Level 1 Chapter 1.1 Introduction

Level 1

Chapter 1.1 Introduction

1.1 Introduction Page 1

Coating Inspector Program Level 1

© NACE International, 2003 January 2007

Introduction Hello! Welcome to the NACE International Coating Inspector Program, Level 1. By the end of today’s session we will have accomplished several objectives.

Objectives • Overview of certification program

We will present the NACE International Coating Inspector Program mission statement which will give you an idea of our overall objectives and what you can expect from this course.

• Overview of this week

We will review the outline of this week’s activities. • Introductions

We will ask each of you to introduce yourself and tell us about your job functions and your hobbies.

• Form teams

NACE believes the coating inspector’s job is part of a team effort with others involved in the coating project. We will form teams reflecting a cross-section of the industries represented here today, and you will work in teams throughout the course.

• Discuss coating inspector’s job

The inspector’s specific job responsibilities may vary from job to job. We will identify the basic (general) duties of an inspector.




• Overview of corrosion

We will discuss electrochemical, or galvanic, corrosion and the ways that protective coatings can be used to control corrosion.

• Identify and demonstrate environmental test

instruments

Ambient conditions affect coating jobs in a variety of ways. We will introduce and demonstrate instruments used to measure ambient conditions.

• Introduce protective coatings and curing

mechanisms

In this review, we will define common coating terms, discuss coating components and curing mechanisms, describe the measurement of wet- and dry-film thickness, and define the inspector’s tasks. We will defer a discussion of generic types of coatings and failure modes to Level 2, where we will have time to study these topics in more detail.

Let’s get started with an overview of the Coating Inspector Training and Certification Program, which we will call CIP—the Coating Inspector Program.

Coating Inspector Program The CIP is designed to accommodate the inexperienced candidate. No prior knowledge or experience is required to commence either of the two levels. A minimum of two year’s work experience in coatings, whether gained prior to, during, or after attendance at the training sessions, is required before any candidate can register for the Peer Review examinations. Upon successful completion of CIP Level 1, CIP Level 2 (which must be taken in sequence) and the Peer Review, the participant will be a NACE-Certified Coating Inspector—Level 3.




Look in your student book at the NACE International CIP Mission Statements which outline in some detail what this program is all about and what you should expect to get out of the two levels.

CIP Level 1—Mission Statement

After attending CIP Level 1 participants enrolled in the NACE Coating Inspector Program (CIP) recognize the role of the independent coating inspector, and appreciate the need for quality control on coating application projects. They are able to perform the basic measurements needed to maintain quality control. Upon successful completion of CIP Level 1, the inspector should be able to:

• Undertake simple coating inspection work on structural steel, on site, under direct supervision of a qualified (Level 3) inspector

• Read and understand a coating specification for surface preparation and coatings application

• Use inspection equipment for basic quality control, including but not limited to:

− Sling psychrometer and weather tables (psychrometric charts)

− Wet-film thickness (WFT) gauge

− Hypodermic needle pressure gauge

− Magnetic pull-off DFT (dry-film thickness) gauges

− Electromagnetic DFT gauges

− Low-voltage (wet-sponge) holiday detector

− High-voltage DC holiday detector




• Understand and use surface preparation standards (NACE, SSPC, and ISO) to recognize specified surface cleanliness

• Recognize the inspector’s job as part of a team effort

• Recognize the importance of pre-job meetings

• Recognize the need to determine the inspector responsibilities and authority

• Recognize the value of record keeping, and learn what information to record and how to fill out inspection reports

Upon successful completion of CIP Level 1, the inspector attains recognition as NACE Coating Inspector Level 1—Certified. [Note that recognition at the same level can be achieved by study of the CIP CD-ROM course (basic level) and successful completion of the short exam course that follows.]

CIP Level 2—Mission Statement

On completion of CIP Level 2, inspectors should be able to perform all those tasks listed for CIP Level 1 and:

• Undertake coating inspection work in a fixed coatings facility (shop)

• Use destructive coating inspection equipment, including

− paint inspection gauge (Tooke gauge)

− adhesion testers

− impressor hardness tester

− pencil hardness tester




• Use eddy current electronic gauges for DFT measurements on nonferrous surfaces

• Test for soluble chemical salt contamination (including ferrous and chloride ions)

• Recognize coating techniques used in specialized circumstances, including pipeline coatings, sheet linings, brick and tile linings, etc.

