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1、ABS Technology ESDCoating Knowledge CenterEnough IMO PSPC theory! Some Basic Monitoring Practice for the ABS Class Surveyor1ABS 工程技术支持部涂漆智囊中心足够IMO PSPC理论! 一些基本的为ABS船级现场工程师实用的监查经验2Documentary before kick offCheck that the so called Tri-Partite Agreement has been reviewed by ABS EngineeringCheck that

2、the Shop Primer and Coating System to be applied are Class Type ApprovedCheck that the mandatory CTF File is preparedCheck certifications of coating inspectors and training records of assistant inspectorsCollect copies of the coating Data-Sheet and MSDS ChartsCheck that the Daily Record Forms to be

3、used are in understandable language and complete.Study the applicable P/I and prepare Check-sheet 3核查文件检定所谓的三方技术协议是否被ABS工程部审核检定车间底漆及其主涂层油漆是否被船级社认证检定造船厂是否准备了必备的CTF文档资料检定涂层检查员是否具备必要的证书以及助理检查员是否具有培训记录搜集相关油漆的技术资料及产品安全资料 (MSDS)检定涂层检查员使用的记录表格及使用的语言船级现场工程师及工程部阅读相关的 P/I 及 核查表格 4Attending Pre-job MeetingIt s

4、hould be clear to the yard Q/C and Owners that, as required by the IMO PSPC, Class is monitoring only.It is responsibility of the Certified Coating Inspector to perform inspections and to produce records as required by the IMO PSPC. It is responsibility of the yard to perform pre-treatments and coat

5、ing applications in compliance with the IMO PSPC. It is responsibility of the yard to up-date the CTF during shipbuilding and to present the completed CTF to Class once the job is finished.It is responsibility of the coating producer to provide approved coating systems in compliance with IMO PSPC re

6、quirements5参加预备工作会议ABS船级现场工程师须清楚向船厂质量管理部及船东表明: 根基IMO PSPC的要求, ABS船级社只负责监查PSPC的实施合格涂层检查员负责执行涂层检查并负责记录数据-根基IMO PSPC的要求船厂负责实施钢板预处理及涂漆. 并满足 IMO PSPC要求 船厂负责准备及记录造船过程的CTF并承交最后完成的CTF给船级社审核油漆商负责提供船级社认证过涂层系统.涂层系统须满足 IMO PSPC所有的要求 6Attending Pre-job Meeting (continued)Verify storage condition of coating cans

7、and grit bagsVerify mutual understanding of areas to be coated Verify that Tri-partite Agreement is knownVerify that PSPC Inspection procedures are knownVerify that PSPC application procedures are known including the Max dft to be applied. Verify supply and operation of heaters / ventilators / prote

8、ction equipment according the tri-partite agreement. Request that any non-compliance found by the Coating Inspector will be notified by written Statement to the builders with copy to Class. (Class must be able to monitor rectifications of non compliances before the job is continued, through field an

9、d documentation review. IACS UI SC223)7参加预备工作会议(续)验证涂漆罐状况及喷沙袋验证大家认可的涂漆物件及场所验证及理解三方技术协议验证及理解IMO PSPC涂层检查程序验证及理解IMO PSPC涂漆程序, 包括要求的最大漆膜 (DFT) 根基三方技术协议, 验证加热,通风及保护设备及其使用如涂层检查员发现任何不符合IMO PSPC规定地方, 须书面通报船厂及船级社 (根基IACS UI SC223的要求, 船级社必须能通过现场监查及文件审核,在继续下一步工序之前, 所有不符合IMO PSPC规定地方须得到矫 )8Lets go to practice

10、请看实用的经验9This is Practice! 这是实际遇到的问题10Stripe Coatings, Brush or Roller?涮漆次数 使用涮子或滚筒?11Yes, the weld has been ground是的, 焊接处须打磨12Chaos on deck杂乱的场地opened manhole 敞开的进口13The result of such chaos!杂乱的工作场地所造成直接后果14Firstly after some suggestions!一些建议15How to Produce dry-sprayNotice the distance and angle be

