Download Corrosion Fundamentals: Definition, Mechanisms, and Control Methods and more Exams Water and Wastewater Engineering in PDF only on Docsity!
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NACE CIP Level 1 Study Guide
1. Define Corrosion: The deterioration of a substance, usually a metal from a reaction with its
environment
2. What is passivation?: A layer of oxides formed on the surface of a metal that provides corrosion
protection.
3. What is an example of passivation?: Stainless Steel
4. What are the elements of a corrosion cell?: Anode, Cathode, Metallic Pathway, Electrolyte
5. Describe what happens at the anode.: The metal dissolves into the electrolyte
6. What is the function of the electrolyte?: Allows the passage of ions to connect the corrosion cell
7. What is the function of the metallic pathway?: Allows the flow of electrons to connect the corrosion
cell
8. What is the galvanic series?: A listing of metals in order of reactivity (more or less noble) in
seawater at 25 C
9. The general rules of galvanic corrosion are:: The less noble (or more reactive) metal when
connected to a more noble (or less reactive metal) will corrode prefer- entially
10. Name the five most important factors that affect the rate of corrosion.: Hu- midity, oxygen,
chemical salts, pollutants, temperature
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11. General corrosion is:: Results in a relatively uniform loss of material over the entire surface,
Results in a general thinning of the affected surface, Relatively easy to inspect, Does not casue catastrophic failures
12. Localized corrosion is:: Typically pitting and crevice corrosion. It is typically of the most concern as
damage is concentrated and loss of integrity or structural failure can result.
13. List some of the common tools/methods used for corrosion control.: De- sign, Inhibitors, Material
Selection, Cathodic Protection, Protective Coatings, Splash Zone Systems, Alteration of the Environment
14. How does NACE define the inspector's role?: The inspector's role is that of a quality control
technician responsible for observing and reporting conformance or deviation from the project specification.
15. What is the inspector's responsibility when it comes to safety on the project?: Safety
enforcement is not the responsibility of the inspector; however, it is his/her responsibility to report any issues that may affect the project.
16. Name some tests that may need to be conducted during surface prepara- tion and coating
operations.: Temperature, Relative Humidity, Dew Point, Anchor Profile, Surface Cleanliness
17. Name some of the documentation/reports that may be required to be maintained on a coatings
project.: Daily/weekly summary, material usage reports, manpower and equipment, non conformance, and conformance
18. What are the most important characteristics of a good report?: Objective, Accurate, and Detailed.
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26. Name some of the effects wind may have on a coatings project.: blowing abrasives, causing
excessive drift or overspray, accelerating solvent evaporation, contributing to the formation of dry spray
27. What are some of the common errors when using an electronic hygrome- ter?: Failure to
acclimate the instrument to the environment with adequate time.
