Q1 What kind of process is corrosion?

Ans corrosion is an electrochemical process.

Q2 What particular problems relate to the maintenance of an

effective coating system in the splash zone?

Ans (i) Growth of marine life.

(ii) Rapid change in oxygen. (Wet / Dry)
(iii) Access to working area.
(iv) Heavy salt laden atmosphere.
(v) Wave impact and erosion.
(vi) Mechanical damage.

Q3 What factors influence the rate of corrosion?

Ans (i) Variation of oxygen content on the steel surface or rapid

change in oxygen.
(ii) R.H. (above 60% is critical) or higher R.H.
(iii) Presence of impurities in the air like acid, alkalis, salts
etc. or
Impurities in atmosphere like acid, alkalis, salts etc.
(iv) Higher nobility metals in contact with the steel
( Eg. Mill scale)

Q4 What is mill scale and why is it a particular problem when

attempting to protect steel?

Ans (i) Mill scale is a thin black flaky layer of oxidized iron
formed on the steel during its manufacture.
(ii) Mill scale is more noble than steel as per the Galvanic
series.
Q5 What is the number of the Swedish Standard contained with in
B.S. 7079 and list the rust and blasting grades together with
their brief relevant titles?

Ans Swedish Standard - SIS-05-59-00.

RUST GRADE
A - Covered in mill scale with little or no rust.
B - A mixture of mill scale and rust.
C - Mill scale gone, rusted with slight surface pitting.
D - Heavily rusted and pitted.

BLASTING GRADE
Sa1 - Light blast cleaning.
Sa2 - thorough blast cleaning.
1
Sa2 /2 - Very thorough blast cleaning.
Sa3 - Blast cleaning to visually clean steel.

Q6 Name three tests for locating Hygroscopic salts and mill scale
on a blast cleaned substrate.

Ans HYGROSCOPIC SALTS

(i) For soluble Iron salts - Potassium Ferricyanide test.
(ii) For soluble Chlorides - Silver Nitrate test.
Mill scale
Copper Sulphate test

Q7 What factors influence how clean and how rough the surface
becomes after blast cleaning.

Ans Abrasive characteristics Human factors

(I) Size (I) Angle
(ii) Shape (ii) Distance
(iii) Hardness (iii) Speed
(iv) Density (IV) Time
Q8 Regarding hand and power tools cleaning state what always
concludes this process and to what standards.

Ans Hand and power tools cleaning is concluded by wire brushing.

ST-2 - Thorough hand and power tools cleaning
(Manuel).
ST-3 - Very thorough hand and power tools
Cleaning (Mechanical).
Wire brushing is carried only for B, C & D rust grades.

Q9 What three basic Ingredients make up a traditional solvent

Carrying paint.

Ans (i) Binder or Vehicle.

(ii) Pigment.
(iii) Solvent.

Q10 What are the functions of each of these three in a solvent

carrying paint?

Ans BINDER
(i) Binds the particles together and holds them in
suspension.
(ii) Gives the paint its finish.
(iii) Gives flexibility to the paint film.
(iv) Gives resistance to Water, Chemicals & Abrasion.
(v) Converts the coating to a solid dry film.
(vi) Makes the coating adhere to the surface.

PIGMENT
(i) Gives co lour to the paint.
(ii) Gives opacity to the paint.
(iii) Gives resistance to Acid, Alkali & Light.
 SOLVENT
(i) Forms the evaporation part of the drying process.
(ii) Thins the paint so it can be applied easily.
(iii) Washes out brushes and equipment.
(iv) Acts as a degreasing agent if approved.

Q11 Name five items that can be included in paint to improve its
performance or suitability for a certain use.

Ans (i) Drier or Catalyst (iv) Stabilizer

(ii) Extenders (v) Thixotropic agent
(iii) Plasticiser (vi) Anti-Skinning agent

Q12 Identify six paints by their binder names.

Ans (i) Epoxy (iv) Emulsion paint

(ii) Chlorinated rubber (v) Vinyl
(iii) Alkyd resin (vi) Acrylic (vii) Silicon

Q13 Name four binder / solvent combinations.

