Free AMPP CIP Level 1 Exam Flashcards

Removes oil, grease, soil, drawing compounds, and soluble contaminants from the surface. Always performed BEFORE mechanical preparation (blasting or power tooling), because blasting first would drive these contaminants into the substrate and cause adhesion failure.

SP 2 is hand tool cleaning (wire brush, scraper) removing loose rust, loose mill scale, and loose paint. SP 3 is power tool cleaning using power wire brushes or grinders. Neither requires bare metal nor produces a minimum surface profile.

The most thorough abrasive blast cleanliness. Requires 100% removal of all visible mill scale, rust, coating, oxides, and foreign matter. Zero staining allowed. Highest preparation grade, used for critical service (immersion, high-temp).

A moderate abrasive blast. Allows random staining on no more than 33% of each unit area. Staining is discoloration from rust, mill scale, or prior coating. Commonly used for general atmospheric service.

The lightest abrasive blast grade. Removes loose rust and loose mill scale/coating but allows tightly adhered material to remain. Often used as a maintenance touch-up before recoating.

High-cleanliness blast: at least 95% of each unit area free of all visible contaminants. Allows staining on up to 5%. A cost-reduced alternative to White Metal (SP 5) for many immersion and severe-service applications.

Removes all visible rust, mill scale, paint, and foreign matter AND produces a minimum ~1 mil (25 micrometer) surface profile. Differs from SP 3, which does not require bare metal or profile. Used where blasting is not feasible.

Water jetting cleanliness hierarchy: WJ-1 is cleanest (removes all existing coatings, mill scale, and rust, leaving matte metal); WJ-4 is lightest. Numbering is opposite dry blast (WJ-1 cleanest vs SP-7 lightest). Water jetting does NOT create a surface profile.

The peak-to-valley roughness created by abrasive blasting that gives the coating mechanical interlock with the steel. Profile depth is set by the coating manufacturer's product data sheet; typically the DFT should be at least twice the profile to cover the peaks and prevent rust-through.

Uses a hardened steel disc with segments machined to known profile depths (e.g. 0.5, 1, 2, 3, 4 mils) such as a Keane-Tator or Clemtex comparator. Compared visually and by touch against the blasted surface. The disc must match the abrasive type (sand, grit, shot) since peak geometry differs.

A spring-loaded pin depth micrometer that measures the vertical distance from a reference base resting on the peaks down to the valley floor. Less common than replica tape; gives a single peak-to-valley reading per measurement.

Compressible foam (commonly Testex Press-O-Film) pressed into the blast profile with a burnishing tool, then read with a spring micrometer. The micrometer reads foam + backing; SUBTRACT the 2 mil (50 micrometer) incompressible Mylar backing to get the true peak-to-valley profile.

The number of profile peaks per unit length. Two surfaces with the same peak-to-valley depth can have very different peak counts; higher peak count gives more contact area for mechanical interlocking and improves adhesion. Measured with stylus profilometers per ASTM D7127.

Pre-blast rust condition of uncoated steel. A = mill scale intact, no rust. B = mill scale rusting/flaking. C = mill scale lost, general surface rust. D = heavy pitting visible. Photographs let the inspector verify post-cleaning SP grade against the matching initial rust condition.

Specification for mineral and slag abrasives covering hardness, density, moisture, and water-soluble contaminants (measured by conductivity). Soluble salts in the abrasive transfer to the steel and cause osmotic blistering and premature coating failure.

Silica sand generates respirable crystalline silica dust that causes silicosis and lung cancer. OSHA limits exposure under 29 CFR 1910.1053 (general industry) and 1926.1153 (construction). Safer substitutes include coal slag, garnet, steel grit, and staurolite.

ISO 8502-6 method: an adhesive patch traps a known volume of deionized water on the prepared surface, extracting soluble salts. Conductivity of the extract is measured and converted to chloride (or total salt) loading in micrograms per square centimeter. Immersion service typically requires less than 3 to 7 micrograms per square centimeter chloride.

