Transcript Structural Designs that Accelerate Corrosion

Digital Data Management For
Coating Inspection Tasks On
Steel Structures
Presented by: Joe Walker, Elcometer
Learning Outcomes
• Define digital data management
• Define key sections where project
information is recorded within a digital data
management software package
• Define surface profile, ambient conditions,
and dry film thickness
• Recognize how to perform profile, ambient
conditions, and dry film thickness
measurements
Introduction
• Optimum corrosion protection and rigorous
inspection is required – on both new build
and existing structures
• Protective coating maintenance costs for
steel structures continue to rise
• Accurate records of inspection
measurements and procedures provide
assurances to the owner or the purchaser
that the coating is being applied properly
Inspection
• Independent inspection provides quality
assurance to the owner
• The time needed to perform quality
inspections will impact overall project
• Inspections are necessary to meet the
required standard
Inspection
• The key therefore is to minimize the time
spent writing the reports, so more time can
be spent inspecting
• This is where digital data management
comes in
What is Digital Data Management?
• What are the issues?
• Not all inspections are with digital gauges
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Surface condition – SA2½
Surface cleanliness
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soluble salts
beading
weld spatter
Surface contaminants
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Oil, grease, dust
abrasive inclusions
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Edge radii
Surface profile
Climate conditions
Dry film thickness
Film continuity
Damage & inclusions
• Some use ‘mark 1 eyeball, others
mechanical, and some have a digital display
but no data output or memory
Digital Data Management
Software for Inspection
• Advantages:
– Significantly speeds up measurement and
recording time- by as much as 70%
– Minimizes (and in most cases removes) human
error- transcribing or keying in errors
– Reduces paperwork
– Provides real time inspection data to the
customer
What is Digital Data Management?
• Digital Data Management comes in many
forms:
• Hand written reports – scanned into the computer and stored
• Hand written reports – manually keyed into the computer
• Inspections using digital test equipment and downloaded into a
computer
• Inspections carried out using a PDA and digital test equipment
emailed to the PC
• Total paperless QA – with inspection task planning
Total Paperless QA
• Provides a framework for planning and
recording coating inspection tasks
• Provides a single point of reference for all
coatings applied – and in which location
• Provides a daily activity log
• Generates a complete inspection report –
automatically
• Provides an electronic method for recording
both digital and non-digital inspections
• Maximises inspection time
Using Digital Data Management
• Provides a framework for planning and
recording these coating inspection tasks on
large projects.
Key Components of Digital
Data Management Software
– A coating library
– Defined coating systems used throughout the structure
– A register of inspectors and their certifications (e.g. PCI
and NBPI)
– A list of individual inspection check/hold points
– Details of the structure being coated (including
drawings)
– A list of individual inspection tasks, along with areas to
record results and links to rework
– A daily log that contains inspection information
recorded by the system administrator
Coating Library
• Repository of information from the manufacturer’s product
data sheet
– Manufacturer
– Product name
– Product ID
– Specified wet film thickness/dry film thickness
– Specified surface profile
– Ambient conditions for application
Defined Coating Systems
• Unique IDs in the coating library tying each
coating system to structure area
Defined Coating Systems:
Application
• Once the coating system’s unique
identification is created, the steps for proper
coating application are specified
Register of Inspectors
• Holds the records for approved inspectors:
– Photograph of inspector
– Copy of inspector’s certificate
– Record of certificate expiration date
– Details of where inspector has permitted
access
Inspection Regime
• Area in the digital data management
system that groups inspection check points
together, for example:
– Surface Preparation Check Points
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Removal of oil and grease
Removal of surface contaminants
Surface profile
Abrasive cleanliness
Cleanliness of abrasive blasting air
Steel Structure Details
• A record of the steel structure and steel
parts
• Provides a basis for planning the job and
inspection tasks
Steel Structure Details
• Example:
– Ship Structure
• Record of:
– Hull number/IMO number
– Customer’s name
– Ship’s name
– Contract date
– Keel-laying date
– Planned launch and delivery dates
– Gross tonnage
– Deadweight
– Length of ship
– The beam
– The draft and depth
Steel Structure Details
• Store drawings of the structure as “jpg.”