Ans (i) Epoxy - Acetone

(ii) Chlorinated Rubber - Xylene
(iii) Alkyd Resin - White spirit
(iv) Emulsion paint - Water.

Q14 Name six opaque pigments together with their respective

colures.

Ans (i) Zinc Phosphate - White

(ii) Zinc Chromate - Yellow
(iii) Red Lead - Red
(iv) White Lead - White
 (v) Red Iron Oxide - Red
(vi) Carbon Black - Black
(vii) Graphite - Black
(viii) Calcium Plum bate - White

Q15 Describe what a laminar pigment is.

Ans It has a particle shape like small leaves or hands upon drying of
their paint film, overlap and interwave with each other to give a
coating which is highly resistant to the passage of water.

Q16 What is the difference between a convertible and a non-

convertible coating?

Ans CONVERTIBLE coating is those, which under go a chemical

change upon drying and after wards cannot be softened or
damaged if they come into contact with their own solvent
whereas

NON-CONVERTIBLE coatings are those, which dry by

solvent evaporation only. No chemical changes take place and
after drying the paint would be softened or damaged if it came
into contact with its own solvent.

Q17 Define the term INDUCTION PERIOD.

Ans It is a length of time z-pack paint has to stand after mixing and
before application. The time allows air bubbles to escape or
chemical reaction to take place, and is stated by the paint
manufacturer.
Q18 Define a BARRIER system of coatings.

Ans Barrier is defined as a coating system of low permeability.

Q19 Define the term POT LIFE.

Ans It is the length of time following induction period or after

induction that a z-pack paint remains in an apply able condition
according to the manufacturers instruction.

Q20 Define the term TIE COAT and give an example of its use.

Ans It is a coat of paint, which can tie two normally incompatible

systems together.
Eg. Solvent Stripping or bleeding.

Q21 What is the difference between THERMOSETTING and

THERMOPLASTIC

Ans THERMOSETTINT is a convertible type of coating, which is

heat, cured and cannot be softened or damaged upon application
of heat after curing completes.
Eg. Fusion Bond Epoxy.

THERMOPLASTIC is a non-convert able type of coating,

which can be brought back to its original applicable condition
by applying heat or can be softened.
Eg. Polypropylene.
Q22 What is IMPRESSED CURRENT? What problem can arise
from its incorrect setting up?

Ans It is second line of cathodic protection to back hole to sacrificial

coating. If two greater voltage is applied hydrogen gas bubbles
form on the surface of the pipeline and bring off the sacrificial
coating. This is known as cathodes disbondment.

Q23 Name two types of paint mills and give two examples of each.

Ans (i) Direct charge mill (ii) Pre-mix mill

(a) Ball mill (a) Single roll mill
(b) Attritor mill (b) Triple roll mill
High speed dispenser Pearl, Sand or
Bead mill.

Q24 (i) What is the title of B.S 3900?

(ii) How many test sets are in B.S 3900.
(iv) How are the tests identified (name, number, letter)

Ans (i) Method of test for paints.

(ii) Eight sets (8 Sets)
(iii) Letters A to H.

Q25 What does a fineness of grind gauge measure?

Ans (i) Measures the size of the pigment particles.
(ii) Measures how finely the pigment has ground in the
milling process.
Q26 What is a FLASH POINT and in what apparatus is it
determined.

Ans It is the minimum temperature at which the vapors of liquid will

ignite if an external source of ignition is introduced. This is
determined in a closed cup of the able type.

Q27 What is viscosity and what equipment is used to measure the

viscosity of (A) a free flowing paint. (B) A thixotropic paint.

Ans It is a process of measuring a fluid resistance to flow

(A) A free flowing paint - Ford flow cup 4.
(B) A thixotropic paint - Rotation viscometer.

Q28 What is a density cup and give an example of its use.

Ans A density cup a small black cup made from aircraft alloy,
usually it holds 100cc and the lid has a hole in the top.

(i) It is used to calculate the density of paint.

(ii) It is used to check the solvent quantity added to the paint.
(iii) Used to check the correct parts of z-pack components are
mixed together.

Q29 Calculate the VS% of paint if the W.F.T. was 186m and the
D.F.T. were 93m.

Ans D.F.T. = W.F.T. x V.S.