28. Explain the process for use of the sling psychrometer.: Make sure the wick is wet and clean,
continue to "sling" until 3 consecutive readings are achieved
29. List three desirable properties of a coating?: Chemical Resistance, water resistance, ease of
application, cohesive strength, impact resistance, dielectric strength
30. Two broad classifications of a coating are:: Organic/Inorganic, Convert- ible/non-
convertible, thermosetting/thermoplastic
31. What are the two primary components of a liquid applied coating?: Pig- ment, Vehicle (Resin or
Binder)
32. What are the three methods by which a coating provides corrosion con- trol?: barrier,
inhibitive, sacrificial
33. What are the three different ways a coating can adhere to the surface?: -
Chemical, Mechanical, Polar, or combo of all three
34. The two broad classifications for curing mechanisms are:: Convertible and Non-Convertible
35. List two Non-convertible coating types:: Chlorinated rubber, vinyl
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36. List three convertible coating curing mechanisms: oxidation, co-reaction (polmerization),
hydration, fusion
37. List two characteristics of oxidation cure coatings: Not suitable for immer- sion service, not
suitable for use over alkaline substrates, limited dry film thickness per coat
38. List three coating types that cure by polymerization: epoxies, polyurethanes, polyureas,
polyaspartics, polysiloxanies
39. Induction time is:: the time required by the product data sheet (coatings man- ufacturer) between
mixing the coating and the start of application
40. What is the main requirement for a hydrolysis coating cure?: Moisture
41. Industrial and marine coatings are commonly referred to by: generic resin type
42. Oil based coatings applied over alkaline surfaces may result in: saponifica- tion
43. List five of the formal sections usually contained in a good specification-
: scope of work, terms and definitions, pre-job conference, application, sampling coatings, inspection
44. What are two of the inspector's responsibilities as it relates to the specifi- cation?: Enforce the
specification, NOT to make changes to the specification
45. During the surface preparation, surface cleanliness should be inspected (as a minimum) the
following three times:: Before any surface preparation activ- ities, after surface preparation - before coating begins, between each application of coating in a multi-coat system
46. Factors during surface preparation that may effect service life include:: - residues of oil, grease,
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47. Common design defects include:: Hard to reach or inaccessible areas. rivets, bolts, or other
connectors. welds. gaps. overlapping surfaces. threaded areas. dis- similar metals. construction aids
48. Common fabrication defects include:: weld spatter, skip welds, sharp corners & Edges
49. Four typical SSPC SP1 pre-cleaning methods include:: Solvent wipe with cloth or rag, immersion
of the substrate in solvent, solvent spray, vapor degreasing, emulsion cleaining, chemical paint stripping, use of alkaline cleaners
50. One standare for use with Power Tool Cleaning is:: ISO St2. ISO St3. SSPC SP-3. SSPC SP-
51. Four examples of tools used for Power Tool Cleaning are:: rotary wire brushes, impact
tools, needle scaler, disc sanders, piston scalers
52. Two Abrasive Blasting methods include:: Centrifugal blasting, sand-injected water blast, slurry
blast, wet abrasive blast, dry grit blasting
53. Visual Standards for abrasive blasting include: SSPC-Vis 1, ISO 8501- 1
54. SSPC SP 10/NACE 2 limits staining to per each unit area: 5%
55. SSPC SP 5/NACE 1 limits staining to per each unit area: 0%
56. SSPC SP 6/NACE 3 limits staining to per each unit area: 33%
57. The two types of abrasive blasting nozzles include:: Straight, Venturi
58. The specified level of surface cleanliness must be achieved and main- tained: immediately
prior to coatings application
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59. Advantages of centrifugal blast equipment include:: Dust and fines are contained, abrasives
are easily recycled, blasting and priming can be an inline operation, general overall economy compared to air blasting, no compressors, piping, or air handling equipment needed for wheel blasting
60. The Inspector's checklist for surface preparation should include:: ambient conditions, conditions
of substrate, pre-blast surface cleanliness, shot/grit size se- lection, shot/grit cleanliness, abrasive blasting equipment, surface profile, surface cleanliness after abrasive blasting, operator qualifications, safety
61. Abrasive media types include:: shot & grit (metallic), crushed slag, ceramic grit, silica sand,
garnet, agricultural abrasives, specialty abrasives
62. Abrasive media typically used for recycling include:: steel shot, steel grit
63. List the pressure ranges that categorize: low pressure water cleaning: <34 MPa (5,000 psi), high-
pressure water cleaning: 34 to 70 MPa (5,000 to 10,000 psi), High-Pressure water jetting: 70 to 210 MPa (10,000 to 30,000 psi), Ultrahigh=Pres- sure water jetting: > MPa (30,000 psi)
