NAPCA Training

Fusion Bonded Epoxy Operational Training Course
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Copyright 2003 by National Association of Pipe Coating Applicators (NAPCA).
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Credits and Acknowledgements

This is the first edition of the National Association of Pipe Coating Applicators FBE Operational
Training Course. On behalf of the Board of Trustees, we would like to thank Dick Brunst,
President, Western Pipe Coaters & Engineers, Inc., who chaired the committee, which developed
the course for his dedication. Without Dicks strong leadership, the course would never have come
to fruition. We also would like to thank Lee Evans, Vice President, ShawCor Pipe Protection
LLC, for chairing the Editing Committee, which finalized the course. Furthermore, ShawCor Pipe
Protection LLC provided the course CDs to NAPCA free of charge. Many other people from
numerous Regular and Associate Members contributed to the development of the course. We
appreciate their hard work and thank them for their contributions. Below is a list of those
companies which participated. They were numerous, and we believe we have shown them all.
However, if any company, which worked in making the course a reality, is not included in the list,
we apologize for the omission.
Regular Members
The Bayou Companies, L.L.C.
Commercial Coatings Services, Inc. (CCSI)
Dura-Bond Coating, Inc.
eb Pipe Coating, Inc.
L.B. Foster Company
Midwestern Pipeline Services, Inc.
Mobile Pipe Wrappers & Coaters, Inc.
Perma-Pipe, Inc.
ShawCor Pipe Protection LLC (formerly Bredero Price Company)
Western Pipe Coaters & Engineers, Inc.
Associate Members
CRC Evans Pipeline International, Inc.
DuPont Powder Coatings/Nap-Gard Pipe Coatings
Ervin Industries, Inc.
Hoffman Blast Room Equipment, Inc.
3M Company
National Metal Abrasives, Inc.
The Valspar Corporation
USF Surface Preparation
Wheelabrator Abrasives, Inc.
Introduction
Welcome to the Fusion Bonded Epoxy Coating Operational Training Course established by the
National Association of Pipe Coating Applicators ("NAPCA"), the trade association for the plant
pipe coating industry. We are pleased you have made a commitment to enhance your skills and
knowledge to further your career. This Operational Training Course was developed as a service
to the pipeline industry to assure personnel involved in the operations of fusion bonded epoxy
coating plants and all inspection personnel are fully qualified to perform their duties. The need
for fully qualified, well trained operating and inspection personnel has become a major issue for
pipeline owners and operators.
Recently, the officers and trustees of NAPCA were asked to discuss current and future problems
in the plant-applied coating industry. It was the consensus of these officers and trustees that there
is a real need for training of pipe coating operating personnel and inspectors who do work at
coating plants. Many times the applicator has to train these people on what is required during
actual operation, which may cause problems where none exist. Training of all operating
personnel and inspectors would be a big step toward total quality control, thus benefiting both
applicators and end users. This training course is a beginning. It is important that you take the
next step in learning and applying the information and skills taught in this course in your daily
work. We value your comments, suggestions and ideas for improvement to this program. Please
feel free to write us, and we will discuss your thoughts. Our address is as follows:
National Association of Pipe Coating Applicators
Am South Bank Building
333 Texas Street, Suite 717
Shreveport, Louisiana 71101-3673
Telephone (318) 227-2769
Telefax (318) 222-0482
If you would like more information regarding NAPCA, please visit our website at
www.napca.com. Our website contains the history and an overview of our association, a
complete listing of all of our members throughout the world, all of our application and other
bulletins, and advertising provided by various members.
History
Fusion bonded epoxy (FBE) coating of below ground pipelines to provide corrosion protection
was developed in 1959. Full commercial availability to the industry was achieved four years later
in 1963. It was one of the first truly effective film coatings. At first, its use was limited, and
operating companies were somewhat skeptical of its ability to eliminate external corrosion on the
pipeline. Today, FBE is one of the most popular coatings being used by the industry throughout
the world. In 1996, over 83 million square feet of pipe were coated with FBE, representing more
than a third of all coatings applied.
Throughout the years, FBE formulations, application methods, testing, and uses have changed,
bringing about a much improved product for use by the end user. This FBE training program is
another effort on the part of the industry to give pipeline companies the highest quality product
possible in the corrosion protection to their pipelines.
Chemistry of Fusion Bonded Epoxy Coatings

I. Components of FBE Coatings:
A. FBE coatings are formed from four constituents:
1. An epoxy resin which forms the coating basis.
2. A curing agent for initiation and completion of polymerization.
3. Filler materials and pigments for improving properties and adding color.
4. Additives, which act as flow controllers to improve viscosity when all
constituents are melted together.
B. Chemistry of Coating Formation:
1. Epoxy Resin + Curing Agent (amine)-----> FBE Coating
2. Properties (both chemical and physical) depend upon composition of the epoxy
resin and the curing agent(s).
3. As temperature of the mixture is increased, the formed FBE powder melts and
becomes a viscous liquid. As the liquid FBE cools, it becomes a gel or semi-solid
and ultimately a solid coating. Cross-linking actually causes the material to
become solidified.
4. Formulation of FBE coating depends on many concerns:
a. Manufacturer: Will the coating react or cure before it is applied by the
applicator?
b. Applicator: Will the coating adhere and remain on the pipe after
application and for many years to come?
c. Contractor: Is the coated pipe tough enough to withstand rock
impingement, handling, and other mechanical shock?
d. End User: Will it stay on the pipe until the end of the design life of the
pipeline? Can it be repaired easily?
Mechanical Pipe Cleaning

An abrasive blast-cleaning machine cleans pipe. In the machine, abrasive is hurled against the
exterior of the pipe by blast wheels rotating at high speeds. The high velocity abrasive knocks
dirt, scale and rust off of the surface of the pipe. A dust collector is used in conjunction with the
abrasive blast-cleaning machine to remove dust-laden air and filter it, and to cool the abrasive.
This chapter discusses the following topics:
Abrasive Blast Cleaning Machine

1. Wheel Unit
2. Cabinet
3. Elevator
4. Separator
5. Dust Collector
ABRASIVE BLAST CLEANING MACHINE
Figure 1.1 Abrasive blast cleaning machine.
This equipment is used by most pipe coating applicators. There are various manufacturers of this
equipment. Machines come in different sizes and configurations with slight variations of
individual components. This chapter will only describe the types of centrifugal blasting machines
used by the majority of pipe coating applicators.
The abrasive performs the actual work of cleaning and profiling by impacting the surface to be
cleaned. It is continuously recycled through the machine that consists of five major components
(Figure 1.1):
1. Wheel Unit
2. Cabinet
3. Elevator
4. Separator
5. Dust Collector
Additional machine components and features, which are essential in an efficient operation,
include:
Ammeters
Standard
Digital
Vestibule and seals
Sunburst type
Brush type
Sheet rubber
Combination brush and sheet
Control system packages
Relay logic
PLC logic
Abrasive level monitoring
Abrasive flow control systems
Manual/Mechanical
Automatic magnetic variable abrasive flow control
Wheel Drives and Speed Control
Unit bearing
Direct drive
Speed control
Cabinet liner packages
Manganese
Cast chrome molly
WHEEL UNIT
The wheel unit is similar to a centrifugal pump. The abrasive flows through the center of the
wheel passing through an impeller that rotates at the same speed as the wheel. The impeller
proportions the abrasive and aligns its release to each vane. (Figure 1.2).
Figure 1.2 Exploded view of a wheel unit.

The abrasive releases from the impeller through the opening in the control cage that is mounted
at the center of the wheel but does not rotate. The setting of the control cage opening controls the
blast pattern location on the work surface (Figure 1.6). Rotating the opening will move the
location of the blast pattern on the work surface accordingly.
Figure 1.3 Unit bearing type wheel assembly - belt driven design.
Figure 1.4 Direct driven wheel assembly.
Figure 1.5 Bi-directional wheel assembly.