• Recognize the personality types present in most work environments and some techniques that can be used to reduce friction and improve working relationships

• Recognize the techniques and some of the problems associated with coating concrete

• Recognize some specialized coating techniques, including:

− spray metallizing

− hot-dip galvanizing

− automated coatings application, including dip, roller, flood, and coil coating

• Understand the role of product technical data sheets and MSDS (material safety data sheets) in communication of coatings information

• Understand various generic types of coatings, including fireproofing, antifoulings, high-heat coatings, and temporary protectives

• Recognize common coating failure modes

• Recognize some laboratory testing methods used to establish coating performance criteria as well as evaluate coating failures

• Recognize the role of cathodic protection in corrosion prevention, particularly when used with coatings.




Upon successful completion of CIP Level 2, the inspector attains recognition as NACE Coating Inspector Level 2—Certified, having completed stage 2 of NACE Coating Inspector Training.

Peer Review—Mission Statement

Inspectors must have a minimum of two year’s work experience in the coating industry and successfully complete CIP Levels 1 and 2 and the Peer Review examination to attain recognition as a NACE-Certified Coating Inspector—Level 3. Level 3 Coating Inspectors have proved their technical knowledge and ability to communicate regarding practical issues that may arise on site. They are capable of supervising coating inspection technicians. Peer Review Examinations are conducted by contemporaries of the coating inspection industry and experts in their field of work.

Level 1—Objectives The CIP overall is an extensive training program, and Level 1 is the most intensive of the two courses. Level 1 is designed to accommodate the inexperienced candidate. The CIP recognizes that those of you who have prior experience may well exceed some of the stated capability and intent of this course. However, both the inexperienced candidate and competent basic inspector will benefit from the structured training available in this course. On successful completion of CIP Level 1, participants have demonstrated the ability to undertake simple coating inspection work under the supervision of a qualified (Level 3) inspector.




NACE Policy—Use of Logo, Certification Number, and Title NACE has a firm policy regarding the use of its logo and certification numbers and titles. The certification number and category title may be used only by individuals who are NACE Coating Inspector Level 1—Certified, NACE Coating Inspector Level 2—Certified, and NACE-Certified Coating Inspector—Level 3 and may not be used by any other persons.

All active CIP card holders are permitted to use the term “NACE Coating Inspector Level 1—Certified,” “NACE Coating Inspector Level 2—Certified,” or “NACE-Certified Coating Inspector—Level 3” (whichever level of certification attained), and their certification number on business cards. This example illustrates how this information can be used by an individual who is NACE Coating Inspector Level 1—Certified.

John Smith NACE Coating Inspector Level 1—Certified

Cert. No. 9650 ACE Inspections, Inc., Knoxville, TN

This example illustrates how this information can be used by a NACE-Certified Coating Inspector—Level 3.

John Smith NACE-Certified Coating Inspector—Level 3

Cert. No. 9650 ACE Inspections, Inc., Knoxville, TN

Individuals who are NACE Coating Inspector Level 1—Certified, NACE Coating Inspector Level 2—Certified, or NACE-Certified Coating Inspector—Level 3, who are members in good standing of NACE International may display the NACE Logo for the purpose of identifying the individual as having achieved NACE Certification.




Update and Renewal Program Update or renewal of NACE CIP certification must be completed every three years. The Update Program applies to individuals who have not passed Peer Review. The update process can be completed by one of two methods:

• Attendance at the next Coating Inspector Program course or Peer Review

• Completing a home study program

If you take another Coating Inspector Program within a three-year period, the date of your next required update will be three years from the date you completed the most recent course. The Renewal Program applies to Level 3 inspectors. The renewal process can be completed by one of three methods, depending on the number of work experience points accumulated in the three years since passing Peer Review, or last renewal:

• 73+ points requires only work experience

• 37 to 72 points requires work documentation and completion of home study program

• 36 or fewer points requires work experience documentation and class attendance with successful completion of CIP Level 2 at a regularly scheduled offering.

Work experience documentation forms and instructions for completing the forms are provided at the back of this manual. Notification of the update or renewal process will be mailed 90 days prior to the expiration date of recognition to the address on file at NACE. The notification packets supply all the information and forms needed to begin the update or renewal process. It is important that inspectors keep addresses current with NACE at all times.




Level 1—Overview For those inspectors wishing to become NACE-Certified Coating Inspector—Level 3, this training course is the first of two that must be attended. We will review the program for this training course. Also, in a few minutes, we will form teams. Many of our activities are done in small groups, so we are going to divide into teams. You will stay with your team all week. From time to time, there will be team presentations during which each team will select someone from their group to present the results of a team project. We want each of you to make at least one presentation to the class.

