PRESSURE AS PER ASME VIII

DIVISION 1?
1.3 times MAWP (as per ASME VIII Div.1 standard)
1.3 times MAWP (as per Aramco)
32. WHAT IS THE HYDROSTATIC TEST PRESSURE AS PER ASME VIII
DIVISION 2?
1.25times MAWP (as per ASME VIII Div.2 standard)
1.25 times MAWP (as per Aramco);

33. WHAT IS AT-301, DIVISION 2?

At-301 is for hydrostatic test.

35. WHAT IS THE LOCATION SAMPLE AND HOW MANY SAMPLE

ON EACH PLATE/HEAT NUMBER?
Six samples on each plate/heat number and location, one sample on edge,
one on the centre on both end of the plate parallel to rolling direction.

36. WHAT IS THE MAXIMUM ALLOWABLE HARDNESS?

VICKERS - VHN 250

37. WHAT U.S. INDUSTRY IS FABRICATING UNFIRED PRESSURE VESSEL?

ASME (American Society for Mechanical Engineers)

38. Give example of Weld Encroachment?

Saddle support, attachment ring, ladder rung.

39. DURING THE COURSE OF LONGTITUDINAL JOINT INSPECTION,

HOW PEAKING IS TO BE CORRECTED?
 Rerolling.

40. WHAT IS 32-SAMSS-004?

Manufacture of Pressure Vessels.

41. WHAT IS SAES-W-010?

Welding requirements for Pressure Vessels.

43. Is it acceptable to carry out hydro testing after primer coat?

No

44. Is Hydro required for all Asme Div.1 Pressure Vessel?

Yes

45. Is minor repair welds are permitted after hydro testing?

No

46. Is tack welding requires qualification?

Yes

47. What is Radiograph Acceptance Criteria for Pressure Vessel?

ASME VIII Div.1

48. Is ASME allowed the welders to weld not employed in manufacturer?

No.

1.) What is Autogenous weld? Autogenous weld is a fusion weld made without the addition of filler metal.
2.) What is the acceptable distance of encroachment to weld? 20mm toe to toe of weld.
3.) What is MR-0175? Sulfide Stress Cracking Resistance Metallic Materials for Oil Field Equipment.
4.) What is the GTAW? An arc welding process which produces coalescence of metals by heating them with an arc between
tungsten electrode and the work. Shielding is obtained from a gas or gas mixture.
5.) What is Preheating. Preheating is the application of heat to the base metal immediately before a welding or cutting
operation. Is to remove surface moisture or wet or condensation on the weld joint.
6.) What is Interpass Temperature? The highest temperature in the weld joint immediately prior to welding.
7.) What is MAWP? MAWP is the maximum allowable working pressure of the vessel.
8.) What is UG-99 of division 1? UG-99 is for hydrostatic test.
9.) What is the Hydrostatic Test Pressure as per ASME VIII division 1? Hydrostatic Test Pressure as per ASME VIII
division 1 is 1.3 times the MAWP of the vessel.
10.) What is the Hydrostatic Test Pressure as per ASME VIII division 2? Hydrostatic Test Pressure as per ASME VIII division
2 is 1.25 times the MAWP.
11.) What is AT-301, Division 2? AT-301 is for hydrostatic test.
12.) What is 01-SAMSS-016? Qualification of Pipeline and Pressure Vessel Steels for resistance to Hydrogen Induced
Cracking.
13.) What is the location the sample and how many sample on each plate/heat number? Six samples on each plate/heat
number and location, one sample on edge, one on the center on both end of the plate parallel to rolling direction.
14.) What is SMAW? SMAW is an arc welding process which produces coalescence of metal by heating them with an arc
between a covered metal electrode and the work.
15.) What is Post Weld Heat Treatment? PWHT is to remove the residual stress, making it softer, refining its of changing its
ductility, toughness or the other properties.
16.) What is WPS? A document providing in detail the required variables for a specific application to assure repeatability by
properly trained welders and welding operators.
17.) What is mean PQR? PQR is a document providing the actual welding variables used to produce an acceptance test weld
and the results of tests conducted on the weld for the purpose of qualifying a Welding Procedure Specification.
18.) What is the welding requirement for pressure vessel as per SAUDI ARAMCO standard and as per ASME? For Saudi
Aramco Standard is SAES-W-010 and for ASME is ASME Section XI.
19.) What is the maximum allowable hardness? VHN250
20.) What is the tolerance of out of roundness as per ASME? 1% of the difference of the diameter.
21.) Tolerance for out roundness will found in ASME paragraph? UG-80
22.) What is the equivalent of one mils? Is equal to 1000 of an inch.
23.) What are three type of hardness? Vicker, Brinnel and Rockwell
 Paint faults and Definitions

Bittiness: Inclusions of foreign material, either from air borne or from the paint itself. Could be
partially cured paint, out of shelf life.

Bleeding: The solvent from the top coat soften the undercoat lying material and allows it to pass
into and through the layer, causing discolouration. Brown for Bitumen, yellow for coal
tars.(Remedy Tie-coat)

Blistering: The formation of dome shaped projections due to Hygroscopic salts presents on the
substrates, which cause to local loss of adhesion and lifting of the film from the
underlying surface. Also blister can be filled with liquid, gas and crystal.

Blooming: Loss of gloss, dulling of colour, due to moisture on the WFT.

Chalking: Degradation of the binder by disruptive factors in the environment, such as UV light.

Cissing; Local loss of Adhesion caused by oil or grease contamination.

Cracking: Causes due to as a result of ageing and the differential expansion and contraction of the
substrates, excess coating.

Cratering: The formation of small bowl shaped depressions caused by escaping solvent or gases.
Paint is of too high a viscosity to glow and fill the depressions.

Curtaining / sagging: A downward movement of a coat between application and setting that
result in an uneven area of coat having a thick lower edge. The resulting
sag is usually restricted to a local area of a vertical surface and may have
the characteristic appearance of a dropped curtain.

Cheeking: Cracking that compress fine cracks which do not penetrate the topcoat and are
distributed over the surface giving the resemblance of a small pattern,

Crazing: Cracking that resembles checking but the cracks are deeper and broader.

Grinning: Loss of hiding power or inadequate DFT, a showing through of underlying substrate.

Run: A narrow movement of a coat which caused by the collection of excess quantities of paint at
irregularities in the surface.

Tear: A small run resembling a tear top.

Lifting: In compatibility, strong solvent coated over weak, and also loss of overcoating time,
and by solvent strength.
Flocculation: loosely cohesive pigments with in the paint.

Flaking: Lifting of the coating materials form the substrate in the form of flakes and scales.

Holidays: Faulty application, insufficient film thickness, complete absence of coating materials
at random locations due to improper application technique. A void, A miss, or
uncoated area.

Pinholing: The formation of the minute holes due to gas air bubbles in the wet film giving rise to
Small craters that fail to coalesce before the film has set.

Orange peel: Appearance similar to citrus fruit skin. Paint application (nozzle block) technique
 for high viscosity. So no level.

Roppiness: Brush marks and over brushing on dried surface.

Wrinkling / Reveling: The developments of wrinkles in the film of a coating material during
drying. Usually due to the initial formation of a surface skin.

Algae and mould growth: Damp environment (environmental condition) treat with Biocidal
agent for 24 hours clean with detergent water washing, stiff bristle
brush.

Efflorescence: A Whitish crystalline formation, usually forms under the film on the above
substrate, and is not a paint defect, caused by soluble crystallizing on the surface.

Residual tack: The degree of stickness remaining in the film of a coating.

Delamination: Over brushing, causing the laminal pigment to settle in correctly.

Rash rusting: Due to rough peaks.

Osmotic blister: Formation of dome shaped blister, which can be caused by water entrapment,
solvent entrapment or hygroscopic salts left on a blast-cleaned surface.