Detects oil and water contamination in compressed air used for blasting or coating application. A white absorbent blotter is held in the air stream for about one minute; any discoloration indicates oil, and moisture droplets indicate water. Run at shift start and periodically.

Field check for residual oil or grease after solvent cleaning (SSPC-SP 1). Potable water is sprayed or wiped on the surface: if it sheets uniformly the surface is clean; if it beads or breaks into droplets, hydrophobic contamination remains and the area must be recleaned before coating.

The temperature at which air becomes saturated (100% relative humidity) and water begins to condense on surfaces. In coating work the steel surface temperature must stay above the dew point; if the steel cools to or below the dew point, moisture condenses and causes blistering and adhesion failure.

The steel SURFACE temperature (not air temperature) must be at least 5 degrees F (3 degrees C) above the dew point during coating application and until the coating is sufficiently cured. This margin protects against condensation as the temperature fluctuates.

A whirling hygrometer with two thermometers: dry bulb (ambient air temperature) and wet bulb (thermometer wrapped in a wetted wick). After whirling about 60 seconds, evaporative cooling lowers the wet bulb reading. The wet-bulb depression is used with psychrometric tables to determine relative humidity and dew point.

Most solvent-borne industrial coating product data sheets cap application at about 85% relative humidity. High humidity slows solvent evaporation, promotes solvent entrapment and blushing, and raises the condensation risk. Moisture-cure urethanes and some zinc-rich primers tolerate higher RH.

Measured directly on the steel, not inferred from air temperature (steel can be colder than air due to radiant cooling). Common instruments: magnetic dial (bimetallic) surface thermometer and electronic contact probe (thermistor or thermocouple). Infrared can be used but depends on emissivity calibration.

When the steel surface temperature equals (or falls below) the dew point, the surface is at 100% RH and condensation is occurring or imminent. Coating must STOP until the steel warms or the dew point drops enough to restore the 5 degree F margin.

Light rust that forms on freshly blasted steel almost immediately when exposed to humid or moist air, because the clean reactive steel oxidizes. SSPC-VIS 4 / NACE VIS 7 grades it as Light (L), Moderate (M), or Heavy (H). Specifications define how much flash rust is acceptable before coating.

Measured with a comb-type wet film thickness gauge pressed into the wet coating. WFT multiplied by the coating's volume solids equals the expected dry film thickness. Used during application to confirm the applicator is on track for the specified DFT before cure.

Governs measurement of cured coating thickness on steel using magnetic or electronic gauges per ASTM D7091. A spot measurement is the average of 3 gauge readings; an area is 5 spot measurements per 100 square feet. Results are compared to the specified DFT using the 80/120 rule.

One spot measurement is the AVERAGE of 3 individual gauge readings taken close together. The 3 readings are averaged to reduce single-reading variability. The spot average (not the individual reading) is compared against the 80/120 tolerance.

For each 100 square feet of coated area, take 5 spot measurements (each spot = 3 gauge readings). The average of the 5 spots is the area measurement level. Larger areas require proportionally more level-2 area measurements, distributed across the zone.

Individual spot averages must be no less than 80% of the specified minimum DFT and no greater than 120% of the specified maximum DFT. Spots outside this range trigger additional measurements and may require correction (add coat or accept by variance).

Type 1 = magnetic pull-off (mechanical; a magnet is pulled from the surface by spring tension, reading thickness at release). Type 2 = electronic (uses magnetic-induction for ferrous or eddy-current for non-ferrous substrates). Type 2 is more common; both require calibration on a smooth uncoated reference (BMR) before use.

Provides sacrificial (cathodic) protection: zinc is anodic to steel and preferentially corrodes, preserving the substrate. Requires high zinc loading (commonly at least 80% zinc in the dry film) and direct electrical contact with the clean, profiled steel. Inorganic zinc silicate also builds barrier protection as it ages.

Standard amine-cured epoxies need temperatures above about 50 degrees F (10 degrees C) to cure fully. Below this, the reaction slows or stops, producing soft film, poor chemical resistance, and amine blush (carbamation). Use low-temperature-cure epoxies or add heat for cold-weather work.