Lecture Sessions

Throughout this week we will present lecture sessions covering many topics, including:

• Coating specification

• Coatings and curing mechanisms

• Documentation (records and reports)

• Pre-job conference

• Conflict and decision making

• Ethics for coating inspectors

• Surface preparation

• Conventional air spray and airless spray equipment and techniques

• Test equipment

• Coatings technology




Hands-On Practical Labs

We will have several hands-on practical labs where you will have a chance to get the feel of the different tools and techniques of the coating trades and develop an appreciation for what it takes to do the job right. Some of the equipment you will use on your own practice piece includes:

• Hand and power tools

Used on small jobs and maintenance projects, and in areas where abrasive blasting is not permitted or is not feasible.

• Abrasive blasting

Air is used to propel abrasives to the surface to provide optimal surface cleanliness and roughness.

• Conventional air spray

Air is used to atomize coating. This method can produce a smooth surface and a fine finish.

• Airless spray

Coating under high fluid pressure is atomized without air. Production rates with airless spray are much higher than with conventional spray

Through all this, you will hear the instructors asking a question over and over:

What does this mean to the coating inspector? We ask this because we want to relate all technical information to the inspector’s job. We will be working with the basic tools and techniques of coating inspection, including:

• Surface preparation inspection

• Use of replica tape

• Use of written surface cleanliness standards, pictorial standards, and visual comparators




• Sieve test for abrasives

• Ultraviolet (black) light

• Measurement of wet- and dry-film thickness

You will be required to keep good records of all the tests you perform.

Examinations

At the end of the week, there will be two final examinations: one is written; the other is a hands-on practical examination on selected test instruments. You must pass both exams and receive a minimum of 70% on your Log Book to proceed to the next course. The written exam is closed book and consists of multiple-choice and true false questions. It will last 2.5 hours. The practical exam covers the tools and techniques for inspection. You will be required to demonstrate how well you know how to perform the coating inspection tests we will be covering this week. You will be assigned tasks and required to record your results. You will be graded on the accuracy of those recorded results. To help prepare for the practical exam, we will have lectures, practical labs, and practice sessions using the basic inspection tools and techniques listed in Level 1. During the week, you will take short written quizzes, all closed book, to help you prepare for the final written exam. You must pass both the written final exam and the practical exam with minimum grades of 70% on each and hand in your log book (written in ink and legible), which is also graded on a percentage basis with 70% minimum in order to pass Level 1. You will receive written notification of your exam results as quickly as possible. We won’t be able to tell you your results on Friday.




Test results will be mailed from NACE headquarters within two to three weeks. PLEASE DO NOT CALL NACE for results because staff are NOT ALLOWED to give out this information by telephone. You will be responsible for:

• Your own learning

• Managing your own time




Introductions

Before we get started with technical issues, we’d like to make sure that we all learn more about each other. I would like for each of you to stand, one at a time and introduce yourself to the class. Tell us:

• Your name

• Your company’s name and location

• Your job function

• Your experience in coating inspection

• Your hobbies

Team Formation Exercise

Now let’s get arranged into teams. You will be working in these teams for the rest of the week, so right now we will make a permanent shift in the seating arrangement.

Instructions: Team Exercise You will be working with your team throughout this session on a wide variety of tasks, exercises, and assignments. Please get together with your group and do the following:

• Team name: Decide on a team name that represents who you are, tells how you intend to perform during the workshop, and gives your group a personality.

• Reason: Select your team name for a specific reason. That is, don’t just give your team an arbitrary name. Think it through carefully. Be prepared to share your reason with the overall group upon completion of this exercise.

• Team logo: Create a logo or trademark for your team that graphically represents your team’s name and the rationale behind the name.




• Expectations and reservations: As a team, develop a list of expectations and reservations about the course. Summarize the responses of your team on the flipchart.

• Presentation summary: On flip charts, summarize all your team’s work on this exercise and prepare to deliver a five minute presentation to the entire group. Select a spokesperson to make your presentation

• Time: You have 20 minutes to complete your work.

• Questions: The instructors are available to answer any questions you have. They will circulate among the teams while you are working.