11、tween spray gun and steel structure.干燥喷漆是怎样产生的注意喷嘴和物件之间的距离及角度16Some Touch ups only ?一些补漆 ?17Coating Surfaces 喷漆涂层表面should beshould not be准确的喷漆涂层错误的喷漆涂层18Lets start at the beginningThe task of Class (on behalf of Flag State Administration)This is defined by the PSPC Section 7 of the PSPC7.1 Check Typ

12、e Approval and Data-sheets7.2 Verify identifications on representative containers7.3 Check qualifications of certified inspectors7.4 Check compliance of inspectors reports7.5 Again, MONITOR implementation of inspection requirements 19让我们从这里开始船级社的责任 (代表旗社) IMO PSPC章节7定义了船级社的责任:7.1 验证涂漆系统认证书及其技术数据资料7.

13、2 检验涂料罐上的数据及标识是否与系统认证书吻合7.3 验证涂层检查员是否合格7.4 验证涂层检查员报告,记录是否符合规定7.5 再次强调,船级社监查IMO PSPC实施是否符合要求 20About MONITORINGAlways remember that Class Surveyors are not PSPC Certified Coating Inspectors Never attempt to be one!The Class Surveyor is just monitoring that the PSPC Inspection Requirements are properl

14、y implemented. Monitoring means checking, on a sampling basis, that the inspectors are using the correct equipment, techniques and reporting methods as described in the inspection procedures.21关于监查切记, 船级现场工程师不是PSPC的认证涂层检查员 千万不要把自己当做涂层检查员!船级现场工程师只是监查PSPC的检查要求是否恰当地实施监查意谓着检查,抽查涂层检查员是否使用正确的仪器,技术及报告方式, 这

15、些都应在检查程序协定中呈述22The Starting Point Shop PrimerPrimary Surface Preparations起始点是从车间底漆开始23Surveyor Monitoring of C.I. activitiesIn the automated shop primer plant, Coating Inspector activities includes the following: applied shop primer Class Type Approved and compatible?Compliance with the PSPC through

16、 a Quality Control System Management of blasting gritGrit quality including salt measurement and dust quantityCleanliness and roughness profile before shop primer is applied Closed film without holidays/pinholes and required dft. Remember that the DFT CANNOT be measured directly on the abrasive blas

17、ted steel surface, simply because the surface roughness is often higher than the thickness of the shop primer! Primary Surface Preparations24现场工程师监查涂层检查员的工作在自动化的车间底漆工厂,涂层检查员的工作包括如下: 检查车间底漆的认证书及其与涂层相容性?QC 系统应符合PSPC要求 喷沙粒子的检查及管理喷沙粒子质量, 包括盐测试及粉尘车间底漆喷涂前清洁度及表面粗糙度 车间底漆喷涂后应无漏漆及孔洞, 并满足油漆商要求的DFT记住, DFT不能在喷沙过

18、的钢板表面进行直接测量. 这主要因为钢板表面粗糙度大于车间底漆厚度! Primary Surface Preparations25Rule of thumb for shop primer DFT If required, during application the shop primer DFT can be established on smooth non-blasted Test Panels, shop primed together with the plates / profiles. Since a smooth surface per square meter repres

19、ents a smaller surface area than an abrasive blasted rough surface, the same amount of primer applied to a smooth surface will provide a higher DFTAs a rule of thumb the following approximate relations exist; Surface roughness:Smooth Rz 40 Rz 75 Dry Film Thickness25 20 15 Dry Film Thickness20 15 12

20、Primary Surface Preparations26车间底漆厚度的经验规律车间底漆厚度可通过测量同时喷涂在喷沙过的钢板表面和没喷沙过的样品表面来进行估计厚度 车间底漆厚度的经验规律有如下关系:钢板表面粗糙度: 光滑表面Rz 40微米Rz 75微米DFT 25 微米20微米15 微米DFT 20微米15微米12 微米Primary Surface Preparations27 Block Building (摸块建造)Secondary Surface Preparations28Monitoring Block Building StageAfter Steel Preparation