The distribution of shot striking the pipe in the blast pattern is not even. A "hot spot" is created
where the highest concentration of the abrasive hits the pipe at the most effective angle (Figure
1.6).
The "hot spot" is where the abrasive impacts the surface at approximately 90 degrees. The
distance from the wheel to the work surface determines the length of the "hot spot" area.
Normally the distance from the vane to the pipe is 16-18 inches, (40-50 cm) and the "hot spot"
length is 8-10 inches (20-25 cm). The area outside the "hot spot" receives less cleaning due to
less concentration of abrasive and lower angle of impact.
Figure 1.6 The setting of the control cage opening controls the blast pattern location on the
work surface.
Since the pipe is spirally conveyed through the cleaning machine, the lead (forward travel of the
pipe for each revolution) should not exceed the length of the "hot spot" or a "barber-pole" effect
will result. The lead is a function of the pipe diameter and the conveyor wheel angle.
Most blast machines used in the pipe coating industry are the two (2) wheel up-blast design. (See
Figure 1.7). The spiral motion of the pipe passing through the blast pattern of the two (2) wheel
machine should allow between five (5) to seven (7) exposures to the propelled abrasive to assure
best cleaning results.
The main wheel components consist of a balanced set of blades, an impeller, and a control cage.
They wear out as a complete set of components. Most parts manufacturers offer replacement kits,
which consists of all three components (Figure 1.2): one (1) set of blades, one (1) impeller, and
one (1) control cage which should be installed at the same time.
Wheel blades/vanes are balanced sets to within one (1) gram. It is most important that they are
always changed as a complete set to eliminate excessive wheel vibration and bearing wear.
Table 1.1 Approximate abrasive flow rates (19-1/2" dia. wheel with 2-1/2" wide vanes)
(lb/min)
H.P.
R.P.M.
1500
1800
2250
10
570
350
210
15
880
540
340
20
1200
750
460
380
960
600
500
25
2480
2660
30
1170
720
600
540
40
1580
980
810
720
50
1200
980
900
60
1470
1200
1100
1470
1370
270fps
285fps
75
ABRASIVE VELOCITY
160fps
195fps
245fps
Table 1.2 Approximate abrasive flow rates (21" dia. wheel with 5" wide vanes) (lb/min)
R.P.M.
H.P.
1500
1800
2250
2480
2660
15
455
316
202
20
733
509
326
268
25
702
449
370
321
30
895
573
471
410
40
1280
819
674
586
50
1066
878
763
60
1313
1081
939
75
1683
1386
1204
100
2300
1893
1646
256fps
282fps
303fps
10
ABRASIVE VELOCITY
170fps
205fps
The wheel is the "heart" of the cleaning machine. Wheel maintenance is important. Worn blades,
impeller or control cage can alter the blast pattern and cleaning efficiency. Other components of
the machine are accessories that deliver abrasive to the wheel and remove spent abrasive and
dust.
Table 1.3 Wheel maintenance check list.
WHEEL UNITS
1. Check wheel for vibration.
DAILY
X
WEEKLY MONTHL
Y
2. Check blades or vanes.
X
X
3. With blades removed, close housing and run

wheel.
Check for vibration.
4. Inspect and replace impellers if badly worn.
5. Inspect control cage. If bevel edge of the opening

has worn way, should be replaced.
6. Inspect wheel housing liners and deflectors,

change as necessary
7. Check blast pattern for correct setting.
*8. Record Ammeter reading.
9. Check ammeter for accuracy with Tong ammeter.

10. Check wheel belts.
X
X
*Ammeter should be steady at full load (or determined setting). Violent fluctuations indicate
improper belt tension, bearing trouble, inadequate supply of abrasive, or drag in some moving
machine part.
RULES OF THUMB:
Excessive vibration at the wheel usually indicates worn

out blades or wheel head.
If squeaking/squawking occurs while starting motor on

wheel, it usually indicates loose belts.
The leading edge of the control cage opening is

approximately 180 from the leading edge of the blast
pattern.
If grinding noises occur in the wheel during start-up, it

usually indicates misalignment of components which
should be corrected.
When replacing worn blades, replace the complete set.

The impeller and control cage should be replaced at the
same time.
Wheel blades are considered worn out when grooves or

wear reaches the original thickness.
CABINET
The blast machine cabinet contains the blast process and keeps the rebounding abrasive, dust,
rust, mill scale, etc. in a confined area where the abrasive can safely be reclaimed, cleaned and
recycled, and dust and other refuse removed. The cabinet consists of a steel box with vestibules
and seals located at each end through which the pipe passes. The cabinet is constructed in such a
manner as to collect the spent abrasive in the bottom and direct it to the elevator boot for reclaim.
There are two basic cabinet designs.
UP BLAST DESIGN
On the up blast machine the blast wheels are mounted under the pipe. The wheels are always in a
fixed position in relation to the bottom surface of the pipe. The majority of this type of machine
reclaims the abrasive by gravity. This requires a sloped hopper to the elevator boot. This type of
machine usually requires a pit.
Some up blast machines have an auger in the bottom of the cabinet to move abrasive to the
elevator boot. These machines may or may not require a pit.
Figure 1.7 Up-blast cleaning theory of operation.

DOWN BLAST DESIGN
The down blast design is configured with the wheels mounted above the pipe (Figure 1.8). Since
the top of pipe varies by pipe size (the bottom of the pipe is usually at a constant or near constant
height), the distance from the wheel to pipe varies. This makes the wheels less efficient when
blasting small diameters. It also allows the blast pattern to spread out. In extreme cases, the blast
pattern becomes so long, it blasts into the cabinet seals.
In some down blast designs, the wheels can be moved up and down to keep the distance from the
wheel to the pipe constant.
Down blast machines can be pit-less or require a shallow pit. They may also be gravity or auger
reclaim.
Figure 1.8 Down-blast cleaning theory of operation.

Table 1.4 Cabinet maintenance check list.
Cabinet Maintenance Check List
DAILY
WEEKL
Y
MONTH
LY
The cabinet should be free of leaks. Flying abrasive

is dangerous to personnel and nearby equipment.
Lost abrasive is expensive.
1. Inspect cabinet interior for evidence of abrasive
wear
2. Clean loose abrasive from roof areas and return it

to system. Determine and eliminate the source of
loose abrasive.
3. Inspect wheel housings and liners. Replace as

necessary.
4. Check entrances, exits, loading doors, and seals for

abrasive losses.
ELEVATOR
The abrasive elevator is usually an endless belt and bucket design that conveys the blast media
(steel grit or steel shot) upward from the bottom of the cabinet into the separator system for
classification. Usually the head section (top of the elevator assembly) has tensioning bolts for
proper alignment and belt tension.
The boot section (bottom elevator assembly) can be fed by gravity hoppers or auger assemblies.
RULES OF THUMB:
If the elevator makes clanging noise while operating, it

usually means the belt tension is too loose. Tighten the
head section take-up bolts.
Cast malleable iron buckets are most efficient on

elevators.
Multi-ply heavy-duty rubber belting 3/8" to 1/2" thick is

most efficient.
Figure 1.9 Cycle of abrasive through blast cleaning system.

Table 1.5 Abrasive handling system maintenance check list.
Abrasive Handling System Maintenance Check
List
1. Storage hopper, feed spouts, screws, etc. Inspected
and scheduled for repairs or replacement, if the
cycling of the abrasive is retarded in any way.
2. Elevator belt check for:
a. Tension
b. Alignment of pulleys
c. Worn or missing buckets
d. Splice condition
DAILY
WEEKL
Y
X
X
X
X
X
3. Check sprockets and drive for tension, alignment,

keys, loose set screws, and bearings.
4. Check abrasive control valve for free operation and

desired opening.
MONTHL
Y
SEPARATOR
Following the wheel, the next most important component is the separator (Figures 1.10 and
1.11). Its function is to receive abrasive from the elevator, separate the undesirable trash, fines
and dust and deliver usable abrasive to the storage hopper.
Separators accomplish this task by air washing the abrasive and are available in two types.
GRAVITY TYPE SCREEN DESIGNS
Figure 1.10 Gravity type abrasive screening system.

The abrasive is delivered by the elevator and dumped onto a pan shaped screen. This screen
collects unwanted trash such as nuts, bolts, bottle caps, etc. It is important that this screen be kept
clean. The abrasive falls through the screen and collects against a hinged baffle, which is swung
open by the weight of the abrasive. The baffle is adjustable and can be raised or lowered so that
the abrasive is spread in a thin stream across a shelf located below the baffle. The abrasive flows
over the lip of the shelf and falls to a permanent baffle. Air flows through the curtain of
cascading abrasive carrying the dust and fines into the air expansion chamber. The dust is carried
on to the dust collector. The fines fall into the settling chamber and are discharged through the
"dribble tube".
The air wash separator system cleans the abrasive.
The baffles and quantity of airflow to the collector control system balance.
ROTARY SCREEN TYPE
Figure 1.11 Rotary type abrasive screening system.