Team Response: Record the main points of your team’s presentation in the spaces below:

_________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________




Coating Inspector’s Job Throughout the CIP, we will talk in more detail about the coating inspector’s job, but for now let’s look at his or her job in general. Coating inspectors ensure—as far as possible—that coating systems are applied according to the coating specification, and they accurately and objectively report the results of all inspection observations. If environmental, time, or other constraints make compliance with the coating specification impossible, inspectors should ensure there is clear written authority for permitting deviations from the specification. The coating inspector’s job responsibilities may vary from job to job, but general duties always include:

• Obtain, read, and fully understand the coating specification. Bring up any questions with the appropriate person, and get them resolved.

• Obtain a clear definition of the authority delegated by the supervisor nominated by the coating specification, particularly with respect to the control of contractors working on the project.

• Determine by measurement and observation that the applicator fully complies with specification requirements and that work performed matches the required standard of quality.

• Determine that all essential raw materials, especially coatings, are stored correctly and used in batches within the manufacturer’s recommended shelf life.

• Maintain records of all work done, the conditions under which it was done, and any other appropriate report items required by the supervisor.

• Avoid directing the work of a contractor’s employees.




• Determine that all items listed in the coating schedule (or scope) have been completed.

• Ensure that the necessary test instruments and standards required are available at all times and that each instrument is fully functional and properly calibrated.

• Perform inspection duties with a fair and objective approach. Good communications and integrity are essential to performing inspection work that is beneficial to all the contractual parties in a coatings project

The Inspector’s Role For the purposes of the CIP, NACE has defined the inspector’s role as that of a quality control technician, who is primarily responsible for observing and reporting the technical aspects of a coating project. Supervision is NOT considered to be part of the inspector’s role. Most projects involve a contractual agreement between the owner and the coating application company (contractor). Responsibility for performing work according to the specification lies with the contractor. Inspectors are employed to help identify the quality of work performed and, specifically, to determine whether or not the work complies with the requirements of the specification. Reports prepared by inspectors for all work performed should indicate which work complies with the specified requirements and which does not. The role of inspectors is frequently misunderstood in the coatings industry. Companies working with Certified NACE Coating Inspectors should know and understand what is expected from the inspectors. They should read and understand both the mission statements and the attestation, which between them define the inspectors’ understanding of their project duties and responsibilities. Before we proceed, we need to explore the use of the words ensure and/or enforce, which are often used in




industry and may be used in this Coating Inspection Program in defining the role of inspectors and their actions on an inspection project. These words in particular have been misinterpreted or misunderstood in the past.

Disclaimer

As an attendee of this CIP course, you are hereby advised that NACE International’s view on inspection is that the function of the inspector is to inspect and document the functions described, always working solely within and abiding by the specifications, or according to a contract, or according to whatever document outlines his or her responsibilities and establishes the authority granted to him or her. By properly inspecting and documenting the work being performed, and by noting that the work is being performed in accordance with a set of specifications, or by issuing a nonconformance report (NCR) on work not being performed according to that specification, and later if the NCR is resolved and duly noted, the inspector is said to ensure an action and/or enforce a requirement. This is the only context in which the words ensure and enforce are to be used. You are advised that by fulfilling the requirements of this course, with its qualified terminology, you understand and accept the fact that NACE International does not state, affirm, imply, endorse, or otherwise by any action, express or implied, indicate that the use of the words ensure and/or enforce is intended to convey any meaning of guarantee nor any other assumption of responsibility for the quality or execution of any work inspected and documented by the inspector.




The following table is a copy of The Coating Inspector’s Checklist. This list gives you an idea of all the things inspectors may have to take into consideration on a coating job. By the end of CIP Level 1 we will have discussed every topic.

THE COATING INSPECTOR’S CHECKLIST Subject Check Here ( ) Specification

• Have it • Read it • Understand it

Pre-job Conference • Request one • Attend it • Participate actively • Know and understand safety rules

Coating Schedule • Know where coating activities will take place

Pre-inspection • Locate areas that will be hard to coat • Weld splatter • Weld flux • Skip welds • Rough welds • Sharp corners • Laminations

Surface Preparation • Observe safety rules • Correct abrasive • Anchor pattern as specified • All dust removed • Neutral surface • Surface as called for in specification • Surface defects corrected




• Weather suitable for abrasive blasting Coatings

• Observe safety rules • Coatings are those specified • Coatings are correctly mixed and agitated • Coatings are correctly thinned • Coatings have not exceeded pot life

Coating Application • Observe safety rules • Weather OK • Ambient conditions OK • Clean surface • Correct WFT • Correct DFT • No flaws • Runs • Dry spray • Holidays • Other • Brush over welds

Report • Take all measurements required • Record and report as required

Documents

Level 1 Chapter 1.1 Introduction