21、, to be checked by Yards Q/C and the coating inspectorWelds ground and weld spatters removedTemporary connections removed Oil / Grease and visible dust removedIf not compatible with coatings, markings to be removedDamaged shop primers and welds Sa2.5 blasted Non-approved shop primers Sa2 blasted for

22、 at least 70% Installation of adequate ventilation/heaters and lightSalt level to be checked Blasting profile to be checked Temperature, humidity and dew point checked Joint acceptance of steel preparation by Q/C and InspectorSecondary Surface Preparations29监查摸块建造钢板构件切割,焊接后, 造船厂QC部及涂层检查员应做如下检查:焊接处须打

23、磨及焊接溅物应去除临时焊的搭架应去除油污及可见灰尘应清除如涂层与车间底漆无相容性,应做上车间底漆清除标记?损坏部分的车间底漆及焊接处须喷沙 Sa2.5 非认证过的车间底漆须用喷沙 Sa2去除至至少 70% 按装恰当的加热,通风及保护设备表面盐量检查喷沙钢板表面粗糙度检查钢板表面温度,空气湿度及凝结温度检查 造船厂QC部及涂层检查员应共同签署以上检查结果Secondary Surface Preparations30How about the Blasting Equipment?喷沙设备检查Abrasive grit type/size/cleanliness and air pressure

24、/cleanliness affect final surface roughness and cleaning:Grit can be excellent, but if blasting equipment is worn or improperly used, the result can still be poor. Inspector should check at-random the air pressure and quality of air delivered by the compressors. Pressure shall be enough for the full

25、 amount of equipment used simultaneously. The air has to be clean and free from oil and water. Hoses should be clean and without leaks. Field Monitoring This can be checked by the inspector by doing a Blotter Test (hold a clean white rag for some time in way of a draining point) Do not forget that t

26、he hose should also be clean at start (!)Check also the wear on the nozzles. Worn nozzles consume more air and have poor influence on the final blasting result. If any doubts, this can be checked by the paint inspector using a conical nozzle calibrator. Normally 2 points max wear are allowed.31喷沙设备检

27、查喷沙粒号/尺寸/清洁度及压缩气压力/清洁度影响最后表面粗糙度及清洁:喷沙粒也许很好, 但如喷沙设备老化或不当使用,最后结果还是会很坏 涂层检查员应抽检压缩气压力及压缩气清洁度. 压缩气压力应enough for the full amount of equipment used simultaneously. The air has to be clean and free from oil and water. Hoses should be clean and without leaks. Field Monitoring Blotter Test Check also the wear

28、 on the nozzles. Worn nozzles consume more air and have poor influence on the final blasting result. If any doubts, this can be checked by the paint inspector using a conical nozzle calibrator. Normally 2 points max wear are allowed.32Salt level of Grit MaterialAsk the inspector for a Slurry TestCol

29、lect a minimum of five random samples, mix well, and take 50 cc from the mix. Pour this average grit sample in a clean container and add 100 ml de-ionized water. Shake for 5 minutes and let it settle for one hourDecant the water into a clean glass and measure the conductivity. Maximum conductivity i

30、s provided by the paint makers Data Sheet. Normally this will be in the range between 25 40 mS/m33Check on Roughness ProfileAccording the IMO PSPC, after grit blasting, the surface should meet Grade Sa 2.5 with roughness between 30 -75 MicronsRoughness can be tested by comparator plate, replica tape

31、 or digital gauges RUGO Test No 3 Comparator plate can be an example for field roughness test by feeling both surfaces with a finger nail tip and not just visually. 34检查钢板表面粗糙度根据IMO PSPC, 喷沙后,钢板表面应满足要求 Sa 2.5 及 30 -75 Microns表面粗糙度表面粗糙度可用参照板, 复制胶带或电子测量器 RUGO测试号3参照板是常见的例子 用指尖触摸而非用眼35Some GO NO GO Fiel

32、d TestsPresence of oil grease on the steel surfaceNormally visible with dark spots. If any doubts, simply draw a line with ordinary chalk. Where the line is interrupted oil/grease contamination can be expected. Oil/grease spots can also be effectively checked by proved ultraviolet light. Suspected a