100
93 = 186 x V.S.
100
V.S. = 93 x 100 = 50%
186
Q30 Calculate the W.F.T. of paint if the VS% was 66% and the
D.F.T. was 88m.

Ans D.F.T. = W.F.T. x V.S.

100
88 = W.F.T x 66
100
W.F.T. = 88 x 100 = 133.33m
66

Q31 Calculate the D.F.T. of paint if V.S.% was 44% and the W.F.T.
was 234m.

Ans D.F.T. = W.F.T. x V.S.

100
D.F.T. = 234 x 44 = 102.96m.
100

Q32 Calculate the density of Paint if a 5 lts. Tin weight 15kg.

Ans Density = Wt.__ = 15 x 1000

Volume 5 x 1000
= 15000 gm = 3.00 gm/cm.
5000 cm

Q33 Calculate the density of a z-pack material if part A (paint) was

1.5g/cm and part B (catalyst) was 0.5 g/cm. (Assume mix ratio
of 1:1)

Ans Average of Z-density = 1.5 + 0.5 = 2.0

= 2.0/2.0 = 1.00g/cm.
Q34 Name an example of a non-destructive D.F.T. gauge &
Destructive gauge.

Ans (i) Non-destructive gauge - Banana gauge or

Electronic gauge

(ii) Destructive gauge - P.I.G.

Paint Inspectors gauge

Q35 Name four artificial weathering devices and say what they are
designed to simulate.

Ans (i) Salt spray box - how paint behaves under

Marine conditions.
(ii) Tropic box - how paint behaves in a
High humidity environment.
(iii) Water soak test - tests for paint film
Permeability
(iv) Temperature cycling - paint film flexibility
(High /Low Temp)
(v) Cold check testing - Low Temp.contraction
Cracking.

Q36 Name two drying / curing test and state how they are operated.

Ans (i) BALLOTINI TEST:

Ballotini are tiny glass ball are dropped on to a wet painted
panel. The time in hours is given at the side of the panel and
where the Ballotini fails to stick to the painted panel drying has
occurred.

(ii) STYLUS TEST:

Similar to Ballotini 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 tack dry, hard dry and fully cured.
Q37 What does a Crypto meter measure and give two examples of a
crypto meter.

Ans Any piece of device or equipment, which measures opacity of a

paint, is called Crypto meter.
(i) Pfund Crypto meter.
(ii) Hiding power charts.

Q38 What determines the degree of gloss paint may posses?

Ans The degree of gloss a paint are as followed

(i) Amount and type of binder.
(ii) Size and fineness of the pigment particles.
(iii) Skill of applicator
(iv) Method of application.

Q39 Name three adhesion tests and describe how one if them is
carried out.

Ans Following is the three-adhesion test.

(i) Cross cut test
(ii) Cross hatch test
(iii) Dolly test

CROSS CUT TEST:

CROSS HATCH TEST:

DOLLY TEST:
(I) Clean, Degrease and Roughen Surface
(II) Stick down dolly with regular araldite
(III) Leave for 24 hrs @ 25C
(IV) Cut around dolly to isolate paint underneath
(V) Apully pull off force
(VI) Check at what P.S.I. failure occurs
Q40 State the conditions under which B.Gas allow painting to take
place.

Ans Mention below the B.Gas allows painting condition place.

(i) The air and metal temperature is at least 3C above the
dew point temperature.
(ii) The relative humidity is less than 90 %
(iii) The temperature for application for application is
within the manufactures given limit.

Q41 Name eight duties of a paint inspector.

Ans Daily duty of coating inspector.
(i) Assess condition of substrate.
(ii) Check that correct materials have been obtained for use.
(iii) Check dew point, relative humidity and steel
temperature. Daily as required.
(iv) Inspect surfaces after blast cleaning (Grade of
cleanliness & Amplitude)
(v) W.F.T. Checks.
(vi) D.F.T. Checks.
(vii) Witness all preparation and painting procedures.
(viii) Make reports as required (Daily,Weekly,Summary etc.)

Q42 List eight contractor malpractices.

Ans 1. Using unqualified personnel.