Chemical curing: A part from the oxidation, paint are cured due to the presents of a catalyst in
the paint when they mix together.

Dry Spray: The production of a rough or slightly bitty film from sprayed coating materials
where the particles are insufficiently fluid to flow together to form a uniform coat.

Saporification: The formation of soap by the reaction between a fatty acid ester and an alkali.

Solvent stripping: Coating with strong solvent applied over existing coating causing part of it to
be stripped of.

Oxidation: After the painting, when the surface is coming in to contact with the oxygen the
binder polymerized and form a strong layer.

Chemical curing:

Oversray:
 Definition

1) Define the term electrolyte?

An electrolyte is a substance, which will conduct a current and be broken down by it.

2) Define what is corrosion?

Generally corrosion is defined as Degradation of a material by chemical or electro-
chemical means.

3) Define what is adhesion?

Commonly adhesion is defined as The force required to separate two surfaces in contact.

4) Define what is dew point?

The temperature at which water vapour in the air will condense.

5) Define Relative humidity?

The amount of water vapour in the air expressed in % of the amount of water vapour which could be in the air at the
same temperature.

6) Define Flash points?

The temperature at which vapour from a solvent will ignite in the presence of an external source of ignitions.

7) Define Damp
No sign of water, but temperature is below Dew point.

8) Define Moist?
No standing water, but a noticeable film of water.

9) Define wet?
Droplets or standing water are presents.

10) Define viscosity?

Defined as A fluids resistance to flow.

11) Define Density?

Defined as being weight per unit volume.

12) Define Pot life?

Time after opening and mixing, in which the contents must be, used (typ 6-8 hours).

13) Define shell life?

Expiry date, the maximum period which paint may be stored after its manufacture date.

14) Define Induction period?

 Lead time or stand time, or the period of time after mixing to allow for thorough wetting of the particles by the
binder, and for polymerization.(typically 20-30 minutes).

15) Define Batch Number?

Manufactures Identification code.

16) Define masking out?

During the spray painting, some sensitive equipment or existing coating protection from paint damage. (Cover out an
item which are not to be prepared and paints).

17) What is A.G.I?

Above ground installation.

18) Define Rust blooming?

First stage of a corrosion process.

19) Define Feathering?

Smoothing down of rough paint edges

20) Define T-wash?

An etch primer for zinc metal surfaces. Blue in colour it turns black upon drying if it has been applied successfully.

21) What is sheeting for protection?

Sheeting of a non-flammable nature must be employed to protect areas not being prepared or painted from
contamination.

22) What is Water borne coating?

Water used as a solvent. (Moisture curing paints).

23) Define B-S.A.2 ?

Rust grade B, very thorough blast cleaning.

24) Define Feathering?

Smoothing down of rough paint edges.

25) Define A- ST.3?

Not possible, adherent mill scale cannot brush out.

26) Define PA9?

B.Gas specification for properties and performance requirements.

27) Define PA10?

B.Gas painting specifications.

Abbreviations.

SPA- Specific paint application

BGC- British gas council
IGE- Institute of gas engineer
BS- British standards,
EPA- Environmental protection act.
COSHH- Control of substances hazardous to health Act 1988
 EH 40- HSE guidance notes: list of all known harmful substances.
OEL- occupational exposure limit.
MEL- Maximum exposure limit
OES- occupational exposure standard.
HASAWA- health and safety at work act 1974
TSA- Thermally sprayed Aluminium
CPVC- Critical pigment volume concentration
SRBs- sulphur reducing bacterias.
MEMs- Metal eating microbes.
VOCs- Volatile organic compounds.
PVB- Poly vinyl butyrl.

General Questions and Answers BGAS Grade 3/2

1) What Kind of process is corrosion?

Corrosion is an electrochemical process (called electrolysis).

2) Define corrosion? Why do uncoated steel structures corrode?

Iron ore is an oxide with chemical balance, Iron are usually extracted from Iron ores through the application of
considerable amount of energy, and the Iron will be at a higher than natural energy states. Certain environments offer
opportunities for the metals to combine chemically with elements to form compounds and return to their lower energy
levels. Corrosion processes are usually electrochemical in nature.
When metal atoms are exposed to an environment containing water molecules they can give up an electrons becoming
themselves positively charged Ions, provided an electrical circuit can be completed.
Generally, corrosion is defined as Degradation of the material by chemical or Electro chemical means.

When the uncoated steel plates are exposed to the atmosphere, the impurities in the air like water, acids and salts will
act as an electrolyte and then the steel will corrode.

3) What factors influence the rate of corrosion?

There are many factors to influence the rate of corrosion. They are, Temperature, Hygroscopic salts (chlorides and
sulphates), Aerobic conditions(presence of oxygen in air),Bacteria on the surface SRBs- sulphur reducing bacteria and
MEMs- Metal eating microbes, Acids and Alkhalis, Bi-metallic contact and relative humidity above 60%.

4) What is a mill scale? When and where does it occur? And why is it particular problem with attempting to protect steel?
A thin, hard flaky black/blue layer of compound iron oxides (Weustite, Magnetite and Haematite) formed during the
rolling process of steel manufacturing at a temperature of approximately 580c. Generally its thickness is
approximately 25-100microns.
Because Mill scale in more noble than steel, so steel may corrode fast, when they come contact with each other. If the
mill scale is not removed from the substrate before painting, it may remove itself and coating system may fail.

5) What particular problems relate to the maintaining of an effective coating system in the
Splash zone?
The area of the materials, which are neither in water nor in air due to waves, high tide
and low tides etc are cold splash zone. There is a variation in oxygen level on the surface of the material,
due to medium change. Corrosion rate can be accelerated due to this reason.

6) What will happen when Hygroscopic salt presence in substrate?

The Hygroscopic salts will attract water and dissolve in it. If a coating is applied over them, water will be drawn
through the film and builds up the pressure under the film. Then the film is forced up to form Blisters are called
Osmotic or hygroscopic Blisters.

7) What is the number of the Swedish standard contained with in the BS 7079 & list the rust
and blasting grades together with their brief titles.
The Swedish pictorial standard 05-59-00 is contained with BS-7079 preparation of steel
Substrates prior to the application of paint and related products.
Rust Grades:
Grade-A: Steel surface largely covered with Adherent mill scale with little if any rust.
Grade-B: Steel surface, which has began to rust and from which the mill scale has began
 to flake.
Grade-C: Steel surface, on which mill scale has rusted away or from which it can be
Scraped, but with slight pitting visible under normal vision.
Grade-D: Steel surface on which the mill scale has rusted away and on which general
Pitting is visible under normal vision.
Blast Grades:
SA-1 : Light Blast cleaning
SA-2 : Thorough blast cleaning
SA-2 : Very Thorough blast cleaning
SA-3 : Blast surface to visually cleaned steel.
Grades of wire brushing:
ST-2 : Thorough hand and power tool cleaning (manual)
ST-3 : Very thorough hand and power tool cleaning (mechanical)

8) Give the essential requirements for abrasive blasting?

Compressor to provide air supply( max 100psi), pressurized pot, vapour trap, carbon impregnated hose to reduce static
electricity, reinforced hoses, dead mans handle for direct operator control, blasting nozzles (correct size), external
bayonet Chicago type hose couplings, whiplash prevention converters.
Personnel equipments: airfed helmet, ear defenders, safety boots, gloves, leather apron, and hypodermic needle gauge
to control the air pressure.
In addition to this, scaffolding with accept tag, skilled personnel, lighting arrangements, work permit and second man
for help, safety to IGE SR 21.

9) Some metals are hard to prepare and paint, name three and how you might prepare them?
New Galvanized- Sweep blasting, hand abrade, T-wash (etch primer) where first two options are impractical
Weather galvanized- Brush damaged area and patch with primer.
Aluminium-sweep blast, hand abrade for thin gauge Aluminium, an etch primer is used prior to intermediate and finish
coats. Not to be blast cleaned. Chlorinated hydro carbon solvent shall not be used. etch primer (PVB) polyvinyl butyl
Stainless steel-sweep blast only Aluminium oxide used as blasting medium.

