[vc_row][vc_column][vc_column_text]Coating Failures / Coating Defects / Coating Degradation / Coating Flaws / Premature Coating Failures All steel structures and auxiliaries in every industry are protected with Industrial Coatings / Cathodic Protection / Thermal Spray / Hot-dip Galvanizing and with many modern methods. Salt test & lead/heavy metal, surface preparation, mixing and application. (7), Software and Online Databases You’ve looked at all the paperwork. All Articles, https://nace.mydigitalpublication.com/article/Systematic+Coating+Failure+Analysis/3846889/688243/article.html. In 1993, following a coating defects survey, 31 cases of AC corrosion were found on a polyethylene coated steel gas transmission pipeline buried one year earlier. 6 … Decks: Basics, Math Formulas, Testing Instruments, And more! That can be detected by DSC. That could be very significant. Determine whether a unique environment exists in the area where the coating failed. potentially have a negative effect on the longevity of the coatings. Blistering and Peeling. If this error continues to occur, please contact NACE First Service for assistance. In the last three steps bell-hole excavations are used to update the performance indicators of the utilized survey techniques, the number of coating and corrosion defects, the defect size distributions and the corrosion rate. Over the years, I have developed a methodology to conduct a systematic coating failure analysis. Editor’s note: This article is based on a webcast originally presented by the author for CoatingsPro Magazine in August 2020. The pipeline is 6 km long with 3 km of parallelism with a 400 KV V.H.V. NACE Members enjoy many benefits, including NACE Standards Credits which can be used to redeem eligible NACE Standards and Reports in the Store. Is it a blister? Conduct as many of the nine steps as you can before drawing a conclusion. Gel chromatography looks for solvents that can cause failures, while ion chromatography looks for soluble salt contamination. Can you find examples of a failure of the particular coating you’re working on? A coating should be inspected for defects after the coating is dry enough to recoat and before the nexy coat is applied. Be conservative and take the samples, label them, and put them on a list. Finding the right surface preparation protocol is imperative to a establishing long-lasting, effective coating system. Coating system failures occur in the field, but how do you determine if a coating has failed prematurely? For coating inspectors & contractors. There is very practical information about selection and evaluation methods for each type of coating system to help those who design pipeline systems. The laboratory will sign for receipt of that sample and what they did to it, giving a complete history of that sample. Application of topcoat before the undercoat has dried. The defect may be due to not cleaning the surface before painting, using the wrong solvents in spray painting or incorrect air pressure. Coating reflects Quality • Inspection and repair of coating on a new pipeline reflects the Quality of the contractors workforces and training. Start by understanding the defects with your asset and cross-checking those defects with SSPC and NACE standards. There are two main types of holiday testing devices: … • Physical Property Tests: Several tests examine the various physical properties of a coating. These nine structured steps, when performed during a failure analysis, will help to ensure you don’t miss anything. Learn faster with spaced repetition. NACE-CIP1-001 exam is a hot NACE certification, if you want to get your CIP Level 1 certification, Passquestion team provides you the latest Coating Inspector CIP Level 1 NACE-CIP1-001 Practice Test Questions for your best preparation, all questions and answers are collected from real test and verified by experts and successful candidates. There is also discussion of how coatings work with cathodic protection, cathodic protection shielding by coatings and other related issues with the various coating systems related to CP. • Differential Scanning Calorimetry (DSC): This is used primarily to look at the degree of cure. Now go out and inspect the coating and see what’s wrong with it. Coatings consist of resin, pigment, solvents or thinner, and additives. When available, historical project records detailing the surface preparation, coating application, coating cure, and subsequent coating maintenance must be reviewed. • Gas Chromatography: This test is often done to look for residual solvents in a coating. Did it blister? Comprehensive visual guide to coating and surface defects. Is it corrosion with rusting apparent? Repairing defects is normally not part of an abrasive blaster’s job description, but when you are charged with prepping the surface it’s imperative the coating adheres properly, and surface defects can prevent that from happening. Review major literature sources, such as ASTM, NACE International, and The Society for Protective Coatings (SSPC). Examine as many work records as you can find. Application of a hard topcoat over a more flexible softer undercoat. I’ll briefly describe the various tests that can be performed. Gas chromatography can determine exactly which solvents are in that coating. 