This separator operates on the same air wash principle as the gravity type except the screen is
self cleaning.
The abrasive discharged from the elevator is carried by a screw conveyor to the inside of a rotary
screen. The outside and inside of the screen contain flights that operate like a screw conveyor.
Trash or undesirable material that will not pass through the screen is carried the length of the
screen and discharged at the trash spout by the inside flights. The outside flights keep the
abrasive from piling up against the bottom of the screen. The baffles distribute abrasive and fines
falling through the screen across the full length of the separator. An adjustable regulating baffle
commonly referred to as the sliding 2/3 baffles accomplishes uniform distribution. Adjustable
counter weights provide backpressure on the swing baffle to spread the abrasive into a thin
curtain the full length of the baffle.
CFS ABRASIVE SEPARATOR
The role of the abrasive separator in the blasting operation is to remove sand, scale, abrasive
fines and other contaminants from the abrasive operating mix so that only clean abrasive,
properly sized, is returned to the blast wheel for reuse. The degree of success of the separator in
performing this operation in a large measure determines parts life, abrasive consumption, the
type of finish given the work being blasted, and the speed and quality of cleaning. Although
there are two general types of air wash separators used on blasting machines - the gravity and
compensating-flow (CFS) - discussion here will be centered upon the CFS type because of its
more general usage and higher efficiency. The CFS separator is designed to utilize compensating
flow to present a full-length curtain of material to the air washing currents. This uniform lowvelocity curtain permits a more thorough air washing of abrasive. It is designed so that abrasive
moves on abrasive, not the separator parts. The overhead rotary screen removes any tramp metal
from the abrasive. It also spreads out the abrasive across the full length of the separator. Two
baffles, as shown in Figure 1.12, a fixed sliding baffle and an adjustable swing baffle are utilized.
When properly adjusted, the baffles permit only a full width curtain to be presented to the air
currents.
RULES OF THUMB:
Maintain a full-length curtain for effective cleaning of

blast.
All abrasive in storage hopper should be free of fines and

dust.
If good abrasive is discharged from fines, trash or rotary

drum trash adjustments are required in the separator.
If excessive dust is coming from blast cabinet, it usually

indicates separator adjustment is required or dust
collector system is not working properly.
Proper balance in the system is accomplished by adjustment of the 2/3 baffle, counter weights,
fixed baffle or airflow gate.
Figure 1.12 CFS (Compensating Flow Separator) abrasive separator.

Table 1.6 Separator maintenance check list.
SEPARATORS
DAILY
1. Clean scalping screen.
2. Check scalping screen for holes.
3. Check shed plates, baffles for wear.
4. With machine in blasting cycle, check abrasive flow

at point of separation (orifice) to make sure it is
uniformly spread over the entire orifice.
5. Make sure dribble valves are in place on refuse

pipes or tubes from separator and are working
properly.
(check separator discharge for usable abrasive.)
WEEKL
Y
MONTHL
Y
DUST COLLECTOR
This is basically a "king size" vacuum cleaner that provides airflow for
the separator and dust removal from the cleaning machine cabinet and
elevator. Air drawn (Figure 1.15) into the collector passes through a filter
medium - usually fabric bags or cartridges. After passing through the
filters, air is exhausted at the blower discharge. Dust is conveyed from
the cleaning machine to the collector via high velocity airflow in the
duct. The velocity of this air must be 3000-4000 ft/min (900-1200
m/min) to maintain the contaminants in suspension. Upon entering the
collector cabinet, the velocity is greatly reduced causing larger particles
to drop from suspension in the air stream and fall into the dust hopper.
Dust collectors that initiate dirty air coming into the top of the dust
collector and leaving out the bottom of the dust collector are said to have
a down draft.
Figure 1.14 Schematic of a typical dust collection system.
Figure 1.13
Cartridge-type
dust collector.
Figure 1.15 Dust collector up draft concept of operation.

Dust collectors that initiate dirty air coming into the bottom of the dust collector and leaving out
the top of the dust collector are said to have an up draft.
The smaller particles continue until they impinge on the filter media surface. This portion of the
collector is referred to as the "dirty side." The air (less contaminants) passes through the filter
media and is exhausted at the blower. This is referred to as the "clean air side." As the process
continues, more large, heavy particles fall into the hopper and lighter particles build up on the
dirty side of the filter media. The buildup results in reduced air flow and increased pressure drop
across the media referred to as the "filter differential pressure."
Dust collectors remove particulates from the air using the same principle as a home vacuum
cleaner.
The efficiency of the collector decreases as the dust builds up on the filters and differential
pressure increases. Various methods are used to control this buildup:
MECHANICAL SHAKER
These are used only on fabric bag type collectors. They employ a mechanism that shakes the
bags, permitting the contaminants to drop off and fall into the hopper. This must be done when
the collector's exhaust blower is off. The electrical controls are usually designed to automatically
start the shaker when the blower is stopped and to run for a preset time. Manual control is also
available to override the automatic. The length of time for bag shake is adjustable.
NOTES
Shaker-type bag houses should have hopper emptied two

times per 8-hour shift.
Anytime dust collector has a sealed fines container under

the slide gate, keep the slide gate open.
If no sealed container exists under the slide gate, keep it

closed.
If belts squeak at motor start-up, tighten them.
Make sure dust collector has a pressure differential

sensing device.
Figure 1.16 Mechanical shakers.

REVERSE PULSE JET
The reverse pulsejet is used in both fabric bag and cartridge collectors to remove accumulated
particles from the filter media. A blast of compressed air (Figure 1.17) is released from a nozzle
into a venturi directed downward in the filter. The venturi pulls in secondary air, increasing the
pulse volume. This sudden pulse of reverse airflow flexes the filter media, causing the
accumulated particles to drop off. An adjustable timer is provided to vary the pulse cycle time
depending on the rate of build up on the filter. The air manifold supplying the nozzles must be
maintained at 90-100 psi (600-700 Kpa) in order to ensure effective operation.
Figure 1.17 Air blast system used to clean dust filters.
Figure 1.18 Basic component of a dust collection system.

AIR PRESSURE SENSING DEVICES
The three types of differential air pressure sensing devices are:

1. Manometer A U-tube with fluid which measures (in inches of water column) the
pressure differential between clean air vs. dirty-air side of dust collector.
2. Magnahelic Gage measures the inches of static pressure between clean air and dirty air
side of dust collector.

3. Photo-Helic Measures the inches of static pressure between clean air and dirty air sides
with pulse upon demand HI/LO automation to clean elements as required by
manufacturer. This pulse action begins when elements achieve high-end static setting and
continues until the low-end static setting is reached. It then stops until repeated
RULE OF THUMB:
Install and use a differential air pressure-sensing device on all
dust collection systems.
A Magnahelic/Photo-Helic pressure-sensing device is required, usually mounted on the exterior

of the collector cabinet to indicate the differential pressure across the filter media. Each
manufacturer of dust collectors has a recommended HI/LO range for the most efficient operation.
It is recommended that an air pressure regulator be located on all air feed lines to the Dust
Collector utilizing air pulse to allow control of pulsing pressure in many situations.
Table 1.7 Dust collector maintenance check list.
DUST COLLECTOR
1. Inspect area around blast cleaning unit to see that it
is free of dust.
DAILY
WEEKLY MONTHL
Y
2. Check all duct work for leaks.
3. Inspect blast gate settings to see that they are

unchanged.
4. Take manometer reading.
5. See that hoppers are empty.
X
X
X
6. Check fan belts.
7. Inspect fan vanes for wear.
8. Check shaker or rapper mechanism while in

operation.
9. Check bag house or filter compartment while

shaking or rapping.
NOTES
When starting up a dust collector with new bags or

cartridges, do not shake or pulse until 3" of static
pressure is registered. It is good to pre-coat filters with
dust when new to reduce airflow temporarily to prevent
damage to the filters or overload on the fan motor.
Dust collector should be located within 50' of the blast

machine.
If good abrasive continues to go to dust collector, add an

abrasive line trap between the machine and dust
collector.
When you find good abrasive in the dust collector hopper,

you can be assured it is in ductwork. Clean ductwork.
Make sure clean air inlet vents on blast cabinet are not
restricted.
All dust collectors have a highly volatile nature and must

be emptied two times per shift.
GENERAL OPERATIONAL PRACTICES

The following is a list of some safe standard operating practices, but are not intended to be allinclusive.
Always lock out electrical power when performing maintenance.
Stay clear of pipe while conveyor rollers are operating.
High noise levels may impair hearing. Stay clear of air discharge area. Avoid extended
exposure in close proximity to machinery that exceeds safe noise levels.
Abrasives that escape at high velocities can cause harm. Do not start the blast wheels
until a pipe fills the blast cabinet vestibule and seals. Make sure the proper size seals are
installed before turning on the system. Wear eye protection at all times.
Keep sparks and open flame away from the dust collector. Dust may be explosive.
Do not activate the blast wheel(s) or shot gate(s) while loading abrasives. Damage to
buckets can result if elevator is not running during loading. Turn elevator on before
loading abrasives into the system.
ADDITIONAL COMPONENTS AND FEATURES