10) Give reasons why different surfaces require different paint systems?
Compatibility, surface operational temperature, environmental conditions, expected
Service life, surface cleaning and preparation method available, limitation of various
Paint system. The specification requirements, rust grade, paint properties cost.

11) What is rough peak? What problem can it cause?

Rouge peaks are peaks, which stand out above the required profile and should be
avoided. When applying thin coatings as they may lead to spot or flash rusting.

12) How do you measure surface profile? Explain the method?

The surface profile may be measured by a number of methods including the use of surface replica tape (testex tape),
surface profile needle gauge, or a surface comparator.

Surface replica tape:

Testex tape or press-O-film is commonly used surface replica tape. It is used in conjuction with a dial micrometer has
an advantage of providing a permanent record. The procedure for carrying out this test is as follows.
Zero the micrometer ensuring the flat contact points are clean.
Remove paper backing and stick testex tape to the surface to be measured.
Rub the testex tape in tot thorough using a blunt instrument until peaks can be seen
butting up to the transparent plastic.
Remove the testex tape from the surface and measure the overall thickness with dial
micrometer.
Deduct 50mic from the reading to obtain the amplitude. The plastic layer to which the
testex paste is attached is 50 thick.

13) Give the three basic ingredients with in a solvent carrying paint
A traditional solvent carrying paint consists of three basic ingredients, they are
Binder, pigment and solvent. Their properties are

Binder- It binds the particles together and holds them in suspension, gives the paint its
finish, makes the coating adhere to the surface, gives flexibility to the paint film. Converts the coating to
a solid dry film, give resistance to water, chemical and abrasion.
 Pigment- Gives colour to the paint, gives opacity to the paint, gives resistance to acids, alkalis and light.

Solvent- Forms the evaporative part of the drying process, thins the paint so it can be applied easily, washes out brushes
and equipments and acts as a degreasing agent if approved.

14) Name four binders / solvent combination?

Binder Solvent
Epoxy Acetone
Chlorinated rubber Xylene
Alkyd resin White spirit
Emulsion paint Water

15) Name six opaque pigments and give their respective colour?
Carbon- black
Compound of calcium- red, yellow
Compound of cobalt- blue
Compound of chromium- green, yellow, orange
Compound of Iron- brown, red, yellow
Titanium dioxide- white.
Opaque pigments are inert particles with excellent light scattering properties in order to
give covering power (opacity) and colour.

16) What factor influence how clean & how rough the surface becomes after blast cleaning?
The cleanliness of the steel surface and its amplitude are governed by the abrasive factors and by human factors as
follows,
Abrasive factors human factors
Size Speed
Shape Angle
Density distance
Hardness Time

17) Name 5 paints and give their drying & curing methods?
Emulsion Coalescence
Alkyd Solvent evaporation followed by oxidation
Chlorinated rubber Solvent evaporation only
2 pack Epoxy Solvent evaporation followed by chemical curing
Fusion bonded epoxy heat cured

18) State at what condition paint must be stored?

In a dry, lockable, well ventilated building away from any source of heat. Material should be stored atleast 5C below
the flashpoint and current legislation and manufactures instruction should be followed.

19) Give six type of Anti corrosive (rust inhibitive) primer?

Zinc chromate- yellow, Red lead-red,
Zinc Phosphate-white, Coal tar-black,
Calcium plumbate-white, Red Iron oxide-red.
Metallic pigment- May be used to anti corrosive properties or to give metallic finish
Cathodic production- Zinc and Aluminium.
20) Name three tests for locating soluble iron salts and mill scale on a blast cleaned
Substrate?
Mill scale- Copper sulphates test
Soluble iron salt- Potassium ferrysynide test
Soluble Chloride- Silver nitrate test.

21) Name 5 methods of applying paints & compare the advantages and limitations of each
method?

Brush Application- Advantages:

Effective for applying primer as it works paint well into substrate, which gives optimum
 coverage and mixes in any dust particles. Thus achieving optimum adhesion. Do not
produce overspray, less environmental hazard, less wastage as less spotting.
Limitations:
Slow production, May not have uniform thickness, high quality brushes quite expensive,
suitable for only small area, not suitable for all places, wastage of paint will be more,
cannot extend.

Roller application- Advantage:

Quicker than brush for large flat surfaces, with extension poles easy to access at elevated
locations.
Limitations:
Non-uniform paint thickness, paint does not worked into the surface, specs not permitting
roller application, skills required compare to brush.

Conventional spray- Advantage:

Suitable for applying thin material, good finish, less operating pressure-move safe, less
equipment and maintenance cost, less over spray, quicker than brush.
Limitations:
Less production, gravity fed guns to be operated at upright positions only, high viscous
paint application not possible.

Airless spray- Advantage:

Higher (more quality) production, highly viscous paint easily applied, more portable,
uniform coating can be achieved, high DFT.
Limitations:
More wastage & over spray, higher equipment & maintenance cost, high risk of safety
due to high pressure operations.

Electrostatic spray- Advantage:

More uniform thickness can be achieved, good finish, less over spray.
Limitations:
High equipment cost.

22) Regarding hand and power tool cleaning state what always concludes this process and to
What standards?
BS-7079 SIS-05-59-00
ST-2 Thorough hand and power tool cleaning (Manual)
ST-3 Very thorough hand and power tool cleaning (Mechanical)
Rust grade B, C & D only.

23) State the advantages of airless spray over conventional spray?

High rate of production, uniform film thickness can be achieved, less fog & rebound, size and angle of the tip can be
easily control the quality of flow pattern; high viscous paint can be easily applied.

24) Describe what is meant by Bi- metallic corrosion?

If two different metals attached together, low nobility metal become anode and sacrifies itself to protect high nobility
metal. Eg- mill scale--- steel, steel---zinc.

24) Describe Galvanic series?

All the metals have an order of nobility which found by testing with sea water at ambient temperature.

25) Which paints have to be considered when brush painting? Or what method of paint application is performed for primer
and why?
Primers have to be considered when brush painting because brushing works as paint into a substrate surface, which
gives optimum coverage and mixes in any dust particles, thus achieving optimum adhesion .

26) Define the tie coat and give an example?

The tie coat is the layer of paint, which ties two incompatible system together (where adhesion problem, solvent
stripping or bleeding might occur).
Eg- Aluminium leafing primer for the application of Alkyd over bitumen due to bleeding.
27) Describe barrier paint system and sacrificial paint coating?
Barrier paint system: The substrate is isolated from the environment, which causes corrosion by using a coating of
low permeability. This may be achieved by applying a thick coat of paint having low permeability. Ex- Epoxy,
polyurethane.

Sacrificial coatings: Sacrificial coating contain pigments, which cathodically protect the
iron or steel substrate to which the paint is adhered. These pigment particles eventually
corrode thereby sacrificing themselves to corrosion. In order to have these properly, the
sacrificial pigment must be ignoble to the material to be coated. Zinc and Aluminium are
the most common type of pigments employed

28) Describe what laminar pigment is and name four pigments?

Pigments having a leafing effect like fallen leaves overlapping each other results in
excellent resistance to the passage of water also create a very strong coating.
MIO, mica, glass flakes and Aluminium flakes are Eg of laminar pigments.

29) Describe the difference between water blasting and pressure washing?
Water blasting is a high pressure process (6000psi) and it can remove mill scale and cut a
profile. Toxic contamination removes with out dust, with or without abrasive.
water wash is a low pressure (100psi) to use clean painted surfaces. It can remove salt and chlorinated contamination
from surfaces, with or without detergent.

30) Briefly describe the mechanisms of the two theories of adhesion?