5th edition 2015 NACE. Make copious notes, and don’t try to memorize things. The problem is most probably caused by too thick a coat trapping solvents into the film, or by air bubbles. These Guidance Notes become effective on the first day of the month of publication. You’ll want to take a lot of photographs and use standards to describe the failure. NACE SP0169-2007 (formerly RP0169) Parts incorporated in pipeline safety regulations The laboratory can also use lower microscopy levels to determine the number of coats, their thicknesses, etc. Before you begin, decide whether the case is really a failure or not. If the coating lasts more than 30 years, you can do a failure analysis, but it will be just for interest’s sake. The work might be 20 or 30 years old, but dig out that old spec as well as the codes and standards that were referenced in it. The NACE recommended practise, SP 0188, also refers to these two test method. NACE, C.G. At times, job records may no longer be available or were never generated. … There is also discussion of how coatings work with cathodic protection, cathodic protection shielding by coatings and other related issues with the various coating systems related to CP. Coatings shrink as they cure, resulting in low film thickness over sharp edges and welds, which is a classic cause of coatings failure.. Excessive film thickness and limited paint flexibility. Participants will be eligible to receive credit from SSPC. If the AC component is removed or limited, the corrosion will be mitigated. The coating has already failed, so you don’t have to worry about damaging it further. Specific Defects – Film Defects Blistering ‘Formation of gas or fluid-filled voids with the coating.’ Liquid / gas exerts a pressure on coating greater than adhesion strength causing localised detachment. Application of coating at the end of its pot life. View • Application variables and tolerances — In the field, these are in the eye of the observer. Do the best you can with what you have. A coating’s economic lifetime should be defined, just as a failure of that coating should be defined. Keep all of this as part of your documentation. Activities of industrial and commercial painting projects. (10), Pipelines, Tanks, and Underground Systems. Some of these tests can be done in the field, but not precisely. If the coating lasts more than 30 years, you can do a failure analysis, but it will be just for interest’s sake. Put all the pieces together. Reaffirmed in 2008; also being revised. Probable Causes: Internal stresses in the coating where the surface shrinks faster than the body of the paint film. Identify the types of defects that may occur when the specification is not followed or when problems occur during the coatings installation and how to identify them. There are many Same as regular logbook but 30 day (vs. 6 month) supply. Corrosion prevention through the use of protective coatings. Munger, Associate Author Louis D. Vincent. I don’t have to do this or that.” Those are the ones that can cause you big problems. When you send them a sample, also send a copy of the chain of custody form. Reference tool for engineers, paint superintendents & maintenance personnel involved in the use of protective coatings to prevent corrosion. This page can be found at https://nace.mydigitalpublication.com/article/Systematic+Coating+Failure+Analysis/3846889/688243/article.html. • Microscopy: Typically, you can’t do microscopic analysis in the field by more than 50x magnification. These definitions have to be in the contract document to indicate when a failure has occurred for that particular lining or coating. CIP Level 1 Flashcard maker: Derek Coburn. Those could be in the nonconformance report, but sometimes they weren’t even noticed. ... Standard St 2 ISO SSPC Standard Standards SSPC-SP 2 Sa 3 Sa 2.5 Sa 2 Sa 1 SSPC-SP 3 SSPC-SP 5 NACE = 1 SSPC-SP 10 NACE = 2 SSPC-SP 6 SSPC-SP 7 NACE = 3 NACE = 4 NACE Standards. Again, the results can be compared to known samples for identification. If you’ve been called in to analyze a failure, the following nine steps can help serve as your guide. How much of it? An even newer form of electron microscopy combines optical and SEM, and it can generate three-dimensional, rotatable images. Second, look at the laboratory analysis to see how that matches up with the good samples of the coating obtained from the coatings manufacturer. A qualified laboratory will be able to recommend a method of analysis based on what you’re seeing in the field. High-performance coatings. Third edition. If it’s a good day, you can do all nine steps. There is a wide variety of testing methods currently available for failure analysis of paints and coatings. Other records include nonconformance reports, the start and end dates of the coating application, environmental data from that time, and any coating formulation changes made by the manufacturer during the coating system’s life. Go to Downloadable Products in your NACE Store Profile to find and download this item. For instance, the cure from an epoxy, when added to a polyurethane, will do some funny chemical things. Look for records of surface preparation, environmental data, blasting, etc. Runs, Sags, and wrinkles may be caused by: Applying the coating too thick. Finally, be careful of making assumptions. Write down the location of the project, the location of each sample you take, and the date and time you took the sample. Contact info., standards, checklists, personnel tracking, safety, weather. Sometimes you can’t make bench batches because the raw materials are no longer available, and sometimes you can’t identify all the process variables that resulted in the failure. • Gel Chromatography and Ion Chromatography: These two tests are similar to gas chromatography but are done for different reasons. A small diameter pipeline that has recently been inspected is used as a pilot study to illustrate the model. Did it lose color? Look for deviations. Too much or the wrong thinner used. coating failure, including the underlying substrate, are often damaged, and of little use after testing. 