• Highlight individual areas of the structure as part
of the structure definition
• Assign the proper coating system to be applied to
individual areas as well as the appropriate
registered inspector
Steel Structure Details
Steel Structure Details
Inspection Tasks
• The inspection record (inspection tests and
results) is created after the structure part,
coating system, and assigned inspector are
identified
Daily Log
• Documentation of inspection tests
performed on a given day as well as any
scanned documents
• Should include supporting photographs as
well as measured data
Reporting Inspection Test
Results
• Written on a hard copy printout of the
inspection task
• Transferred electronically to a Smart
Phone/PDA
• Entered directly into a computer
Reporting Using a Hard Copy
Printout
• Finished written document is scanned to
create an electronic file within the digital
management software
Reporting Using a Smart
Phone/PDA
• Transfers the inspection test results along
with any photographs to the portable device
Reporting Using a Computer
• Enter testing results directly into the
computer
The Three Digital Inspection
Techniques
• Surface Profile
• Ambient Conditions
• Dry Film Thickness
Surface Profile
• The roughened surface that results from
abrasive blast cleaning or power tool
cleaning to bare metal
• A measurement of the peak-to-valley height
of the surface roughness
Surface Profile
• ASTM D 4417, Standard Test Method for
Field Measurement of Surface Profile of
Blast Cleaned Steel
– Method B
Surface Profile
• ASTM D 4417, Method B
– The depth of profile is measured using a fine
pointed probe at a number of locations and the
average is determined
Ambient Conditions
• Weather conditions at a specific place and
time or time period:
– air temperature
– relative humidity
– dew point
– wind velocity
• Monitored on the job site
Ambient Conditions
• Measured using:
– Electronic dew point meters
Ambient Conditions
Ambient Conditions
• Maximum relative humidity of 85%
• Surface temperature typically must be at
least 5°F/3°C above the dew point in
order for final surface preparation and/or
coating work to begin or to continue
Dry Film Thickness
• Depth of cured film usually expressed in
mils (0.001 inch) or microns (millionths of a
meter)
Dry Film Thickness
• Measured with:
– Type II Gage (Non-Destructive)
Dry Film Thickness Gages
Dry Film Thickness Standards
– ASTM D 7091, Standard Practice for NonDestructive Measurements for Dry Film
Thickness of Nonmagnetic Coatings Applied to
Ferrous Metals and Nonmagnetic,
Nonconductive Coatings Applied to NonFerrous Metals
Dry Film Thickness: SSPC PA 2
• Measurement of Dry Coating Thickness
with Magnetic Gages
– Type II Gages
– Describes how many measurements to take in
a given area
SSPC-PA 2
• Provides guidance on:
• Frequency of verifying gage accuracy
• Frequency of measurements (number of
measurements to obtain based on the
size of the coated structure
• Places limits on thickness readings vs.
specified thickness
• Procedures supplement manufacturers’
operating instructions but do not replace
them
SSPC-PA 2
• Gage Reading- a single reading at one
point
• Spot Measurement- the average of at least
three gage readings made within a 1.5 inch
diameter circle
SSPC-PA 2
• Make five separate spot measurements
spaced arbitrarily over each 100 ft2 area to
be measured
• For structures NOT exceeding 300 ft2, each
100 ft2 area shall be measured
• For structures NOT exceeding 1000 ft2,
three 100 ft2 areas shall be arbitrarily
selected
SSPC-PA 2
• For structures exceeding 1000 ft2, the first
1000 ft2 shall be measured as stated in
previous slide
• Each additional 1000 ft2 of area or
increment thereof, one 100 ft2 area shall be
arbitrarily selected
SSPC-PA 2
Conformance
• Minimum Thickness
– No single spot measurement in any 100 ft2
area shall be less than 80% of the specified
minimum thickness
• Note- it is possible for any single gage
reading to under-run by a greater amount
Conformance
• Maximum Thickness
– No single spot measurement in any 100 ft2
area shall be more than 120% of the specified
maximum thickness
• Note- it is possible for any single gage
reading to over-run by a greater amount
Summary
• Using digital data management can reduce
time spent on the inspection process and
overall project costs while providing an
electronic record of the job in all its stages.
Conclusion
• This concludes our webinar for today.
Please join us for our next webinar, Coating
Selection for the Wastewater Industry on
October 20th at 1 pm EST