Molecular interference: The surface is rough and uneven the paint wets and locks into
the profile. Physical (analogy Velcro).
Molecular attraction: Negatively charged particles attracted to positive areas and vise
versa. Chemical (Analogy magnet)

31) Name four advantages of centrifugal blasting over open blasting?

They are ideal for long production runs.
The abrasives are used efficiently because the system is fully enclosed.
Therefore the quality can be controlled by adjusting the feed roller speeds. And it is more
reliable too.
Gives more productivity than open blast unit.

31) How is abrasive cleansed in a wheel abrator system?

The conveyor carries the used abrasives from the recollected hopper to the top of the
machine. Then the abrasive passes over the edge of the weir plate, a current of air is
drawn through it. This air removes the rust, mill scale, flakes of paint etc. this is known as air wash separator.

32) Describe the Duplex process?

Footness duplex system involves the pickling process followed by passivation using
chromate or iron phosphate salts, which passivates the surface and increase the adhesion
properties. They are also extremely resistance to cathodic dibondment.

33) What would be considered to be advantages of wet blasting over dry blasting?
Removes toxic coating without dust,
Removes chlorides from surfaces,
Simple to operate,
Spark free operation,
Removes algae and mould growth,
Environmentally safe and
Low cost.

34) What are the disadvantages of wet blasting over dry blasting?
Safety associated with pressure up to 20,000 psi,
Availability and drainage of large Quantities of water,
Disposal of sludge (large amount of slurry)
Cost of supplying and mixing substrate inhibitor,
Problems of drying large surface area,
Cuts no profile and flash rusting.
 35) Describe the phosphating process?
The phosphating process is only applies to the footner or duplex process. The final
treatment in a 1% to 2% phosphoric acid solution held at 80C for 1 to 2 minutes. This
leaves a thin rust inhibitive phosphate coating, which acts as a rust preventive for a
limited time.

36) What are the advantages and disadvantages of Venturi and straight bore nozzles?
Venturi Nozzles- Advantages:
Very high speed, faster operation, large area coverage and large blast pattern.
Dis- advantages:
Less accuracy more costly and more wear.

Straight bore- Advantages;

More accuracy, low cost and less wear.
Dis- advantages:
Low speed, slow operation, covers small concentrated area, operator fatigue, and small
blast pattern.

37) If corrosion occurs at Anodic areas, why does steel corrode evenly all over the surface?
Trace elements (nickel, carbon, Aluminium etc) in the steel provide million of anodes and
cathodes though bi-metallic contacts.

38) Name four expendable abrasives and state the difference between expendable and
re-usable abrasive?
Copper slag, crushed glass, Ice, walnut shells and ceramic grit.
Expendable abrasives- are used in open site blast cleaning and they are expendable. Can
be used only once. When they hit the substrates at high speed they shatter on impact.
Re-usable Abrasive- are used in a closed cleaning system. They are not expendable,
because they do not shatter on first impact and it is very expensive and can be re used
up to 20 times.

39) Describe how you would carry out a check on air pressure of a blasting operation?
First alert the operator, stop the abrasive flow, insert the hypodermic needle gauge in to
the hose at very near to the nozzle at an angle of 45 towards the flow direction and
read the pressure.

40) Name some advantages and disadvantages of chlorinated rubber?

Advantages: high resistance to mould growth, Non flammable after solvent release,
good resistance to acids and alkhalis, very high resistance to water vapour transmission,
one component physically drying.
Dis advantages: low resistance to solvents, i.e only resistance to Aliphatics and water,
low temperature tolerance, 65C maximum, Spray application resulted in Cobwebs.

41) Name some properties of binders?

Ease of application (flow properties or viscosity)
Adhesion to the substrate for the expected life of coating
Resistance to abrasion
Resistance to chemical attack according to environment
Cohesive strength, its ability to hold together as a film
Diaelectric strength (Resist the passage of electrons)
Ability to resist the passage of water
Ability to change from a liquid state to solid state.

42) Name some pigments and their respective colour?

Calcium plumbate White
Zinc phosphate White
Zinc chromate Yellow
Red iron oxide Red
Red lead Red
Graphite Black
Coal tar Black
 43) Name some extenders pigment and why it is added in paint?
Clays, chalk, talcum and slate flour are the extenders pigment. It is added to paint to expect the main properties of the
film such as adhesion, cohesion, film strength and durability.

44) What does a fineness of grind gauge measure?

It measures the degree of dispersion of paint. Also known as Hegman grind gauge.

45) What does a crypto meter measure and two examples of crypto meter?
The crypto meter measures the opacity or hiding power of paints possesses.
Pfund crypto meter and hiding power charts.

46) What determines the degree of gloss of paint may posses?

The degree of gloss determined by
Degree of pigment dispersion,
Size of pigment particles,
The pigment volume concentration,
Binder type- measured by gloss meter.

47) What is a flash point? Describe the procedure for determining of flash point?
The temperature at which vapour from the solvent will ignite in the presence of an external source of ignition.
Flash point determination of paints or solvents may be carried out in accordance with BS3900 part A9 using a closed
cup of abel type.
Procedure:
Fix the Abel cup containing the substance for the assessment into a water bath.
Activate the source of ignition every c rise in temperature.
Apply a heat source to the water baht monitor the air/vapour temperature in the Abel cup.
The flash point temperature is identified when a blue flame flashes over the substance being assessed.

48) What is Density? Hoe do you assess it? Give two reasons for its use?
Density is weight per unit volume of a substance possess.
Density = mass/volume unit=gm/cc
By using laboratory balance weigh the cup to the nearest decigram with sensitivity of
0.19.
Remove the cover and fill with paint to within 2.5mm of the brim.
Carefully replace the cover so that air and any excess paint is expelled through the vent.
Wipe off any surplus paint from the cover then reweigh
Determine the weight of the paint by subtraction.
Divide the weight by 100 if the density in gm/cc is required.
Purpose:
To determine whether two pack paints have been mixed in the correct proportions.
This procedure can be used to determine the quantity of any added thinner.

49) What is viscosity and what equipment is used to measure viscosity of the free flowing
paint and thixotropic paint?
Viscosity is a measure of a fluids resistance to flow. Viscosity of free flowing paints can
be measured by using a flow cup, there are many types including Ford cup, red wood and
Zohn flow cups- Procedure for measuring viscosity using ford cup No 4.
Bring temperature of paint to within 20 0.5c
Level the apparatus, Keep one finger and close the orifice at the bottom of the cup and
rapidly fill it with paint. Allow a moment for air bubbles to rise, then draw a flat edge
across the top of the cup to wipe off the excess paint. Remove the finger from the orifice
and start the stop watch simultaneously with the commencement of the paint stream
The watch is stopped when the first distinctive break in the paint stream occurs.
The time in seconds is taken as the viscosity. Check the time against manufacturer
recommendation.
For thixotropic paints, the viscosity can be measured by a rotation viscometer or another
type of viscometer, which works the paints.(Kerb-stormer viscometer, cone and plate
viscometer and rotothinner).

50) What is specific gravity and how is testing for specific gravity carried out?
 Relative density or specific gravity is the density of any substance compared to the density
of water
Specific gravity= Density of given substance
Density of water

51) Name three adhesion tests and describe how one of them is carried out?
Adhesion is the force that resists the separation of two surfaces in contact.
There are three types of test: Dolly test, cross cut test & cross hatch test
Procedures for pull of Dolly test:
Clean and degrease the surface to be tested.
Roughen the surface with fine / medium grade emery cloth.
Mix regular araldite and stick dolly to the surface, leave it for 24Hrs at 25C.
Cut paint around the dolly down to the substrate using a special cutter.
Attach of pull off instrument and apply pulling force. Check at what PSI failure occur
Check whether failure was adhesive or cohesive.