2011 by MPI Group, 4-3/4” x … These defects affect the coating’s thickness, thus revealing enough of the underlying metal to complete the circuit between the electrode and the grounding wire. Coating defects will tend to reduce the life expectancy of a coating in service, particularly if the service is to include immersion, such as the lining of a pipe or a tank. When observing design defects the NACE Inspector should: Document the defect and the potential problems that could result Ignore the defect as the inspector can’t change the design Request that the item be rebuilt with a better design for coating Compiled by coating specialists to provide a useful pictorial reference to all who use and encounter paint coatings, their defects and failures. electrical lines, and has a diameter of 100 mm. ... All NACE online courses are subscription-based for a period of one year from the date of registration and are non-refundable. Use a “chain of custody” form. Document clearly. Those interviews sometimes add an important piece to the puzzle to diagnose the failure. A coating inspector is an individual who has undergone a training and certification program such as the NACE Coating Inspection Program (CIP). You’ve gotten a feel for what was supposed to be done. For more information, contact: Jon R. Cavallo, (603) 767-8650, jrcpe@aol.com. NACE CIP Level 1. 2.2 DCVG % IR Calculation The NACE test method TM0109-2009 offers a formula to determine the severity of a coating defect or holiday. Cavallo is a certified nuclear coatings engineer of the National Board of Registration for Nuclear Safety Related Coating Engineers and Specialists, a senior nuclear coatings specialist of Board of Registration of Nuclear Coatings Specialists (BIRNCS), and a NACE International coating inspector program (CIP) Level 3 inspector with bridge and nuclear facilities endorsements. JON R. CAVALLO, PE, FASTM, is a registered professional engineer in three states and holds a bachelor of science degree in engineering technology. For example, high humidity, high temperature, or extreme chemical exposure may be unique to the facility. This guide is not intended to be all encompassing; rather, it is intended to be an introduction to specific reference standards and test We are unable to complete this action. Appendix B: Direct Examination-Data Collection Methods Prior to Coating Removal ... 44 Appendix C: Direct Examination-Coating Damage and … Go to Downloadable Products in your NACE Store profile to find this item. For example, ASTM D610 is a pictorial guide to the degree of rusting that has occurred. 2011 MPI Group, Fitz's Atlas is a 200 page, pocket-sized ring binder including more than 190 illustrations to provide the most comprehensive visual guide to coating and surface defects. Make detailed records of the coating failure sites. Surface too hot to apply the coating. Examine the product data sheets for the coating. Sophisticated and highly calibrated laboratory equipment can detect the slightest imperfections on If a coating lasts as long as it was guaranteed, it really hasn’t failed. Jon R. Cavallo, PE, FASTM 2020-12-24 03:10:02. Blistering and peeling are defects in which swelling of the paint film occurs. Then there’s no way to recreate a sample to determine whether your hypothesis is correct. Chemical terms have been reduced. You can perform destructive and nondestructive examinations. Decks: Coating Defects, And more! This is where you get up close and personal with the failure in the field. NACE has developed a test standard (NACE TM0112-2012) to determine the potential corrosion effects of Ballast Water Treatment Systems on Ballast Tanks. Take a painter’s 5-in-1 tool and tap on the coating in the field, and see what it sounds like or whether it can be easily removed from the surface. repairing the coating defect or holiday. But with SEM, we can go down to 10 nanometers — 20x higher than optical magnification. Types of Holiday Testing Devices. Remember that these change over time, so try to find the data sheets that were contemporaneous with the coating’s procurement and application. Indication pipe to remote earth DCVG signal magnitudes (P/RE) are calculated using the following formula. If you’re a contractor, by know what these steps are and taking them into consideration when working, you may be able to avoid a headache down the road, too. All Rights Reserved. The result is a formula described as % IR. As you get more senior in your career, be careful not to think, “I know all about this. New technology. Please login to use NACE Standards Credits*, * NACE Members receive NACE Standards Credits in order to redeem eligible NACE Standards and Reports in the Store. Defects may be either circled with grease-free chalk, marked on the drawings, or noted in the inspection report. Coating stretches to form hemispherical blister (s). Coatings have issued consensus standards to minimize surface preparation and application inadequacies. Sometimes you can’t buy the resins anymore. • Scanning Electron Microscopy (SEM): This test is a very high-magnification scanning technology utilized to find small defects. • Destructive adhesion testing — This can be done in the field, but a much more precise measurement of adhesion can be done in the laboratory. That could be 30 years or more. NACE Standard SP21424-2018 AC Corrosion on a cathodically protected underground pipeline is commonly the result of a combined action of the AC voltage, the CP conditions, a coating defect, and the chemical and physical conditions of the soil. • Solvent resistance testing — You can put a solvent on a clean cloth and rub it on the surface of the coating. 2011 by MPI Group, 4-3/4” x 7-1/2”, ring binder, 200 pages, illustrations, The selection and use of protective coatings. Application of topcoat before the undercoat has dried. They can come back to haunt you. Poor gloss rentention. 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