2. Carrying out further work before inspection
completed.
3. Attempting to skip a coat.
4. Preparing and painting when weather conditions are
unsuitable.
5. Using paint, which is out of date.
6. Using incorrect solvent for degreasing.
7. Not observing induction and pot life times.
8. Incorrect storage of paint.
Q43 Name three methods of applying paint and compare the
advantages and disadvantages of each in terms of quality and
cost effectiveness.

Ans There are three methods of applying paints are as followed.

(i) BRUSH:
a. Cheap to purchase.
b. Easy to maintain.
c. Slow to use.
d. Cannot apply all coating type.
e. Good for applying primer.
f. Best for strip coat application.
g. Access is poor.

(ii) ROLLER:
a. Cheaper to purchase.
b. Easy to maintain.
c. 2-3 times quicker than brush.
d. Leaves an uneven coating.
e. Exterior poles make better access.
f. Roller spray is messy.
g. Orange peel & heel marks effects are undeniable.

(iii) SPRAY:
a. Very expensive.
b. Up to 30 times quicker then brush.
c. Only method for applying high volume and high
thickness
d. High degree of safety required
e. P P E is required.
f. Marking out is required.
Q44 What does B.S 2015 Glossary of paint terms refer to and give
three examples.

Ans Refers to faults, which occur with paint.

(i) Bleeding.
(ii) Cussing.
(iii) Chalking.
(iv) Pinhole.

Q45 What is B.S. 4800 and how is it used in the construction

industry.

Ans It is a range of 100 Standardized colures for using in industry

taken from 237 colures from B.S 5252.
USES: a. Identifying colures on new construction.
b. Identifying colours on existing paint on
maintenance works.
c. All manufacturers can make same colour.

Q46 How do B.Gas define the following?

a. Long term protection. b. Medium term protection.
c. Short term protection. d. New galvanizing.
e. Weathered galvanizing.

Ans a. Typically 10 years.

b. Typically 5 years.
c. Typically 2-3 years.
d. Less than 3-months, bright and shiney.
e. More than 3-months dull lacking in sheen & rough.

Q47 What is the procedure for removing soil and grease from a
surface before preparation commence?

Ans All contamination shall be removed by means of an approved

solvent Eg. Xylene.
Q48 What is the procedure for removing oil and grease from a
surface if found after preparation.

Ans Contaminated area must be swabbed with an approved solvent,

followed by a 2% detergent wash, further followed by a
washing with clean water, thorough drying and re-blasting. Care
must be taken that disposable lint free swab must be used once
only.

Q49 What is the procedure for removing algae and mould growth
from pipe work.

Ans Algae and mould growth shall be treated with a biocidal 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.

Q50 Under what conditions must paint be stored.

Ans In a cool, dry, lockable, well ventilated building away from any
sources of heat and taking into account current legislation and
manufacturers storage conditions or 5C below or less than flash
point.

Q51 (a) What is T-wash (b) What is it used for

(c) What colour is it (d) How do we check for a correct
Reaction when using it.

Ans (a) An etch primer

(b) Providing a key on new galvanizing
Blue
(d) It turns black upon drying.
Q52 What two coats of paint are applied at works?

Ans S.P.A-1 (i) High solids solvent based epoxy primer to

75m minimum D.F.T.

(ii) Epoxy strokes M.I.O. to min 75m D.F.T.

Q53 What distance must be left at areas to be welded when painting.

Ans 75 mm

Q54 How much must new paint overlap old on repairs.

Ans 100mm

Q55 What is maximum allowed time for priming to take place

following preparation and by what method is primer applied.

Ans Max 4 hrs except for S.P.A-4 (when it must be immediate)

Primer applied by either brush or spray as appropriate.

Q56 What do B.Gas class as a hot duty service.

Ans Metal Surface that will reach a temperature in excess 99C

when in use.

Q57 What must all pneumatically and electrically operated power

tool equipment be?

Ans Earthed or grounded against static shock or fire

Q58 What type of sheeting may and may not be used for protection
against spillage and spotting.

Ans Non flammable or fire proof sheeting must be used tarpaulins

must not be used.

Q59 What must not be used to clean out paint kettles or to dispose of
rubbish?

Ans Fire or Flames should not be used.