52) Name four artificial weathering device and what are these designed to stimulate?
Artificial weathering devices are designed to create accelerated weathering to speed up to
the duration of different test to be carried out to determine the coating systems behavior at
specific condition.
Tropical box- to simulate high humidity environment
Salt spray box- simulates a marine environment
Water soak test- to assess paint systems resistance to water absorption
Cold check test- test for low temperature contraction cracking
Temp cycling- to assess film flexibility at alternate hot and cold temperature.

53) State 2 drying curing tests & how they are operated?

Ballotini test:
Tiny glass balls known as Ballotini, are allowed to fall on to a freshly painted test panel.
The test panel moves slowly beneath the falling ballotini over a preset period of time, the
time of the test is variable and the speed can be adjusted so that a panel 300 mm long can
take between 1 to 24 hour to test, where the Ballotini fails to stick, to the painted panel drying has occurred.

Stylus test:
The stylus test employs a series of trailing needles which pass over the wet painted panel,
because the needles are set at different tensions it can be established when the paint is in
tack dry, hard dry and fully cured.

54) What is WFT? How do you measure it? What are the advantages of using?
WFT is the thickness measured immediately after a coating has been applied. The WFT may be found by using a comb
gauge or an eccentric wheel.
Procedure for measuring WFT using comb gauge.
Immediately after the application of paint the comb gauge should be firmly placed on to the surface in such a way the
teeth are normal to the plane of the surface.
The gauge should then be removed and the teeth examined in order to determine the shortest one to touch the wet film.
The film should be recorded as lying between the last touching tooth and first non touching tooth.
Atleast two further readings should be taken in different places, in a similar manner, in order to obtain representative
results over the painted area.
Advantages:
If the WFT is known, any deviation from the thickness range can be immediately rectified. And the approximate DFT
can be calculated if the volume of solid is known.
DFT= WFT x VS/100

55) What is DFT? State the principle of being able to use a banana gauge for taking DFT?
State calibration procedure for a banana gauge?
DFT is the dry film thickness of the coated surface and is measured in microns.
The banana gauge is only used for measuring the thickness of non-ferromagnetic coating
 applied over a ferromagnetic substrate.
Calibration procedures:
Choose a magnetically insulated shim of known thickness, close to the thickness of the
paint you expect to find.
Place the shim on the same substrate surface finish as the surface finish on which the paint to be measured is attached.
For Eg, if the paint is on a blasted surface, calibrate the gauge on a uncoated blasted surface.
Place the magnet on the shim and press firmly on the instrument, wind the scale wheel forward until the magnet is
definitely attached to the shim/substrate.
Gradually wind the wheel backwards slowly until the magnet detaches itself. At this point, move the curser on the
instrument to the thickness of the shim as shown on the scale wheel. With some instrument the scale itself may be
moved to line up with fixed cursor. The instrument is now calibrated and may be used to measure the DFT of any non
magnetic film to within a claimed accuracy of 5% in some cases.

56) Describe a destructive test for determining the DFT calculation?

Paint inspector gauge (PIG)
PIG is one such type pf destructive test gauge. A small V shaped channel is cut into the
Coating at a fixed angle governed by a cutter built into the gauge. The width of the channel is then measured on a
gratitude scale my means of microscopic which is again built into the instrument. It is also useful to determine the
number of coatings.

57) Describe the Cathodic disbondment test?

If the impressed current exceeds the corrosion current, hydrogen gas bubbles are evolved from the metal substrate i.e.
at the interface between the material and coating. This is a
Significant problem when curing defects are present due to stripping action caused by the hydrogen bubbles, the
coating disbondment is known as cathodic disbondment.
The test incorporates a coated test panel with hole drilled into the coating; this simulates a paint film defect.
Surrounding the hole a plastic tube is glue down and filed with sodium chloride solution to act as an electrolyte. Wires
from a battery are attached to the panel and to a metal rod set into the liquid of plastic tube; a current is then impressed
to make the panel Cathodic.
The coating is assessed after a period of time.eg a few weeks, for the amount of stripping which has occurred from the
boundary of the hole.

58) Name 3 environmental conditions when would you stop painting? Or when shall coating
not be applied?
3 environmental conditions: Rain, Snow & High wind.
It is not permissible to apply paint when the following conditions apply.
During rain, snow or high wind.
When the air or metal temperature is down to within 3C of the dew point temperature.
When the relative humidity is above 90%.

59) Explain how environmental test are carried out? What equipment is used to find RH and
DP? Explain its use?
Environmental conditions like RH and DP are measured using hygrometer of which there
are many types. The whirling hygrometer consists of two mercury thermometers set side
by side in a frame which is provided with a handle and spindle so that the frame and thermometer can rotated quickly
about horizontal axis. The bulb of one thermometer is called wet bulb thermometer. It is covered with a closely fitted
cylindrical cotton wick, the end of which dips into distilled water or clean rain water contained in a small cylinder
attached to the end of the frame.
The frame is rotated by hand for 30 to 40 seconds as fast as possible so that the bulbs pass through air atleast 4m/s.
This causes the water to evaporate from the wet bulb. The wet bulb cools down to a constant wet bulb temperature due
to the evaporation rate of water from the wet wick. Always read the wet bulb temperature before dry bulb temperature
immediately after the rotation. Repeat the operation until consecutive readings of each bulb temperature agree to with
0.2C.
If it is 100% RH, the wet bulb will be same temperature, because no evaporation can occur, i.e. the air is saturated. If
wet bulb and dry bulb temperature are the same the current temperature is the dew point. The RH and DP cannot be
read directly from the apparatus, hygrometer tables or special slide rules must be used.

60) Why the environmental test carried out during a paint project?
In order to verify the weather conditions are acceptable to the specification to carry out the painting operation.

61) Explain RH, DP, Ambient temperature and steel temperature?

RH: Relative humidity is the amount of water vapour in the air expressed in a percentage.
 DP: Dew point is the temperature at which condensation would form on a surface.
Ambient temperature: It is the surrounding air temp also referred as dry bulb temp.
Steel temperature: it is the temperature of the substrate prior to painting.

62) How do you calculate DFT, WFT & VS%?

DFT = WFT VS / 100
WFT= DFT 100 / VS
VS = DFT 100 / WFT

63) What does BS 2015- GLOSSARY OF PAINT TERMS refers to and give three
examples?
Faults, which occur with paints, are described in BS 2015- glossary of paint terms.
These faults are due to three main caused.
1. Fault in the can (manufacturing fault)
2. Problem, which occur due to poor preparation.
3. Problem, which occur due to incorrect or poor application or interference by weather.
Examples:
Bleeding: The action of a material in penetrating and discoloring a coating applied on top
of it.
Blistering: The formation of dome shaped blister in a paint film. They can be dry blisters
which are usually caused by the expansion and contraction of the paint film against the
substrate or Osmotic blister which can be caused by water / solvent entrapment or
hygroscopic salts let on a blast cleaned surface.
Chalking: The breaking down of a paint film to become chalky or powdery usually due
to disintegration of the binder caused by attack from UV light or severe weather
condition.

64) What are the essential difference between a blister and an osmotic blister?
Blister: Formation of a dry dome shaped blister in a paint film. Due to expansion and .
contraction of the paint film
Osmotic blister: Is one which contains liquid, gas and crystal. It can be cause of water,
Solvent , hygroscopic salt entrapment on a blast cleaned surface.

65) Name five items that can be included in paint to improve its performance or suitability for a certain use?
Plasticizer (prevent paint film and opacity)
Drier or catalyst
Extenders- improve flow and opacity
Thixotropic agent
Stabilizers.

66) What is BS4800 & how it is used in construction industry?