1. AMMETER
The ammeter is the only instrument that will register the efficiency of the blast wheels. Each
wheel unit is equipped with its own meter that measures the current drawn by the wheel motor.
The current is proportional to the amount of abrasive thrown by the wheel. Each motor size has a
specific full load current rating. (See Wheel Ampere Chart below). When the ammeter indicates
the wheel motor is pulling full load current, the wheel is throwing the maximum amount of
abrasive. If the wheel is pulling less than full load, it is not being used to its full capacity. There
are two (2) types of meters as follows:
a. Analog Type This style registers the actual motor load with a needle on a graduated scale.
This style must be calibrated regularly via a thumbscrew and can drift out of calibration.
b. Digital Type Motor load amperage is displayed digitally on the meter face. Digital meters are
available with LED or LCD display.
WHEEL AMPERE CHART
Table 1.8 Ammeter Readings
440 VOLTS
220 VOLTS
H.P.
NO LOAD
FULL LOAD
NO LOAD
FULL LOAD
10
13
10
26
15
19
14
38
20
27
18
54
25
10
31
20
62
30
12
36
24
72
40
17
49
34
98
50
20
61
40
122
60
25
73
50
146
75
33
94
66
188
100
41
116
82
232
NOTES
Each wheel unit must have its own meter.
All wheel units must operate at full load amps.
The difference between the no load amps and full load

amps is the available cleaning amps.
2. VESTIBULE AND SEALS

Most blast cabinets have inner and outer seals mounted on vestibules on each end. The vestibules
provide a space between inner and outer seals. The space between the seals is connected to lower
portion of the cabinet so that abrasive that escapes the inner seal can run back into the cabinet.
Seals come in different materials and configurations. They can be sheets of natural rubber,
rubber sunburst segments or nylon brushes.
a. Sunburst Type Conventional pipe machines are designed to run small diameter as well as
larger diameter pipes. In order to maintain a positive seal, each machine must go through an
entry and exit vestibule seal change. A particular seal will cover approximately 4" increment and
seal pipes ranging in sizes from 2" up through the maximum diameter it is designed for
(approximately 36", 48" or 60"). This design is a typical sunburst style utilizing an inner and
outer arrangement of replaceable rubber segments.
NOTE
Seals must be maintained for proper machine ventilation as
well as abrasive retention.
b. Brush Type Brush seals allow air flow through the seal yet contain the abrasive in the cabinet.
Brushes are designed to fit one size pipe. Steel adapters are required for each pipe size. Primary
steel adapters adapt from maximum pipe size to a smaller pipe range i.e. primary adaptor 36''-48''
allows secondary adapters for each size in the range from 28-34. The 36"brush seal mounts
directly on the primary adaptor.
There are two brush seals at each interface: two at the cabinet-to-vestibule interface, two at
the vestibule-to-outside interface. An abrasive resistant rubber sheet in the blast area
protects the innermost brush seals.
MAINTENANCE NOTE
Rotate the brushes approximately 1/8-turn periodically to
spread out wear around the brush. This will increase the life of
the brush seal.
Figure 1.19 Typical Rubber or Brush Sequence Seal.
NOTE
If seals are too tight, conveyor may have difficulty pushing the
pipe through the machine. Increase the diameter of the hole or
make radial cuts around the hole to reduce the drag on the
pipe.
c. Sheet Rubber Type Many blast machines use rubber sheet for seals. The normal material
used for this purpose is natural rubber. The rubber seals are attached to the vestibule with bolts or
wedges. A hole, which is slightly smaller than the outside diameter of the pipe, is cut in the
rubber sheet to match the pipe as it passes through the machine. The hole diameter is usually 2"
smaller than the pipe diameter.
d. Combination Brush & Sheet Rubber Type Use brush seals at the vestibule-to-outside
interface and use sheet rubber for the cabinet-to-vestibule interface. This allows airflow to the
vestibule while the more abrasive-resistant rubber is in the blast area. Both of these help contain
the abrasive.
3. CONTROL SYSTEM PACKAGES
The blast machine typically has a separate control panel that is dedicated to the operation of its
motor components. There are several types of controls as follows:
a. Relay Logic Type. This is the most commonly used system and is simply electromagnetic
components and relays wired to allow the functions to operate sequentially. The control
panel will have operator push buttons located on the panel door and possibly will have
remote operation buttons in the systems main control line.
b. "PLC" Logic Type. This is the new technology that operates the machine functions via a
"PLC". This type of system can be utilized to control wheel speed, abrasive flow and
other functions with simply a program input. It also can supply system repeatability and
performance guarantee with printed documentation if desired.
4. ABRASIVE LEVEL MONITORING SYSTEM
This feature is designed to help the operator control a proper level of abrasive in the
machine to insure a well rounded operating mix. A bin level probe is mounted in the
abrasive storage hopper to monitor the abrasive level. This component can be integrated
with lights in the control panel to indicate levels or can be integrated with an automatic
abrasive adding unit.
NOTE
This eliminates the guesswork on the amount of abrasive in
the machine.
5. ABRASIVE FLOW CONTROL SYSTEMS

Each wheel unit must have its own valve to meter the flow of abrasive. There are several types as
follows:
a. Manual/Mechanical. This type is either a manually operated or air cylinder operated
dipper valve that opens to a pre-set position to achieve full load amps and then closes to
stop the flow.
Figure 1.20a Manual/Mechanical abrasive flow control valve.
b. Automatic Magnetic Variable Abrasive Flow Control. This style is utilized with a
"PLC" and can variably change the flow of abrasive to any degree very precisely via a
program insert. This allows the abrasive flow to be varied for maximum efficiency.
Figure 1.20b Automatic magnetic variable abrasive flow control valve.
RULE OF THUMB:
All wheels must operate at full load amps.
6. WHEEL DRIVES AND SPEED CONTROL

There are two (2) types of wheel drive systems as follows:
a. Unit Bearing Type. This is the most common style that utilizes sheaves and belts which
connect the motor to the unit bearing which is attached to the wheel.
Direct Drive. This is the newer technology that allows the motor to be directly connected to
the wheel itself.
b.
NOTE
Direct drive eliminates loose belt problems.
c. Variable frequency Drives/Variable Wheel Speed This concept allows the variable
control of the wheel speed, which will vary the velocity of the abrasive being thrown.
This can be of value when variations are present in pipe sizes as well as profiles to be
achieved.
7. CABINET LINER PACKAGES
The typical blast machine is fabricated from mild steel that can vary in thickness from 1/4" to
1/2". There are two types of internal lining packages to maximize the abrasive wear resistance as
follows:
a. Manganese Lining. This is a special (11% to 14% Hatfield) work hardening steel that
gives good results against a nominal abrasive in the hardness range of 40 to 50 RC (Steel
shot or soft grit).
b. Cast Chrome Molly Lining. This is the premium design in which cast tiles are bolted to
the inside surfaces and have excellent results against hard grits above 50 RC. This lining
will typically out last manganese by a factor of 15 to 1. The cost of cast linings is
considerably higher than manganese plate. Economics will play an important role in the
decision to use this type of lining.
NOTES
When using steel shot, use a manganese-lined cabinet.
When using hard grit, use a cast chrome molly-lined