33、rea Dew PointIf condensation is suspected due to low dew point. Simply attach a dry cigarette paper to the steel surface. If it falls down, the dew point can be expected to be O.K. If it sticks to the surface, condensation can be expected. 36一些实用的现场测试检查表面油污通常肉眼可看得见深色斑点. 如不能肯定, 用粉笔画一条线.粉笔线断处即是油污处.油污点

34、也可用紫外灯检测. Suspected area凝结温度如怀疑由于低凝结温度引起表面凝结, 可用干烟纸贴在钢表面.如贴不上表示表面没凝结, 相反则有凝结. 37Power Tool RequirementsWhat should be checked by coating inspectors? Lack of oil and water separators between compressors and equipment may result in oil drops on the steel surfaceBristles of wire brushes should be sharp

35、 and unbend to avoid polishing of the surfaceGrinding disks and sanding paper should be of suitable grain size and not clogged with paint or residues. Polished mirror surfaces are never, repeat NEVER(!) acceptable as it allows no adhesion of the coating and will delaminate in early stage resulting i

36、n corrosion. 38电磨工具的要求涂层检查员应检查:压缩器和工具间如无油与水分离器, 会导致钢表面油污铁丝打磨器的铁丝应尖利而非弯曲. 否则会导致钢表面抛光而无表面粗糙度产(会导致涂层剥落)打磨盘及沙纸应具有一定的粗糙度而避免沾上油漆或残余物. 39Excessive power tooling may result in polishing. As a result the surface is extreme smooth without any profile which results in a lack of adhesion of next coating and con

37、sequently in poor adherence. 40Something about testing of adhesion in the fieldTesting of adhesion in the field is normally done by so called X-Cut (A Method) or Cross-Cut (B Method) Tape Tests. (ASTM Tests D3359 ISO 2409 by Qualicheck Kit)Remember next thingsCross-Cut not to be applied 125 Microns

38、Dft !The cutting tool must be sharp, coating fully curedThe tape must be of certified type (ASTM D 3330)X-cut test cuts have to penetrate to the steel, approx 40 mm long and the angle between 30-45 Good contact of the tape is indicated by even color Tape must be removed rapidly within 90 seconds Thi

39、s is an destructive test and should be avoided if not required!41The X-cut test 5A 4A 3A 2A 1A 0A Straight Crumbled Lifted Lifted Removed Removed Sharp line line over 2X 1.6 mm over 2X 3.2 mm between the X-cut beyond the X-cutIf above test is done, exact location, date and time should be recorded an

40、d pictures should be taken. Destroyed area to be repaired!42Grinding of Weld BeadsAbove welds must be rectified. 43NOT Acceptable Sharp Edges !44Coating Materials and Data-Sheet LimitsRecord spot checked batch numbers for monitoring purpose Special Data Sheet recommendations/instructions to be check

41、edMixing and thinning instructions. Never mix with other brandsTemperature limits Specially when heated by sun or when freezingRecommended Dft in accordance with Data Sheet (Minimum 320 m)Recommended nozzle size and spray pressure. 45Some Spray Nozzle KnowledgeThe Data Sheet provide recommended nozz

42、le sizes in Inches and Degrees for spray angle. Depending the practical situation this may be changed. Commonly used Brand Codes:SizeAngleAtlasVilbissWiwaCopcoBinksGracoLincoln_0.015”401540JAC299-1540163.4150.015”65 1565JAC39163.615 68628-70.015”80 1580JAC40163.7150.018”65 1865JAC31163.61968628-60.0

43、18”801880JAC419-1880163.81968628-5 0.021”802180JAC429-2180162.7210.026”402640JAC43163.4250.026”952695JAC440.036”403640JAC36 163.435Typical nozzle sizes are ranging between 0.017 and 0.025 Inch Typical Spray Pressures ranging between 150 Bar for primers up to 250 Bar for epoxy coatingsCoating Inspect

44、or to confirm recommended nozzle size and spray pressure asprovided by the Data Sheet and specified by the manufacturer. 46About Spray NozzlesCoatings are designed to be sprayed at certain pressure with specified types/sizes of nozzles. In case different pressure and/or different nozzle sizes are ap