Bs 4800- Paint colours for building purpose specifies 100 colours which have been
Selected from the frame work of the 237 colours contained in BS 5252.
Each colour in BS4800 is identified by three as Hue, Brightness and saturation.
Hue- refers to basic colour Red, green, yellow, blue etc from 00 (neutral) to 24 even
numbers only.
Brightness: The darkness or lightness of the colour.From A (max white) to E (max black)
Saturation: 01 to 56 Higher number =stronger colour, Lower number= greyer the colour.
Black and white and all the grey colours in between are Achromatic, colours as they
lack Hue. Anything having colour is said to be Chromatic.
BS 4800 can be used to identify existing colours when maintenance painting and is a
method by which all manufactures can make exactly the same colours.

67) What is the procedure for removing oil & grease from a substrate after preparation has
taken place?
Wash out the area with 2% detergent wash and immediately wash with clean water and
dry. Reblast surface.

68) What is the procedure for removing oil & grease from a surface before preparation
commences?
Small areas of oil and grease shall be removed with an approved solvent. Where as large
areas can be given to low pressure detergent washing, which must be followed by rinsing
 with clean water and thorough drying.

69) What is the procedure to removing algae and mould growth?

Algae and mould growth shall be treated with a biocidal agent and left for 24 hour atleast in order to
that biocide can kill the spores. It shall then be removed by scrubbing with stiff bristle brushes and clean water or by
use of high pressure water wash.

70) What distance must be left at areas to be welded when painting?

For zinc rich paint 75 mm shall be left from the end preparation.

71) How much new paint overlap required over old paint?
Minimum 100mm.

72) What must pneumatically and electrically operated power tool equipment be?
All equipments shall be earthed. All equipments shall be non-spark and the flame proof.

73) What type of sheeting may or may not be used for protection against spillage & spotting?
Sheeting of a non-flammable nature must be employed to protect areas against spillage
and spotting. Tarpaulins must not be used.

74) What areas of work, do PA 10 does not cover?

PA-10 not covers painting work of the following,
Below ground (buried), offshore installations, internal coating of pipes & strore enamel
coating.

75) How do BGAS define the following?

New galvanizing: a galvanized steel surface upon which cohesive oxide layer has not yet
formed. (Bright and shiny, Less than 3 months old)
Weather galvanizing: A galvanized steel surface upon which a cohesive oxide layer has
formed by natural weathering (dull & lacking in shine).
Long term protection: The estimated period for the corrosion protection is typically 10 yrs.
Medium term protection: Typically 5 years.
Short term protection: Typically 2 3 years.

76) As an inspector what do you consider as your main responsibilities?

To assess the condition of substrate prior to treatment.
To inspect surface preparation in accordance with BS 7079, measure and record amplitude
once daily.
To ensure material used on site are to client specifications.
Relative humidity, dew point, air temperature and steel temperature to be checked and
recorded atleast four times daily.
Wet and dry film thickness to be checked and recorded at frequent intervals.
To witness and inspect application of each coat and inspect competed paint system in
accordance with the clients specifications.
To submit daily and weekly reports, recording all the relevant information as required by
client. Copies to be retain by the inspector.

77) Conditions for final surface preparation?

When conditions in the working area are such that metal surfaces are moist, damp or wet,
final preparation shall not be carried out.
Any surface preparation, procedure or method of cleaning shall not be allowed to.
contaminate wet paint film.
Equipment used shall be of non-sparking type. Electrically operated tools are not permitted.
Power tools operated by compressed air shall have oil and vapour trap fitted to the
compressed air lines. All contaminants shall be removed by means of an approved solvent.
Algae and mould growth when in evidence shall be treated with a Biocidal agent and left
for atleast 24 hours in order that the biocide can kill the spores. It shall then be removed by
scrubbing with stiff bristle brushes and clean water or by use of a high pressure water wash.
All surfaces shall normally be dry before painting commence.
78) What is BGAS PA-9 and PA-10?
PA-9 refers to paint properties and performance requirements.
PA-10 refers to the technical specifications for New and maintenance painting at works
and site for above ground pipeline and plant installation.
79) What is document state health & safety at work? And what do you know about that?
H.A.S.W.A. Health and safety at work act 1974.
It deals with the responsibilities and duties of the employer and employee at work site.
The duty of the employer is to provide safe working environment to the employee.
The employee duty is to work safely at all time to protect himself and other self.
They have legal responsibilities to report any accident, incident and or spillage.

80) What year was the Health & safety Act passed? And what do you know about that?
Control of substance Hazardous to health regulations 1988 came into force on 1 st oct 1989.
COSHH Regulations.
It deals with handling, storage, packing, transportation and labeling of many hazardous
substances. In our industry it deals with mostly solvent, sand and dust.

81) How long would records of personnel exposed at work?

Employers must keep records of examination / monitoring test for 5 years, 30 years for
identifiable employees.

82) What is EPA and VOC?

Environmental protection Act and Volatile organic compound.

83) What is the impressed current & and what problem can arise from its incorrect use?
Impressed current is a type of cathodic protection system e.g. used for large areas of pipes.
If the impressed current exceeds the corrosion & current, hydrogen gas bubbles are evolved
from the metal substrate i.e. at the interface between the material and the coating. This is a
significant problem when curing defects are present due to a stripping action caused by the
hydrogen bubbles leads coating disbondment is known as cathodic disbondment.

84) What is the difference between thermosetting & thermoplastic?

Coating which do not melt after the application of heat is known is thermo setting coating.
Paint which melt when heat is applied are known as thermo plastic coatings.

85) What are the metallic pigments and why it is used?

The metallic pigments are zinc and Aluminium, which is used to protect the steel substrate
by cathodic protection.
Zinc - better for galvanic protection and Aluminium better for solar protection.

86) Explain about CPVC?

CPVC is critical pigment volume concentration. This is divided into three, they are,
below CPVC, Near CPVC and above CPVC.
Below CPVC- Poor opacity, high gloss, blistering (low cohesive strength).
Near CPVC- Good opacity, cohesive strength, low gloss, impermeability.
Above CPVC- porous, low cohesive strength, poor adhesion and increase viscosity.
Low pigment/higher binder high gloss, good water resistance
Low binder /higher pigment good opaque coating, poor water resistance.
87) Define galvanic series? How to use galvanic series in cathodic protection?
Metals and metal compounds are arranged in order of nobility is called galvanic series.
E.g. Gold, silver, copper, mill scale, steel, Aluminium, zinc and magnesium.
There are two ways to use the galvanic series in cathodic protection.
1) Bi- metallic corrosion. When two different metals are attached together the less noble one will act as an anode to the
more noble one. The less noble one sacrifice itself and preserve more noble one.
2) Sacrificial coating: When a coating, whose have the metallic pigments are less noble than steel are coated on to steel,
they will sacrifice themselves in order to preserve steel.
E.g. Zinc or Aluminium pigment will be around 90% of the coating.

88) Define method of arresting corrosion? (Coating system)

a) Barrier principle b) Sacrificial principle c) Galvanizing d) Sheradising
e) Passivation- chemical reaction between the rust inhibitive pigment of the primer and
steel substrate.
 f) Metal spraying
g) Sacrificial anodes.

89) State the advantages and disadvantages of using an Epoxy paint system for long term
protection?
Advantages: Chemically curing-two components, good resistant to water chemical
solvents oil etc., good resistance against mechanical strains, more flexible, can be used in
modified form for high temperature and damp surfaces, high solid content.
Dis-advantages: Required special solvent, maximum curing time required for successive
application, poor UV resistants, chalk in sunlight, temp dependent +10C, require good
predeterminat blast clean. Cannot apply on top of others paint types, risk of dissolution
(lifting) other paints. Epoxy is not cured by oxidizing but cured by chemical reaction
between two components.

90) What is T-wash? An etch primer for zinc metal surface.

What is it used for? To provide a key for new galvanized surface.
What colour is it? Blue
How do we check for a correct reaction when using it? Blue in colour it turn black upon
drying.