cabinet.
MAINTENANCE PROGRAM SUGGESTIONS

MAINTENANCE
All blast cleaning equipment is self destructive, but the key to low cost operations is
PREVENTIVE maintenance. Preventive maintenance anticipates and schedules repairs, and
trains operating and maintenance personnel in the proper use and repair of equipment.
Leaks of any nature are not conducive to economy as the abrasive is lost. Abrasive consumption
is high and hazardous conditions are created for personnel and surrounding equipment.
SUMMARY
Proper surface preparation is an important part of a good pipe coating operation. To ensure
equipment is operating at peak efficiency, be sure to:
Check daily: Wheel components, ammeter wheel flow readings, dust collector
manometer readings, abrasive curtain at separator and blast patterns.
Adjust pipe rotation so that forward travel of pipe through blast machine does not exceed
length of blast pattern.
Maintain a full abrasive curtain in the air wash separators.
Maintain operating mix by making small frequent additions of new abrasive. Never let
abrasive feed hopper fall below 2/3 full.
Maintain daily records of abrasive additions, parts replaced and wheel hours operated.
Screen analysis: One per week at the very minimum; check operating mix, discard from
separator and scalp screen.
Check your mastery of lesson 1
Surface Preparation
ABRASIVE MEDIA
Shot
Grit
Operating Mix
Abrasive media provides the finish to the surface being cleaned. The media falls into two
categories: shot and grit. Both are manufactured to specifications in a variety of sizes and
specific hardness ranges, enabling the user to obtain the desired finish. This lesson addresses
high-carbon cast steel abrasive media only.
High-carbon cast steel shot and grit are manufactured to the following Society of Automotive
Engineers Specifications:
SAE J827: Covers material composition and hardness (shot).
SAE J444: Covers size and new material screening (shot and grit).
SAE JI993: Covers material composition and four (4) hardness ranges (grit).
SHOT
Shot is manufactured in a round shape. Its standard designation is the letter "S" followed by a
number to indicate the size. The number is the approximate diameter, in inches, of the nominal
screen size. For example; "S-280" is shot with a nominal size of approximately .028 inches in
diameter. The higher the number the larger the shot size. The standard hardness of shot is 40-51
HRC.
GRIT
Grit is crushed shot, angular in shape. Its standard designation is the letter "G" followed by a
number to indicate size. The number is the nominal screen size with an opening the same as the
grit number or size. For example; "G-25" is grit with a nominal size of approximately .0278
inches on a #25 screen.
RULE OF THUMB:
Steel shot is usually used in sizes from S-280
through S-390 for cleaning pipe.
RULE OF THUMB:
Steel grit is usually used in sizes from G-50 through
G-16 for cleaning pipe.
NEW SHOT AND GRIT

SIZE SPECIFICATIONS
S.A.E. SHOT SCREENING SPECIFICATIONS
Screen opening sizes and screen numbers with maximum and minimum cumulative percentages
allowed on corresponding screens.
SAE Size No.
Shot Tolerances
Screen Opening
S-1320
All Pass No. 4 Screen
.1870
90% Min on No. 6 Screen
.1320
.1110
.1570
.1110
.0937
.1320
.0937
.0787
.1110
.0787
.0661
.0937
.0661
S-1110
S-930
S-780
S-660
S-550
S-460
S-390
S-330
S-280
S-230
.0555
.0787
85% Max on No. 14 Screen
.0555
.0469
.0787
.0661
.0469
.0394
.0661
.0555
.0394
.0331
.0555
.0469
.0331
.0278
.0469
.0394
.0278
.0234
.0394
.0331
.0234
.0197
S-170
S-110
S-70
.0331
.0278
.0165
.0139
.0234
.0197
.0117
.0070
.0165
.0139
.0070
.0049
S.A.E. GRIT SCREENING SPECIFICATIONS

Screen opening sizes and screen numbers with minimum cumulative percentages allowed on
corresponding screens.
SAE Size No.
Grit Tolerances
Screen Opening
G-10
.1110
.0787
.0661
.0937
.0661
.0555
.0787
G-12
G-14
G-16
G-18
G-25
G-40
G-50
G-80
G-120
G-200
.0555
.0469
.0661
.0469
.0394
.0555
.0394
.0278
.0469
.0278
.0165
.0394
.0165
.0117
.0278
.0117
.0070
.0165
.0070
.0049
.0117
.0049
.0029
.0070
G-325
.0029
.0017
.0049
.0017
GRIT HARDNESS
Grit is available in four (4) SAE hardness ranges. Each manufacturer uses a slightly different
letter designation to identify the four (4) SAE hardness ranges for their product.
The four SAE J1993 hardness ranges are as follows (Hardness ranges listed are from standard
hardness through higher hardness.)
(1) Grit size designation from SAE J444
a. HCS G(1)S - The hardness ranges shall be 40-51 HRC.
b. HCS G(1)M - The hardness range shall be 47-56 HRC.
c. HCS G(I)L - The hardness range shall be 54-61 HRC.
d. HCS G(1)H - The hardness shall be 60 HRC minimum.
90% of the hardness readings shall be within the specified range.
EXAMPLE:
HCS G-25-L indicates a high-carbon cast steel grit meeting the G-25 requirements in SAE J444,
with a hardness designation of L (54-61 HRC).
OPERATING MIX
Cleaning and surface finish is obtained by numerous impacts of the abrasive media. During the
impacting process, the abrasive media is subjected to very high stresses that cause eventual
failure through fracture and fatigue, creating a range of particle sizes. The mix of various particle
sizes is referred to as the operating mix or work mix. A properly balanced mix is essential for
effective results. Larger particle sizes are required to remove rust and scale while smaller sizes
are needed to clean pits and minute crevices. The formation of an operating mix is a continuous,
ongoing process. Once it has been established, it can be controlled by frequent small additions of
new, original size abrasive and removal of undesirable fines.
RULE OF THUMB:
Maintain operating mix by periodically making

small additions of new abrasive and removing all
undesirable fines from the mix.
A number of variables affect abrasive usage and the operating mix, such as:
Velocity of abrasive hitting the work
Hardness of the work being cleaned
Hardness of the abrasive media
Type of anchor pattern desired (profile)
Improper abrasive additions
Separator take out size
Blast cabinet leaks
Dust collector abrasive loss
SCREENING
To ensure the operating mix is maintained, a screen analysis should be taken frequently. This is
done by using a set of standard screens or sieves which are stacked on top of each other with the
largest screen opening on top and decreasing in size to the bottom. A pan on the bottom of the
stacked screens catches whatever passes the smallest screen. A known quantity of operating mix,
by weight or volume, is placed on top screen. The stack is shaken for 5 minutes to allow the
abrasive to sift through the screens. The stack of screens should be tapped on a hard surface
frequently when shaken, to help the sifting action. The volume of abrasive remaining on each
screen is then recorded. The amounts are compared to the original quantity to arrive at the
percentage remaining on each screen.
SAMPLING PROCEDURES
Obtaining samples to be screened is a simple process. An operating mix sample can be obtained
from the separator abrasive curtain below the point of airflow through the separator. Use a
suitable receptacle that can be drawn completely across and through the abrasive curtain flow,
capturing a representative sample after the point of air wash separation. The sample size required
is lb. It is recommended that a sample be taken from the separator discard (dribble pipe) at the
same time as the operating mix sample is taken. This sample is a simple catch test of material
discarded by the separator.
Once screened, the operating mix sample will verify if the mix is balanced with proper size
distribution. The separator discard sample screen results will indicate if the separator is
discarding usable abrasive.
It is also important to do a catch test of the rotary drum screen discard on a daily basis. A screen
test will indicate if usable abrasive is being discarded due to the screen being plugged by paper
or trash material.
Periodically, samples should be taken from the dust collector dust discard and screened to see if
usable abrasive is being lost to the collector.
When taking samples of new abrasive to verify size, be sure to collect the sample from the midportion of the container in which the abrasive was packaged. This will cut down on segregation
of sizes in the container that occurs when material is transported from manufacturer to user.
RULE OF THUMB:
A balanced operating mix can vary depending on
finish required; take out size, hardness of
abrasive, new material additions, and machine
separator capability.
RULE OF THUMB:
Guidelines for a balanced operating mix: 45-55% of sample will be the cumulated
% on the nominal screen. The take out screen would have an individual reading of
2 to 5%.
EXAMPLE:
SCREEN
SIZE
SHOT
S- 280
GRIT
G-25-S
#16 - .0469
CUM % 45 TO 55
NOMINAL SIZE
#18 - .0394
#20 - .0331
#25 - .0278
NOMINAL
NOMINAL
SCREEN
SIZE
SHOT
S- 280
GRIT
G-25-S
#30 - .0234
CUM % 40 TO 53
MID RANGE SIZE
#35 - .0197
#40 - .0165
#45 - .0139
SCREEN
SIZE
SHOT
S- 280
GRIT
G-25-S
#50 - .0117
TAKE OUT
TAKE OUT
IND % 2 TO 5
TAKE OUT SIZE
Once an operating mix is established, it can be maintained with small additions of new abrasive,
removal of undesirable fines, and regular screen analysis. The removal or take out size represents
the undesired fines remaining in the mix.
If undesirable fines are not removed from the operating mix, they could be deposited on the pipe
and may contaminate the steel surface. This is visible as dark particles on the backside of coating
chips removed from the pipe.
RULE OF THUMB:
Abrasive larger than the established take out size
should not appear in separator fines discard
(dribble pipe).
BACKSIDE CONTAMINATION
The pipe coating industry has always maintained concerns regarding backside contamination that
remains on the pipe after surface preparation. This backside contamination is normally the result
of an expanded operating mix with too many fines. This is normally the result of a
malfunctioning separator or dust collector, or a combination of both.
RULE OF THUMB:
Backside contamination is usually the result of too
many undesirable fines in the operating mix.
ABRASIVE CONSUMPTION
Abrasive consumption depends on the breakdown characteristics of the abrasive, velocity
thrown, abrasive flow rate, horsepower of wheels, take out size, and leaks or loss at the machine.
Abrasive consumption should be monitored by usage per wheel hours. Keep track of wheel hours
run and abrasive added over a given time period. This will establish consumption by wheel hour.
RULE OF THUMB:
Standard hardness (40-51 HRC) shot consumption
should run approximately lb. per horsepower per
wheel hour.
RULE OF THUMB:
Guideline abrasive consumption
rates per lb. by horsepower,
hardness and type.
S=STEE
L SHOT
G=STEEL GRIT BY
HARDNESS
H.P
.
GS GM GL
GH
10
5.1
6.3
9.6
37.5
15
7.5
7.7
9.4 14.4
56.2
20
10
10.3 12.6 19.3
75
25
12.5 12.8 15.7 24.1
93.7
30
15
15.4 18.9 28.9
112.5
40
20
20.6 25.2 38.6
150
50
25
25.7 31.5 48.2
187.5
60
30
30.9 37.8 57.9
225
75
100
37.5 38.6 47.2 72.3