45、plied, this may result in a coating character completely different from the one which has been Class Type Approved! Never allow the use of nozzles and/or spray pressures not specified by the Data Sheet unless accepted by the Paint Inspector and recorded in the CTF.Good to knowChanging from size 0.02

46、6” nozzle to size 0.035” and upgrading the pressure from 100 to 150 Bar may result in a raise in production from some 8000 m2/day to some 20,000 m2 for 1 sprayer! This may be attractive to speed up production but also may be dangerous. 47At the Mixing Station48Cans - liquid coatings/thinners/hardene

47、rsCoating Inspector checks:First of all, collect the Data-sheet and check conformance of Brand & Type with the TCF. Same for the hardeners and thinners.Monitor if notes have been taken of the batch numbers and if wet samples have been saved and recorded in the CTF. Confirm the procedures at the mixi

48、ng station andThat no components of other Brands are mixed That no excessive thinner quantities are mixed Monitor that proper mixing equipment is usedMonitor that coating cans are not overheated by sun radiation and properly protected against infiltration of dirt, rainwater, grit, dust, etc49Cans &

49、Cans and Cans again50Shelf Life, Interval, Induction, and CuringPot Life is the time period a coating can be used after mixingShelf life is the same as for many food products. After this date the coating should not be applied anymore. (Unless agreed in writing by the coating manufacturer and stated

50、in the CTF)Induction time gives the time period between mixing and application. This is in fact a period to allow pre-reaction of the components.Interval. This is the minimum and maximum allowable period that shall be applied between two successive coatings. Remember that this time is strongly depen

51、dent of the temperature. Overshoot of interval will result in poor adherence of next coating. Curing time. This is the time that a coating can be expected to be fully cured.Remember Rub-Test During the whole curing period the ventilators should be kept in operation. If required also the heaters shou

52、ld be kept running. Any doubts about curing, this can be checked by the coating inspector by a so called rub-test using thinner. If required by severe winter conditions, insulation of the steel by insulation blankets may be required. 51Also really Important!Summer & Winter Type Coatings and their ha

53、rdeners/thinners shall never be mixed. Normal (summer) epoxies shall never be applied below 10 degrees C !Winter Type epoxies should not be applied at prolonged periods above some 15 degrees C unless otherwise recommended. Review that summer/winter type shifting has been recorded in the CTF52During

54、Spray ApplicationCoating Inspector to verify:Correct spraying technique with correct nozzle size and pump ratio. The temperature of the coating (cans). Remember; overheating due to open sun storage may cause Dry Spray, too low temperatures may result in high viscosity which may require extra thinnin

55、g. Monitor the application of thinners at the mixing station. This should be prevented as much as possible and NEVER exceed the percentage recommended by the coating producer. 53Smooth and Fully Closed Coating Surface54High Production Spraying55Over Spray / Dry spray56Results of Dry Spray RemovalDry

56、 spray removed by sand disk often results in local exposure of bare steel. Repairs consume time and efforts and therefore Dry Spray should be prevented.57GOOD TO KNOWSteel temperatures should preferably be checked at multiple locations. (Shadow / Sun / High / Low Locations)Too low temperatures preve

57、nt proper curing. Curing under humid conditions and/or cool temperature may result in so called amine blush which causes poor adhesion of the next coating. Too high temperatures may result in Popping and internal retaining of solvents which may cause blistering. Amine Blush can be recognized by a fa

58、tty yellowish coating surface. Such surface causes poor adhesion of the next coating which results in delaminating. In case Amine Blush is suspected the coating inspector can be asked to perform a so called Amine Blush Test. Monitor temperature and humidity to avoid amine blush. Popping is caused by

59、 excessive heating of the wet coating on hot steel structures. The heating causes a closed skin on the coating which prevents the escape from solvents in the coating. Consequently these solvents forces an escape by breaking the film resulting in a permanent hole in the coating which allows entrance

60、of water and oxygen and subsequent a growing under creep corrosion. 58Important - Stripe CoatingsStripe coatings should be applied as prescribed by the IACS UI SC223. As a coherent film showing good film formation and no visible defects. Rollers may be used for scallops and rat holes but not for edg