Oil-modified resins that cure by solvent evaporation followed by oxidation of unsaturated oil bonds with atmospheric oxygen. Not suitable for immersion or alkaline environments because the oxidized film saponifies (hydrolyzes) in water or alkali, causing disbondment.

UV-stable, gloss-retentive topcoat cured with an aliphatic isocyanate. Used over epoxy intermediate coats for weathering and color stability. Moisture-sensitive during application; the isocyanate reacts with water to form carbon dioxide, which can cause pinholes or bubbling.

Single-component urethane that cures by reacting atmospheric moisture with isocyanate groups. Tolerates higher relative humidity and slightly damp surfaces, making it useful for field maintenance. Downside: the pot life is governed by ambient humidity rather than a fixed mix ratio.

A passive fire-protection coating that expands when heated, forming a thick insulating char layer that slows heat transfer to the steel substrate. Used on structural steel to meet fire-rating requirements. Coating thickness is critical and verified by DFT.

Pot life is the usable working time after a multi-component coating is mixed (the coating gels and becomes unworkable beyond it). Induction time is the wait period after mixing before the coating can be applied, allowing the chemical reaction to start. Both come from the product data sheet.

Brush-applied coating on edges, welds, rivets, and other hard-to-spray areas BEFORE the full spray coat. Ensures coverage on surfaces where spray would thin out or pull away. Stripe coating is a common inspector hold point because edges are the first place coatings fail.

A textured, dimpled surface defect resembling an orange skin, caused by improper spray technique: gun too far from the surface, low air pressure, overly viscous material, or too fast a thinner evaporating before the film levels. Reduces gloss and can trap moisture.

Excess coating flowing down a vertical surface, forming thick ridges or drips. Causes: applied too thick, spray gun too slow or too close, or solvent too slow to flash. Beyond appearance, the thick area may solvent-entrap, wrinkle, or never fully cure.

Pinholes are tiny holes left by trapped solvent or air escaping through the film. Craters (fish-eyes) are circular depressions where the coating failed to wet the surface, almost always caused by silicone or oil contamination. Source of contamination must be removed before recoating.

A pinhole, void, or thin spot in the cured coating film that exposes the substrate. Even microscopic holidays are pathways for corrosion. Detected after cure with a holiday detector; the location is marked, repaired, and re-tested to confirm the discontinuity is closed.

ASTM D5162 method for coatings up to about 20 mils DFT. A wet sponge connected to a low-voltage circuit (typically 9 to 90 V) is swept over the surface; current flows and an alarm sounds where a holiday bridges the circuit. Suited to thin-film coatings.

Used for coatings above about 20 mils (e.g. tank linings, pipeline FBE). A charged brush or ring electrode is swept over the dry film at a voltage calculated from the thickness and the coating's dielectric strength (per NACE/AMPP SP0188). The substrate must be electrically grounded so a spark completes the circuit at a holiday.

A destructive test: a metal dollie is glued to the coating and pulled perpendicular to the surface with a hydraulic or pneumatic tester until the coating fails. The pull-off stress (PSI or MPa) and the failure mode (adhesive at interface, cohesive within a layer, glue failure) are recorded.

A less-destructive tape test for coatings up to about 5 mils. A blade cuts a lattice (or X) through the film to the substrate, adhesive tape is applied and removed, and the percentage of coating removed is rated on a 0B to 5B scale (5B = no removal, best).

Coating inspectors must act with impartiality and honesty, perform only work they are competent to do, avoid conflicts of interest (and disclose any that arise), report findings accurately without falsification, and protect confidential client information. Breaches can result in certification suspension or revocation.

1910.1053 limits respirable crystalline silica exposure during abrasive blasting (engineering controls, respirators, air monitoring). 1910.146 governs permit-required confined space entry for tank interiors and enclosed blasting enclosures (atmosphere testing, attendant, rescue plan, entry permit). Both directly affect coating inspector field safety.