50
51.5
63
96.5
281.2
375
This general guideline can be

different due to abrasive loss and
wheel velocity.
RULE OF THUMB:
Standard "S" hardness abrasive breaks down
slower than harder abrasive.
CLEANING EFFICIENCY
Cleaning efficiency is a direct result of size of abrasive used, the velocity of the abrasive, and
amount thrown per minute. For efficient cleaning, it is important to throw as many pellets as
possible from new material size through the established take out size. The more pellets thrown
using a balanced operating mix gives coverage which increases speed of cleaning.
A balanced operating mix provides a greater number of impacts. See charts below on number of
pellets of shot and grit by size in new material. As you can see, as the material down sizes in a
mix, the pellet count per pound goes up.
RELATIONSHIP OF SHOT/GRIT SIZE TO COVERAGE
SAE GRIT SIZE
(MID RANGE)
SAE SHOT SIZE

(MID RANGE)
APPROXIMATE PELLETS PER LB.

GRIT
SHOT
G-10
S-780
7,400
8,000
G-12
S-660
12,500
14,000
G-14
S-550
23,200
26,000
G-16
S-460
40,500
45,000
G-18
S-390
54,500
65,000
S-330
G-25
S-280
110,000
175,000
S-230
210,000
360,000
G-40
S-170
440,000
520,000
G-50
S-110
1,300,000
1,700,000
G-80
S-70
4,400,000
6,000,000
SUMMARY
Maintain a full abrasive curtain at the air wash separators.
abrasive feed hopper go below 2/3 full.
Screen analysis: one per week at the very minimum; check operating mix, discard from
Defining Blast Cleaning and Profile

DEFINITION OF BLAST CLEANING
Blast cleaning can be defined as an impact-cleaning operation in which the work surface is
pounded by successive impacts of abrasive. An effective blast cleaning operation is a function of
proper abrasive selection, shot or grit, blast wheel speed, and proper work-mix size distribution.
DEFINITION OF PROFILE
Surface profile, which is also called etch, anchor pattern or texture, is a measurement of surface
roughness resulting from abrasive blast cleaning. The height of the surface profile is measured
from the bottom of the lowest valleys to the tops of the highest peaks. The profile depth or height
is dependent upon the size, type (shot or grit), and hardness of the abrasive, particle velocity and
angle of impact, hardness of pipe surface, and amount of size distribution in recycled work mix.
DEGREES OF CLEANING
Blast cleaned surface cleanliness is categorized by NACE (National Association of Corrosion
Engineers) and SSPC (Steel Structures Painting Council) into four (4) grades. The four grades
are defined as follows:
BRUSH-OFF Blast Cleaned Surface Finish:
When viewed without magnification, is a surface from which oil, grease, dirt, loose rust, mill
scale, paint, or coatings can be removed. Tightly adhering mill scale, rust, paint, and coatings are
permitted to remain if they have been exposed to the abrasive blast pattern, and numerous flecks
of the underlying metal are uniformly distributed over the entire surface. REF: NACE No. 4
and/or SSPC - SP7.
COMMERCIAL Blast Cleaned Surface Finish:
When viewed without magnification, is a surface from which oil, grease, dirt, rust, scale, and
foreign matter have been completely removed. All rust, mill scale, and old paints or coatings
have been removed except for slight shadows, streaks, or discoloration caused by rust stain or
mill scale oxide binder. At least two thirds of the surface shall be free of all visible residues. The
remainder shall be limited to light discoloration, staining, or light residues mentioned above. If
the surface is pitted, slight residues of rust, paint, or coatings are found in the bottom of the pits.
REF: NACE No. 3 and/or SSPC - SP6.
NEAR-WHITE Blast Cleaned Surface Finish:
When viewed without magnification, is a surface from which all oil, grease, dirt, mill scale, rust,
corrosion products, oxides, paints, coatings, or any other foreign matter have been removed
except for light shadows, streaks, or slight discoloration of oxide bonded with metal. At least
95% of the surface area has the appearance of a white metal blast and the remainder of the area is
limited to slight discoloration. REF: NACE No. 2 and/or SSPC - SP10.
WHITE-METAL Blast Cleaned Surface Finish:
When viewed without magnification, is a surface with a gray-white metallic color, roughened to
a suitable profile for coatings. The surface is free of all oil, grease, dirt, mill scale, rust, corrosion
products, oxides, paint, and any other foreign matter. REF: NACE No. 1 and/or SSPC - SP5.
There are visual standards available through the NACE and SSPC which clearly show each of
the four (4) grades. The visual standards are helpful tools in determining degree of cleaning.
SURFACE FINISH AND PROFILE

Surface finish and profile on the work piece is created by the size of the shot or grit thrown and
its velocity. The larger the abrasive particle, the harder it hits, transferring that energy to the
work piece. As each particle hits, it indents or etches the surface, leaving a profile. The chart
below will help illustrate the impact relationship by size at standard velocity.
The above chart shows impact value by size.

Example: G-80 grit and S-70 shot have an impact value of 1. G-18 grit and s-390 shot have an
impact value of 100. The chart illustrates that G-18 and/or S-390 hit the work surface 100 times
harder than the smaller G-80 or S-70.
RULE OF THUMB:
Large shot or grit results in fewer pellets
per pound and effects coverage.
RULE OF THUMB:
At standard velocities, large shot or grit

delivers more impact than smaller sizes
(more profile).
RULE OF THUMB:
When selecting an abrasive size (shot or
grit), always choose the smallest size
possible to give the desired cleaning
profile results.
PROFILE
Profile on the pipe surface is critical for proper adhesion of the coating. Profile is created by the
shot and grit thrown by the wheels. Shot leaves a rounded profile and grit leaves a sharp or
peaked profile. Larger sizes of abrasive leave a higher profile. For pipe coating, grit is preferred
over shot for the type of profile desired. Hard grit delivers a more distinct profile than softer grit
due to its hardness and break down characteristics. Also, when blasting hard pipe the harder grit
impacts the hard surface better.
RULE OF THUMB:
Hard grit creates a sharper profile then
softer grit or shot.
RULE OF THUMB:
Various profiles achieved with shot and
grit
1 Mill Profile
1.5 Mil Profile
G-80
G-50
S-110
S-170
2 Mil Profile
2.5 Mil Profile
G-40
G-40, G-25
S-230
S-280
3-4 Mil Profile

G-25, G-16
S-330, S-390
This is profile guideline information only.
Actual profiles could be significantly
different due to abrasive hardness, wheel
speed, angle of impact, or hardness of the
surface being blasted.
SUMMARY
equipment is operating at peak proficiency, be sure to:
Additional Surface Preparation

