NAVSEA Basic Paint Inspector Training: Introduction 1−1 Introduction NBPI Course Developed by Naval Surface Warfare Center, Carderock Division Code 614 under direction of NAVSEA 05M1 NAVSEA Basic Paint Inspector Course (NBPI) Topics Certified paint inspector duties Formal inspection responsibilities Course objectives Scope This unit provides an overview of the NAVSEA Basic Paint Inspector Course and the course learning objectives. Learning Outcomes Plan the job Recognize chain of authority (Technical Authority) Appreciate coatings assessment Select surface preparation methods and proper coatings Measure environmental conditions Evaluate newly painted surfaces Learning Outcomes (cont.) Appreciate the practical aspects of the preservation process Identify health and safety precautions Locate preservation information Duties of Inspector Formal inspections Assist Naval activities regarding coatings QA Train ship’s force
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l Pre-job meeting l Affirm proper safety practices l Inspect surface preparation l Check paint in can l Ensure proper application l Measure coating thickness l Observe, assess, document, report results
Coatings and Surfaces to be Protected
l Will be discussed throughout the program
Why Course Developed?
l Extend coating service life to – Reduce maintenance
– Reduce hazardous waste
l Trained personnel needed to implement NSTM 631 and 009-32 QA requirements
Skills Learned
l Steps needed to do quality surface preparation and application l Recognize Technical Authority l Recognize Decision Tree for Departures from Specifications
(Appendix J) l Appreciate coatings assessment l Select proper surface preparation methods and coating
materials l Use available tools to perform inspections and tests l Evaluate applications l Recommend corrective actions l Basic safety l Identify sources of information
l Lecture and discussions l Demonstrations and workshops
l NBPI Course Written Final Exam (closed book) l NBPI Course Practical Instrument Exam (closed book) l NPBI Specification Navigation Exam (open book)
Certification Process
l Pass NBPI Course (80% or better on each component)
l Document 2 years marine coatings experience
Work Experience
l Work experience must be in one or more of the following areas: – Inspection of Coating Application on Navy, Coast
Guard or similar vessel – Repairs, Surface Preparation and Application of
marine coatings on Navy, Coast Guard or similar vessel
– Project Management of Coatings Projects on Navy, Coast Guard or similar vessel
Work Experience (cont’d.)
– Coating Specification and/or Contract Development on Navy, Coast Guard or similar vessel
– Coating Equipment and Material Supplier Technical
– Representative on Navy, Coast Guard or similar vessel
– Failure Analysis of Coating on Navy, Coast Guard or similar vessel
Recertification
l Maintained for 4 years
l Take an open book refresher exam online
l Pass with 85%
l NBPI Recertification full details online (http://www.sspc.org/training/nbpi_recert.html)
Certification
**All individuals who have been certified prior to the implementation of the new certification program will retain their certification status until their next scheduled certification renewal date.**
Failure Caused by Blast Embedded Particles Initiating Corrosion Intergranular
NAVSEA Basic Paint Inspector Training: Corrosion
2−7
Intergranular
Intergranular corrosion of sensitized stainless steel
Exfoliation
Exfoliation
Aluminum alloy plate!
Exfoliation
Aluminum Grain Structure
Grains are flattened and elongated during rolling
of aluminum plate
General Corrosion
Environmental Effects
l Humidity/Oxygen
Corrosion of Underwater Hull!
Environmental Effects
l Humidity/Oxygen
l Salt Water
NAVSEA Basic Paint Inspector Training: Corrosion
2−8
Corrosion of Battery Box Caused by Battery Acid
Environmental Effects
l Humidity/Oxygen
l Salt Water
l Chemicals
Environmental Effects
l Humidity/Oxygen
l Salt Water
l Chemicals
l Heat/Temperature
Corrosion of Steam Piping
Environmental Effects
l Humidity/Oxygen
l Salt Water
l Chemicals
l Heat/Temperature
l Stack Gases
Paint failure caused by stack gases, without protection area, will soon begin to corrode!
Environmental Effects
l Humidity/Oxygen
l Salt Water
l Chemicals
l Heat/Temperature
l Stack Gases
l UV Radiation Chalking of an epoxy topcoat—
eventually coating will fail allowing corrosion of substrate!
Open Forum
l What other conditions or items can be found on board ship that could contribute to corrosion or coating deterioration? – Examples:
• Decontaminating solutions • AFFF (Aqueous Film Forming Foam) • Biofouling • Smog and Acid Rain • CHT and Sanitary Tanks
Summary
l Corrosion continuously occurs everywhere.
l Different alloys and metals have different tendencies to corrode
l Corrosion is broken down into these types: – Uniform – Dissimilar metals – Pitting – Crevice – Stress cracking – Intergranular
l Environmental factors play a significant role in corrosion
NAVSEA Basic Paint Inspector Training: Corrosion Control
3−1!
Corrosion Control
NAVSEA Basic Paint Inspector Training!
Topics
l Three mechanisms of corrosion control by coatings (barrier, sacrificial, inhibitive)
l Sacrificial and impressed current cathodic protection systems
Scope
l Acquaints students with the basic mechanisms for controlling corrosion on Navy ships (coating and cathodic protection) and how they work well together
Learning Outcome
l Define the different mechanisms by which coatings control corrosion and the basic properties of coatings used for corrosion control
l Recognize the basic differences between sacrificial anode and impressed current cathodic protection for corrosion control
Corrosion Control
l Materials Selection
l Control Environment
l Design Details
Coatings to Prevent Corrosion
l Three primary ways coatings act to prevent corrosion on steel – Barrier Coatings
• e.g. epoxy – Sacrificial Primers
• e.g. inorganic zinc – Inhibitive Primers
• e.g. zinc molybdate
NAVSEA Basic Paint Inspector Training: Corrosion Control
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Barrier Coatings
l Requirement: – Reduced permeability to moisture and
oxygen • Both oxygen and moisture are required for corrosion
to occur • No coating is completely impermeable • Pigment selection can be important
Barrier Coatings
l Requirement: – Coating must adhere tightly to the
substrate with no breaks • If the coating adheres tightly, moisture
cannot get close enough to the surface to cause corrosion
• Breaks in the coating allow corrosion to begin very quickly
Barrier Coatings
l Requirement: – Resistance to the environment
• Coatings must withstand the environment in which they are used
• For example: – Chemical (ballast tank, fuel tank, CHT tank) – Abrasion (non-skid, deck coatings)
Sacrificial Primers
Steel Substrate: Cathode!Zinc Rich!
Coating!Anode!
Topcoat!
Water!Electrolyte!
In sacrificial primers, pigments provide active electrochemical protection by reacting with the
environment.!
Sacrificial Primers
l Must be used as the primer—needs to be in electrical contact with steel.
l Generally, need a high loading of zinc powder by weight. – Adjacent particles must be in contact for
effective protection.
– Inorganic binders are typically more effective than organic (e.g. epoxy) binders.
Class Input
l Name some other types of sacrificial coatings processes – Galvanizing (zinc) – Electroplating (zinc, cadmium) – Metal Spray Coatings (zinc, aluminum)
NAVSEA Basic Paint Inspector Training: Corrosion Control
3−3!
Inhibitive Primers
Substrate!
Moisture Penetration!
Inhibitive Primer!
Inhibitive coatings react with moisture absorbed by the topcoat to form products
which inhibit the corrosion process.!
Inhibitive Primers
l Must be used as primer coat—needs to be in contact with steel.
l Examples: – Red lead, lead oxide, lead chromate (Banned!) (form