Q60 Give the rules for the mixing of paint regarding sizes

Ans Upto 5lts in size may be mixed by hand.

Above 5lts must be mechanically mixed (Stirrers)

Q61 What are Osmotic Blisters and what can cause them?

Ans Osmotic Blisters contains liquid, gas, and crystal and can be
caused by solvent entrapment; water entrapment or Hygroscopic
salts left on a blast-cleaned surface.

Q62 Some metals are difficult to prepare name the three and describe
how you might prepare them.

Ans Mention below the three names.

(a) New galvanizing
(b) Weather galvanizing.
(c) Aluminum.
Preparation by sweep blast or stiff bristle brushing or hand
abrades.
Q63 Whore a pipeline leaves the ground what problems would you
find and how might you treat this.

Ans Problems:
(i) Rapid change in oxygen.
(ii) Mechanical damages.
(iii) Soil is damp, dark and chemically active.

Cure:
(i) Extra thickness of coating.
(ii) Wrapping with tape.
(iii) Applying of polyethylene heat shrink sleeves.

Q64 What additional information would you record when

maintenance painting a pipeline without removing the previous
coats.

Ans (a) Whether existing system contains any toxic coatings.

(b) Are the existing coatings compatible to the new
system in terms of adhesion, solvent bleeding or
stripping?
Intent of surface contamination, paint breakdown or
corrosion.

Q65 Name five paints and states their drying or curing method.

Ans F.B.E. - Heat cured

Z-Pack epoxy - Solvent evaporation followed by
Chemical curing
Chlorinated rubber - Solvent evaporation only.
Alkyd resin - Solvent evaporation followed by
Oxidation.
Emulsion paint - Coalesance.
Q66 Name a black pigment in common use apart from coal tar.

Ans Carbon black.

Q67 What is a Holiday and Pinhole detector, what does it detect, and
how does it work.

Ans Holiday is a missed or poorly coated area.

Pinhole is a minute defect caused by escaping air bubbles.

It works as: (i) Earth substrate to be tested.

(ii) Pass metal brush (holidays) or wet
Sponge detector (pinhole over the surface
At a pre-set voltage, typically 5-Volts per
m) and at controlled speed.
(iii) When a defect is found an audio or visual
Warring is given
(iv) These area must be marked, repaired and
Re-tested.

Q68 If you worked on a contract where frequent stoppage occurred

for poor weather, what additional information would you
record?

Ans (a) Record time of stopping & starting.

(b) Progress of work to stoppage time.
(c) Record of wasted material (abrasive or mixed paint)
(d) Record of damage to wet films or newly blasted
area.
Q69 If a pipe line was in direct contact with acoustic cladding, what
paint system might be applied if we wished to maintain it every
three years, or not at all.

Ans For 3-years maintenance rust inhibitive prime required for not
maintained, full system as specified minus finish coat.

Q70 What is important about selecting a paint system suitable for a

certain environment?

Ans Which is suitable for environment conditions.

Q71 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.

Ans Paints shall be supplied in suitable containers, which shall be

Indelibly and legibly marked with the following information
As follows
(i) Manufacturers name
(ii) Description of product.
(iii) The Transco identification code PA9
(iv) Expiry date
(v) The co lour code (where specified by Transco)
(vi) Any special storage requirements.
(vii) Application grade (brush or spray)
(viii) Batch identification code
(ix) Identification of parts and mixing ratio by volume for
Multi pack material only.
(x) Any markings required by current legislation.
Q72 What is UN usual about the preparation of surfaces, which are
dealt with under SPA4

Ans Blast cleaning is followed by clean water washing and drying

Prior to the application.

Q73 State the principles of being able to use a banana gauge for
taking D.F.T. readings.

Ans Ferrous substrate and non-ferrous coating.

Q74 Give one advantage of using testex tape and plastic disposable
W.F.T. combs.

Ans Both can be kept as permanent record.

Q75 Describe what you know of HASWA and COSHH.

Ans HASWA - Health and safety work act-1974 this act deals
With the safety working at site for employee
Provided by employer.

COSHH - Control of substances hazardous to health

1988 this act deals with the use, handling,
Storage, packaging, labeling and transport of
Many hazardous materials like solvents, sand,
Dust etc.