This chapter is about the surface treatment of pipe prior to application of fusion-bonded epoxy
coatings. It includes a short section on cleaning pipe prior to blasting as well as washing/surface
treatment after blasting. Its purpose is to:
Discuss background reasons for considering additional surface preparation.
Describe the mechanical steps in acid wash and in surface treatment.
Review options and plant layout.
BACKGROUND
There is no question that a contaminant on a steel surface will result in reduced performance
properties of ALL coatings. This is also true of fusion-bonded epoxy coatings.
This chapter is only a brief overview of some of the contaminants that may be found on steel
pipe surfaces. For more information on this subject see the Tenneco Gas MQ-845, "Surface
Contamination: Sources and Tests," and NACE Publication 6G186, "Surface Preparation of
Contaminated Steel Surfaces."
CONTAMINANTS
OIL AND GREASE
Oil and Grease can come from a variety of sources--equipment in a pipe manufacturer's plant,
railroad ties, port or ship's tackle, the applicator's handling and conveying equipment, or
contaminated abrasive. If the pipe is in a generally rusted condition, an unrusted area will likely
be contaminated with grease or oil.
CONTAMINATION
A SLOW DAWNING
"We first suspected a contamination problem
when we ran some blast cleaned pipe out in
the yard. After two days in the rain we noticed
the pipe hadn't rusted."
1979 Germany
"We found the contamination problem by
accident. We had some blast cleaned panels
stored near a steam bath. After a few hours
some panels got rust spots - some didn't."
1981 Newcastle Upon Tyne

"I know we're doing a good job of cleaning.
I've had blast cleaned parts in my garage for
months and they didn't rust."
1983 Indiana
Recirculating blast-cleaning machines used in pipe coating mills are very effective tools for
spreading concentrations of contaminated material over very large surface areas. Therefore, it is
essential to remove oil and grease prior to the blast cleaning process. Solvent or detergent wash
or steam cleaning are effective methods. If detergent wash is used, employ a thorough rinse after
the washing operation to remove all detergent.
WATER-SOLUBLE OIL
Water-soluble oil is used during the manufacture of ERW pipe. The term water-soluble oil is a
misnomer. It is actually an oil/water emulsion, which contains microscopic droplets of oil
suspended in the water. Freshly rolled ERW pipe will have a sooty film (often called carbon or
smut) on the surface. This film is composed of an oil and mill scale mixture and weathers away
fairly quickly when exposed to the elements. Repeated wetting (approximately 30 days) of the
pipe accelerates the weathering process. Steel pipe manufacturers remove it by detergent
washing prior to shipment.
Field experience indicates that acid wash after mechanical blasting is also effective to remove
smut.
ETHYLENE GLYCOL
Anti-freeze materials such as ethylene glycol are used to prevent freezing of hydro test water.
These materials often get on the pipe and must be treated like water-soluble oil.
RULE OF THUMB:
"...visual appearance of a steel surface,
immediately after blast cleaning, is an
unreliable means of identifying either the
presence or the type of contaminant."
NACE Publication 6G186
FERROUS SALTS
An example of ferrous salt is table salt also called sodium chloride or NaCl. However, ferrous
salt contamination, includes a whole class of inorganic compounds such as sulfates and nitrates.
These compounds possess a common property with table salt - they can cause a reduction in
adhesion of the coating to the steel and/or porosity (foam bond) in the coating itself.
Synthetic Sea Water

sodium chloride (NaCl)
potassium chloride (KCl)
2815 g
67 g
magnesium chloride (MgCl2 6H2O)
551 g
magnesium sulphate (MgSO4 7H2O)
692 g
calcium chloride (CaCl2)
145 g
water
100 liters
Figure 4-1 Seawater is a common source of salt contaminations.

How does salt contamination get on the steel surface; where does it come from?
Common sources of salt contamination include salt used for road deicing and from seawater.
Seawater contamination can be a result of direct contact with seawater or from ocean side
storage of either the rolling plate or the pipe itself. Another possible source of salt contamination
is acid rain.
Figure 4.2 Acid rain can also result in salt contamination of the pipe.
SURFACE TREATMENTS
There are many kinds of pipe surface contaminants that cannot be adequately removed by blast
cleaning. For this reason, many in the pipe coating industry believe that additional surface
preparation steps need to be considered. Surface treatments now in practice include:
Cleaners
Cleaners are materials and processes such as high-pressure water, detergent, or acid washes that
remove contaminants from the steel surface. Although the intent of this process is contamination
removal, the cleaning agents may also enhance the surface properties of the steel.
Enhancers
Enhancers are treatments deposited on the steel surface to improve the performance properties of
coatings. In fact, the improvement may be such that it can overcome the negative effects of lowlevel concentrations of contaminant. The next steps spell out in general terms the application
process for an acid wash (cleaner) and for a chromate treatment (enhancer). The specific
application steps for cleaners and enhancers depend on the recommendations of the manufacturer
of the product used. Read all Health Hazard, Precautionary, and First Aid statements found in the
Material Safety Data Sheet, and/or product label of chemicals prior to handling or use.
ACID WASH (Cleaner)
Thc acid wash process is fairly simple.
1. Wet out the pipe surface with the cleaning agent
2. Let it work.
3. Rinse.
RULE OF THUMB:
The higher the pipe temperature (below
the boiling point of water) the more
effective the cleaning step.
The longer the dwell time - the longer the
cleaning agent is in contact with the pipe
surface - the more effective.
Do not let the cleaning agent dry before
the rinse step.
The actual process conditions depend upon the chemical cleaning agent employed, the condition
of the pipe surface, and the level of contaminants. For phosphoric acid wash the following
general steps are applicable:
Blast Clean - blast clean the pipe surface to remove all mill scale. Grind to remove slivers and
other unacceptable surface imperfections before the acid wash.
Application - apply the cleaning agent uniformly over the pipe surface using either a spray or
gravity feed method.
Dwell Time - with an acid wash there is a chemical reaction between the cleaning agent and the
steel. This chemical reaction is time/temperature dependent. In a typical operation, the pipe will
be at a temperature of about 110 degrees Fahrenheit (49 degrees Celsius), and the dwell time will
be on the order of 21 seconds. Some specifications require the extension of the dwell time by one
second for each degree below the typical temperature. Check the acidity of the cleaning agent on
the steel using pH paper. It should be at a pH of two or less - indicating a strong acid.
Rinse - remove the acid wash and dissolved contaminants by rinsing. Some specifications
require the use of high-pressure water [500 to 1,000 psi (3500-7000 KPa)] in the rinse step. The
high pressure may be useful in removing solid particulates imbedded in the steel by the blast
cleaning process. Other specifications require a water rinse without high pressure. In any event,
the objective is removal of both the acid and contaminants. Using pH paper on the rinsed pipe
surface can check this. The pH should be greater than six or at least near the pH of the water
used to rinse the pipe. Rinse additives can be used to reduce flash rust and to improve coating
performance, if required.
Dry - the pipe is then dried quickly to minimize oxidation. Techniques used are squeegee, air
knife, or heating elements (gas-fired furnace). If an air knife is used, the high-pressure air supply
should be routed through oil traps and filters to remove any contaminants.
Disposal - check with the supplier of the cleaning agent for safe disposal procedures.
An acid wash station requires a significant amount of space because of the required dwell time
between the wash and rinse steps. An example of the layout for an acid wash station follows:
Figure 4-3 Set up for acid wash station.
Figure 4-4 An acid wash stem after final blast clean allows the surface to remain chemically
active.
Advantages of Figure 4-4:
In the case of phosphoric acid wash, there is evidence that the phosphate surface provides
improved performance in the subsequent coating.
Immediate furnace heating after acid wash rinse reduces flash rust.
Disadvantages of Figure 4-4:
There is the possibility of contamination carry through from one blast machine to the
next. See QC TESTS
The anchor pattern is not easily reestablished after grinding, unless allowable by specific
conditions.
Figure 4-5 An acid wash step before final blast clean keeps the last machine
uncontaminated.
Advantages of Acid Washing Between Cleaning Machines:
Allows ground areas to be reblasted to establish the anchor pattern.
Contamination should not carry from first machine to second.
Contamination is removed prior to final blasting.
Disadvantages of Acid Washing Between Cleaning Machines:
Many present plants are not set up with space between two blast machines.
If phosphoric acid wash is used, there is evidence that the phosphate surface does provide
improved performance in the subsequent coating. Blasting after wash may remove
phosphate coating.
Figure 4-6 A typical surface treatment takes less space than acid wash.
Figure 4-7 An acid wash followed by surface treatment provides cleaning as well as an
active surface for improved coating adhesion.
SUMMARY
For best performance, all coatings require a good surface for application. Chapter 1 described
aspects of mechanical treatment of the steel surface. This chapter reviewed techniques and
procedures for further improvements in surface preparation through chemical cleaning and
treatment. Plant layout can affect both productivity and product performance. Several diagrams
provide a few of the many possibilities.
Some specifications now require a chemical surface preparation step; many others mention it, but
allow the applicator to make the decision.
Pipe Heating
In the fusion bonded epoxy coating process there is a need to heat the pipe prior to cleaning and
application of the epoxy resin. The steps to compete these functions, the types of equipment
utilized and the temperature measurement procedures are as follows:
1. HEATING PRIOR TO PIPE CLEANING: The proper cleaning of the pipe surface
requires that any moisture on the pipe be removed and the pipe surface temperature is
above the dew point to prevent reformation of water on the surface. If the surface is wet
the oxides removed in the cleaning machines will adhere again to the moist surface and
impair the coating bond. The pipe is generally heated by means of gas fired tunnel type
ovens or electrical induction coils as shown in Figures 1.1 & 1.2.
Figure 1.1
Figure 1.2
The gas fired heater permits the pipe to pass through the center of a gas fired radiant heater or a
direct impinging flame. The temperature of the pipe is controlled by the settings on the gas fired
heater and the rate of speed of the pipe going through the heater. The heater must be coordinated
with the conveyor stopping and starting, so as not to over heat the pipe when the conveyor is shut
down. In a similar manner the induction-heating coil can be controlled for output and the line
speed may be varied as well to increase or decrease the pipe temperature. The dew point
temperature is defined by using a sling hygrometer to determine the dewpoint temperature and
then a safety factor is added, such as 10% to ensure the pipe does not drop below the dewpoint
due to other variables. Typical preheat temperatures are generally in the 125F range. It is
essential to maintain a consistent preheat temperature, joint to joint, to provide for optimum
heating control on the coating line prior to powder application. If the pipe heat prior to epoxy
powder application moves outside of the specified temperature parameters the performance
properties of the coating may deteriorate.
2. HEATING OF PIPE PRIOR TO EPOXY POWDER APPLICATION: Epoxy powder
resins require application temperatures of 450-480F and a minimum period of time at this
temperature to wet out and cure in order to provide the specified performance parameters. The
details of this heating and curing process are described in other chapters of this training course.
To heat the pipe to the specified temperature gas fired ovens or electrical induction coils are
utilized. Generally a series of 3 to 5 gas fired radiant ovens are used, that allow the pipe to pass
through the center while being heated. (Figure 1.3)
Figure 1.3
The temperature of the pipe is controlled by the output of the ovens and the rate of travel of the
pipe passing through the oven. In a similar fashion the induction heating coils output and the
speed of the pipe are used to control the heat of the pipe.
Figure 1.4
With the pipe heated to the required high temperatures it is necessary to have solid metal
conveyor heads between the ovens and the epoxy application booth. If rubber tired conveyor
heads are used the rubber will degrade and particles of rubber may adhere to the pipe and inhibit
the bond between the coating and the pipe surface.
3. TEMPERATURE MEASUREMENT DEVICES: The monitoring of the pipe temperatures
is essential for process control and there are generally three devices used:
A. Melt Crayon: Temperature sensitive compound that will melt at a specified temperature. The
melt crayon is touched on the pipe as it rotates along and the operator observes if the small mark
of material melts out and shows a sight change in color. The melt crayon sticks have
approximate 15 F temperature range sensitivity.
B. Infrared Pyrometer: This device measures infrared radiation emitted from the pipe and
displays the pipe temperature in either degrees Fahrenheit or Celsius. The unit must be calibrated
for the degree of emissivity of the bare steel pipe that affects the level of infrared radiation
reaching the instrument. The surface conditions of each pipe can vary somewhat and for this
reason this device may provide a wider indications of bare pipe temperatures. The device is more
applicable to monitoring the temperature of the FBE coated pipe, which is much more consist, in
the level of infrared radiation emitted to the instrument. The instrument is available in either a
fixed mounted style or a hand held unit. The fixed unit can have permanent recording
attachments to document pipe temperatures. Calibration of the unit requires the use of a hand
held contact thermocouple.
C. Contact Thermocouple: This instrument combines a thermocouple contact device with a
temperature readout unit and provides very accurate pipe temperature readings. The contact unit
is available in two configurations that provides for temperature readings from either fixed or
rotating pipe.
Powder Application Process and Systems