91) State the qualities of poly urethane finish coat can give a paint system?
Polyurethane finish coats are often used to replace epoxy finish coats. They have the .
following qualities.
High gloss, retain the gloss, hold the colour, abrasion resistance, easily cleaned, good
resistance to UV light, chemical and weather resistant cures down to 0C.
Dis-advantages: Two components may cause skin problem.

92) Describe the attribute of MIO?

Ultra violet A&B reflection, retards permeation, durability, provides adhesion to next layer.

93) What are the advantages and disadvantages of water borne coating?
Advantages:
1) Suitably low viscosity for any application method, brush, roller, and spray.
2) Recyclable, abundant, non toxic, non flammable.
3) No harmful to environment, the ozone layer and to humans.
4) Water can be applied over any existing binder type with impurity.
5) Several coats can be applied in one working day.
Dis advantages:
1) Water is usually needs a small amount of solvent for modification.
2) During high humidity time drying process will be delayed.
3) Needs controlled storage conditions.
4) Not as versatile as Hcs for application window.

94) Determination of Volatile and non volatile?

Take thoroughly cleaned dry glass, stirring rod and watch glass, and weigh on a sensitive
balance to the nearest milligram. Put approximately 2gm of paint in to the watch glass and
weigh again. Place the watch glass with paint into a hot air oven, no naked flame or
element, repeatedly stir to drive away the volatile content. Take a final weight of the glass,
rod and dry paint and simple calculations will give volatile and non volatile ratio by weight.

95) Which test is carried out for soluble salts in a marine environment?
Potassium ferricyanide test commonly used. The other name for this test is potassium
hexa- cyanoferrate (marine & industrial).
Silver nitrate test 2% with distilled water is most commonly used in marine environment
for detecting chloride.

96) Why etch primers are used? Where and when?

Etch primers are used to etching New galvanizing. For surface preparation of new
galvanizing and Aluminium surface. When the preferred and first option of surface
preparation is not feasible. (Sweep abrasive blast and hand abrading respectively).

97) Duties of Inspector?

 1) Understand the procedures,
2) Understand the plant and equipment,
3) Understand the personnels,
4) Ensure all personnels relative to painting work are aware of spec.
5) Monitoring the process,
6) Assess conditions of substrate,
7) check correct materials has been used.
8) Wet and dry film test, check dew point, relative humidity and metal temperature,
9) Making reports.

98) List the contractor malpractices?

Using untrained personnel,
Substituting new materials with out of date materials,
Substituting approved products with unapproved products,
Reusing expendable abrasives,
Not observing recommended over coating time,
Missing out one coat,
Using incorrect paint,
Incorrect of storage paint,
Not observing induction and pot life time,
Continuing with the next stage of operation without inspection clearance,
Painting coating over area of inadequate preparation,
Working in condition outside of specified requirements,
Insufficient attention for awkward area,
Using cotton clothes for cleaning.

99) What are the documents to be prepared and submitted at the end of the contracts?
Daily painting inspection report / weekly reports,
Manufacturing data sheet,
Painting / coating materials certificate,
Instrument calibration certificates,
Testing reports.

100) State the advantages and disadvantages of conventional and airless spray?
Conventional spray: Advantages:- Disadvantages:-
More accuracy, Low deposition rate,
Good atomization, High viscosity fluids cannot be used.
Inexpensive nozzle, Heavy hose line,
Concentrated flow pattern Separate container to be used,
Low working pressure, operator fatigue,
Less cleaning after use.

Airless spray: Advantages:- Disadvantages:-

High deposition rate, Low accuracy
Can be apply high viscosity fluids, Poor atomization,
Versatile (No air hose), Expensive nozzle,
High transfer efficiency, Narrow flow pattern,
Lower waste, Coatings limitations,
Large area coverage, Increased maintenance,
Manufacturer container can be used. High skilled required, increased safety risk.

101) What is polymerisation?

Monomers link together with other monomers to form polymer. This chemical process
known as polymerisation. This takes place during the drying of a paint film.
102) Briefly describe the difference between saturated and unsaturated when referring to
oils and polymers?
Oils: Saturated oil cannot be used as a binder, because it will not solidify by
polymerisation to form a film.
Unsaturated oil can be used as a binder, because it has the ability to combine
with Oxygen, solidify by polymerisation to form a film
Polymers: The atoms or molecules which form the polymer will join on at the end of the
 structure, when structure gets saturated. (E.g. methane and ethane).
The Ethylene and Ethyne molecules is defined as being unsaturated.

103) What is meant by convertible and non convertible coating?

A convertible coating is permanent or non reversible, and therefore cannot be returned to
Its original liquid stage, it is generally thermosetting.
Non convertible coating is said to be reversible as re-application of the solvent will soften
the binder and return the coating in the original liquid form. This resulting drying
mechanism is by solvent evaporation.

104) Identify six paints by their binder names?

Epoxy, Acrylic, Alkyd, Emulsion, polyurethane and cellulose.

105) What does a CRYPTOMETER measure and give two examples of a cryptometer?
Opacity---Hiding power chart and pfund cryptometer.

106) Under what conditions must paint be stored?

Less than 5C of flash point, dry lockable well ventilated building, away from any source
of heat and following any legal storage requirements and following paint manufacturer
instruction.

107) What two coats of paint are applied at works?

High solid Epoxy primer minimum 75, Epoxy MIO coat 75 minimum.

108) What additional information you should when maintenance painting a pipeline without
removing the existing coating?
The following additional information to be recorded are:
Nature of the existing system must be established to decide the type of preparation to be
carried out.
Amount of surface contamination
Extent of paint breaks down.
Extent of corrosion.
Compatibility of the existing system with the new system. If not compatible select the
appropriate Tie-coat.
In service environmental condition.

109) What determines the degree of gloss paint may possess?

Amount and type of binder, Fineness of grind of pigments, method of application, skill of
applicator, absorbency of surface. The gloss is measured by gloss meter by reflective
light. Polyurethane- high glossness

110) What are the 2 coats applied @ work?

Primer and first mid coat.

111) What are the points to be considered for selecting a surface preparation for a paint
project?
a) Demands of the specifications,
b) Location (environment of the systems,
c) Type of paint being applied,
d) Operational restrains etc,. (control service temperature)
Because correct and effective preparation will providing the length of life and quality of finish of the paint systems
being used.

112) What are the potential fire hazards in an operational are?

Sources of ignition
Naked flame, hot surfaces, smoking, striking metal surfaces, electric power supply and
static electricity.
Fire and explosions hazards.
- Concentration of vapour in air is above UEL.
- Flammable liquids are contact the temp above its flash point.
113) Surface preparation and painting what are the points you will record or report?
General:
Date, project and job identification, name of contractors, inspection location and time,
safety aspects.
Ambient condition: Air and surface temperature, relative humidity, dew point, presence
of wind or dust, sunlight.
Surface preparation:
Condition of surface before cleaning, cleaning method, abrasive used, nozzle used and
pressure, achieved surface profile in micron.
Coating application:
Manufacturer type, Batch #, ratio of paint and thinner, over coating time, application
method, equipment used, spray nozzle size, inspection test, WFT / DFT, holiday etc,.
including instrument calibration details, repairs etc.

114) What is the title of BS 3900?

Method of test of Paint,
How many test sets are there? Eight
And how are they numbered? From letter A-H

115) Recording of information following project completion?

To have record of work stoppage due to adverse weathering condition down time.
To have records of materials, consumables (equipments and instruments) qualitities and batch certificates.
Man power deployed and equipment used.
Record of wastage of materials.
Cost effectiveness
Estimation of project cost.

116) Preparation of 2 packs paint for use?

Plastic paper to be laid underneath of the paint tin.
All dust to be removed.
Lid to be open with out damaging of the ring.
All solidment at bottom of the tin to be mixed by stirring.
Solvent or catalyst to be added, according to the manufacturer instruction (quantity). Slowly and gradually mixed
thoroughly.
Up to 5 liter can mixed by manually, if more than 5 lit can be mixed bt mechanically.
Tin should cover with out opening.
Never mix the paint in open dust area.