64. Three types of Water-Blasting include:: Comparator and coupons, replica tape, digital surface
profile gauge
65. Types of soluble salt contamination include:: chlorides, sulfates, nitrates
66. If inspection is to be effective with regards to soluble salts, the specifica- tion should very clearly
state:: limits to be accepted, specific salts to be limited, test method to be used, frequency of testing,
10 / engineer, specifying engineer, operations personnel, spec- ifier, purchasing agents, coatings manufacturer, coatings inspector, project safety personnel, coatings applicator
75. Before the start of the Pre Job Conference the inspector should obtain a copy of, read, and
understand the:: specification, any standard / procedure referenced in the project specifications, manufacturer's product data sheets, safety requirements of the MSDS
76. Documentation may include:: Detailed written daily reports, inspection logs, routine reports,
reports for weekly progress meetings, daily entries in a project log book, a daily inspection report using standardized forms, routine reports, monthly or quarterly reports
77. Inspection records show:: environmental conditions, pretreatment details, cleaning details,
materials details, coating applications details, results of work and all tests
78. Good records allow management to:: detect and tag design defects for future work, evaluate
coating performance, determine annual cost data on each coating system, develop ongoing maintenance program
79. Project inspection documentation provides:: inspection (QC) records, man- agement information,
verification of work by the contractor, details of non-conform- ing work
80. One guide for enclosures for coatings projects is:: SSPC Technology Guide No. 12, SSPC
Technology Update No. 6 Guide for Containing Surface Preparation Debris Generated During Paint Removal Operations
81. Low Temperature concerns during coatings application include:: Slow the curing of chemically
11 / curing coatings, will increase the viscosity of material, some coatings may use special cure
82. High temperatures concerns during coatings application include:: Can cause the solvent to
evaporate too fast, will reduce the pot life, decrease the viscosity of many two-component materials
83. High humidity during coating application:: Slows the evaporation of the solvent, can leave
moisture on the surface of the coating, may effect the gloss or color, may cause amine blush (must be removed prior to top coating)
84. Coatings may be applied by the following methods:: Roller, brush, airless spray (including plural
component), conventional spray, high volume low pressure (HVLP), air assisted airless
85. Coatings Product Data Sheets (Paint Specs) provide users with the follow- ing:: surface
preparation, storage, mixing and thinning, application procedure, DFT requirements
86. SDS contains the following:: Provides workers and emergency personnel with critical information
on composition, handling or working with the substance. Includes information such as melting point, boiling point, flash point, toxicity, health effects, first aid, reactivity, storage, disposal, protective equipment, and spill handling procedures. Provides info regarding the safety issues associated with any hazardous (or potentially hazardous) material. Provides instructions for the correct action to take in the event of a spill, explosion, fire or hazardous exposure.
87. Failure of coatings to cure may be caused by:: not adding curing agent, wrong curing agent or
incorrect amount of it. problem with material from the man- ufacturer. environmental issues (too cold, hot, or humid). wrong or contaminated thinner (solvent)
88. Some of the problems that can be caused by amine blush are:: surface tackiness or greasiness,
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99. Low-voltage (wet sponge) holiday detectors are powered by batteries with output voltages
ranging from .: 5 to 120 V DC
100. Describe Low-voltage (wet-sponge) holiday dectectors:: ground cable is attached directly to
substrate, sponge saturate with a solution of tap water/wetting agent, maximum rate of 30 cm/s ( linear ft/s) double stroke, used on coatings up to 500 uM (20 mils), may be used on concrete
101. High Voltage DC Holiday detector types include:: DC - Pulsed, DC - Con- stant Current
102. Describe High Voltage DC Holiday Detectors:: Ground connection must be made direct to metal
substrate (preferred) or indirectly when necessary (e.g., to soil for pipeline measurement). Rule of thumb: 100V/mil (4V/um). Electrode rate of 0.3 m/s (1 ft/s) in a single pass (according to NACE Standard SPO 188). Voltage output range from 800 to 60,000 V
103. The type of High Voltage Holiday dectector used for concrete is a:: High Voltage DC Constant
Current
104. What is a Standard?: An established norm or requirement that is written by industry
professionals. A formal document that establishes uniform engineering or technical criteria, methods, processes and practices
105. What percentage of NACE Standards relate to coatings?: 50%