117) Profile reduction; what will be the action?

If the blasted surface has the profile higher than the specification requirement is called profile reduction.
a) Change the blasting nozzle type
b) Reduce the abrasive size
c) Increase the distance between the nozzle to surface.

116) If you worked on a contract where frequent stoppages occurred for poor weather, what additional information
would you record?
Time of starting and stopping
Progress of work at stopping time
Record of waste materials
Record of damaged to newly blasted or partially cured or painted area.
Calculate the stand down time.

117) Pipe line leave on ground, what problems would be occur?

Rapid change in O2 wet / dry
Contamination caused by rain splash up lower part
Impact damage
Soil damp chemically active change dark / or light.
Up grade coating system, wrapping with tape, polyethylene heat shrink sleeves
118) If a pipe line was in direct contact with accoustic cladding, what paint system might be applied if we wished to
maintain it every three years, or not at all?
Rust inhibitive primer only every 3 years maintenance
Full system specified, finish coat not required.

119) What is important about selecting a paint system suitable for a certain environment?
Selecting a coating system which is suitable for particular environment as per MDS of manufacturer.

120) What information do B.Gas require to be on a paint tin and what B.Gas document deals with the properties and
performance of paints?
Pot life, induction period, PA-9 stamp (MDS).

121) What is unusual about the preparation of surfaces which are dealt with under S.P.A.4?
Damp surface, further they shall not be used when ice is present. Type of material modified satisfactory for use on
damp metal surface include-
1) moisture curing polyurethane,
2) High solid multi- component epoxy paint.

122) Limits for coarse and X coarse?

Coarse only 50 microns
X coarse only 37 to 100 microns
Grain size- coarse grain 0.37 micron and X coarse grain 37-112microm.

123) Principle for using the Banana gauge?

It works on a magnetic principle, on a ferrous surface (substrate) with non ferrous coating, i.e measuring the
thickness of non ferromagnetic coatings applied on ferromagnetic substrate.

124) Actions taken when coating are applied out of sequence?

Stop the job, inform to engineer or client representative, find out the problem, if wrong type of paint is applied it
must reblasted off, restart with correct system, note down the area blast cleaned and quantity of paint mixed, area of
wrong coating, prepare the report.

125) Problems occur when the density and viscosity of the paint are not correct?
Thin coating will result in poor durability and lower resistance of corrosion.
Poor opacity and slow drying, poor gloss and finish, it may be creating the surface like runs and sag.

126) Rust inhibitive pigments properties on paint system?

To protect the piping or pipelines by the use of rust inhibitive primer, which will retard corrosion to take place.

127) How the contractor has to maintain the relationship with client?
To fulfill the requirement of the client according to the client inspectors priority.
Good communication about fulfillment of scope and relevant activities carried out.
Submission of the document without undue delay.
Incase any deviation against the standard and specification submit those document for his decision making, (or
approval).
Incase any changes in priority, inform and get permission from the client.
Good coordination and relation ship will contribute to understanding the job more precisely.

128) Function of primer; midcoat; and finish coat?

Primer: To provide maximum lasting adhesion to substrate for the next paint layer and retard corrosion.
Mid coat or under coat: Barrier to prevent the passage of water. Also build up the film thickness provide more even
surface.
Finish coat: It gives the final appearance, degree of colour and gloss, resistance to abrasion, UV light, weather etc.
also allow the water to flow more readily from the surface.

129) What are the risk assessments under taken when coating and painting?
All site work normally subject to a permit system.
Tool box talk shall be carried out before the work start, points to be discussed regarding hazards involve in the job.
All equipment whether electrical or pneumatic shall be earthed.
No smoking regulation shall be observed.
Fire / flame shall not be used to dispose or rubbish or clean of paint kettles.
Non spark tools and flame proof equipment shall be compulsory.
 Tarpaulin sheets must not be used.
Display warning boards and barricading the work area.
Appropriate P.P.E. shall be used during job. E.g. (air fed helmet, boots, goggles, mask, gloves etc).

130) What of abrasives used for open site blast cleaning?

Normally use the expendable abrasive i.e. use only once which cannot be re-used or recycled. E.g. copper slag,
walnut shell, garnet, ceramic grid, crushed glass, etc.

131) Reasons for different types of surface preparation?

Areas which are inaccessible for mechanical buffers we go for hand abrade by emery paper.
Area is small and spot repair, we go for mechanical cleaning by brush (ST3).
Large area and open site, we go for expendable abrasive blasting.
Area have existing coating with toxic, we go for water blasting,
Also depend upon the coating systems will get differ the surface preparation.
It depends on coating system.

132) Describe the sequence of the events for inspection before calling the 3 rd party inspector?
Carry out the internal inspection of the components prior to offering 3 rd party inspection.
Request for inspection.
Make availabilities of the relevant documents and reports for inspection.
Make availabilities of all the personal involved in the inspection with relevant testing equipment and with
calibration certificates.
Give the clearance for further activities.

133) What is the use of QC plan in paint project?

Quality control plan precisely represents following activities.
QC plan indicates responsibility and sequence of activities involved and inspection frequency involved in the
process.
Identify the nature of inspection to be conducted.
Who shall conduct the inspection and whose witness required for the inspection.
Whether the activities can be proceeded till the clearance is over.
Identify the standard and specification requirements for inspection.
Whether the activities need any additional qualification for the people who involved.
Identify the equipment and instrument used for the inspection and key personal responsibilities.
The purpose of the QC plan is setting out the specific quality practice to achieve the desirable quality to meet the
specification requirements following the various stages of inspection.

134) What are the important things for selection of a paint system?
Appropriate cost effective methods of surface preparation..
Appropriate cost affective paint system to meet the required service life.
New painting:
Consider the specification requirement.
Location of the system. (Environmental system).
Purpose of the system (paint system) Industrial or degeneration
Operational restrains (service temp)
Cost effective of the paint system
Maintenance Painting:
Need to established whether the existing system contains any toxic coating for surface preparation.
Terms of compatibility with existing system,
Adhesion,
Possibility of solvent stripping,
Possibility of bleeding,
Further information required like,
Extent of surface contamination,
Extent of paint break down,
Extent of corrosion.
Flammable substance are contact the temp above its flash point.
Vapour of the paint constituents are in air above the UEL.
Due to involvement of the ignition source.(Naked flame)
Important safety requirements.
Use correct tip.
Fluid line in good condition. Ensure no leaks in fluid line.
 Ensure safety catch on when hot in use
Never point the gun to any one and your self.
Never attend to clean or adjust the gun when line under pressure.
Ensure equipment to be earthed to avoid static shock.
Wear an air fed helmet.

135) How does the Air less spray work, define?

A non pressurized container is held remote from the gun.
The fluid pump will suck the paint from the container and fed through the high pressure reinforced fluid line.
The pressure is supplied from the compressor approximately 100psi.
This air inlet pressure is adjustable.
The fluid pump will multiple the pressures by 1: 35 ratio. (100psi=3500psi).
Spray tips are normally lined with tungsten carbides.
A titan tip exists which can adjust the tip hole size.
Size of the orifice governs the amount of fluid delivered (flow).
Angle of the orifice governs the size of the pattern.

136) What is holiday and pin hole detector, what does it detect, and how does it?
The holiday and the pinhole detector detect the discontinuity of the coating and painting system. Both the
techniques are similar.
Holiday - missed or poor coated area.
Pinhole minute defect caused by escaping air bubbles.
Process of detection and cure:
Earth the substrate to be tested.
Pass metal brush (Holiday) or wet sponge (pinhole) over the painted surface at a preset voltage (Typically around
5V per micron) and at a controlled speed.
When defect is found an audio or visual warning is given.
The area must mark and repaired and re tested.

137)