Successful application of powder coatings requires properly designed powder application
processes and pipe handling systems that will work with various powder coating formulations.
This chapter discusses the following topics:
Powder Application Properties of the coating material
Gel Time Definition, effect of temperature and temperature measuring devices.
Pick-up Time - Definition, importance of application speed.
Cure time - Definition, effect of application temperature, cool down rate and product cure
requirements.
Coating thickness Factors include line speed, application temperature, gun output and
electrostatic voltage. Coating thickness can affect cure time.
Coverage Specific gravity
Powder Application Systems
Illustrations of general systems currently in use with advantages and disadvantages of

each
Equipment elements.
Dust collectors.
Screens Operation and equipment illustrations
Magnets.
Rotary valve Illustration.
Powder gun output.
Fluid bed Purpose and illustration.
Feed lines Flow versus pressure and size.
Air dryers.
Figure 6.1 Pipe being coated in a continuous process coating plant
Powder Application
Properties of the Coating Material
To optimize economics, it is desirable to apply powder that meets end product performance
requirements at a high production rate.
Assuming the pipe can be cleaned and heated at the desired rate, the powder application system
must have the capacity to provide the quantity of powder required to meet coating thickness
requirements.
Properties of the powder that affect application rate are:
Gel Time
Pick up Time
Cure Time
Coating Thickness
Coverage
Gel Time
Gel time is the time elapsed between powder melting and solidification. It varies with
powder formulation and application temperature. (Figure 6-2) The temperature measuring
device can affect gel time results. A typical example is shown in Figure 6-3 where a
Thermo-Electric Co, hotplate with an internal probe thermometer was used. The hot plate
surface temperature was also measured with a surface thermocouple and a surface
thermometer. Approximately 30F difference existed between the devices. This
difference results in gel time variations as shown in Fig.6-4.
Fig 6-2 Coating material gel time varies with product and application temperature
Figure 6-3 Surface temperature may vary by as much as 40F. from gel plate internal
thermometer.
RULE OF THUMB:
Gel time calculations can be affected
by measuring devices.
TYPICAL GEL TIMES
Fig 6-4 Using different temperature measuring devices to set the gel plate temperature will
result in different surface temperatures. Gel time will vary depending upon the device
used.
PICK UP TIME
This is the time required for the applied coating to develop sufficient strength to support the
weight of the pipe on the transport wheels without damage to the coating. The elapsed time
between the last powder gun in the coating booth and the next conveyer wheel is the pick up
time. This time is also known as "time to touch."
Factors in predicting pickup time include gel time, cure time and pipe weight. Gel time alone is
not a good predictor of pickup time. For most currently used systems, the pickup time should be
3 5 seconds longer than the gel time. Pipe size and wall thickness affects gel time and cure,
therefore a visual inspection is necessary to determine pickup time. Powder manufacturers are a
good source for estimated pickup times.
RULE OF THUMB:
Pickup time should be 3-5 seconds
after gel time.
Higher Application Temperature

Lower Application Temperature
Longer gel time
Longer pick up time
Longer cure time
Slower line speeds
Shorter gel time
Shorter pick up time
Shorter cure time
Faster line speeds
Potential porosity
Figure 6-5 Pickup time is a function of powder gel and cure time, application temperature,
and pipe weight.
CURE TIME
This is the time required to complete the chemical reaction of the applied powder coating.
Application temperature and cooling rate of the pipe along with powder formulation are factors
affecting the cure time. Powder coatings on pipe with thinner walls will cure at a slower rate than
pipe with thicker walls. Since coating cure is a function of temperature and time, the cooling rate
of the pipe must be considered when determining time to quench.
RULE OF THUMB:
Use the lowest measured pipe
temperature to calculate time to
quench.
Fig 6-6 Cure time for FBE powder versus application temperature for various pipe wall
thicknesses.
POWDER APPLICATION SYSTEMS

Existing powder application systems are fairly similar. They will vary in the type of components
and accessory equipment, but they all operate on the basic concept of feeding powder into a
system, electrostatically spraying it onto the heated pipe, and collecting the over spray for reuse.
The following system variations are the most common in use today.
Example #1
Virgin powder is fed into a virgin bin. This is generally a manual operation unless the plant is
equipped to handle the 2500 lb. reusable bags rather than the 60 lb boxes. Reclaim powder is
drawn from the coating booth by the reclaim collector where a rotary valve discharges it to a
reclaim bin. The main collectors draws material from both the virgin and reclaim bins,
combining them after each has passed through ratio valves. The valves can automatically control
opening and closing times. The setting of each ratio valve determines the ratio of virgin and
reclaims powder fed to the main collector. A rotary valve from the main collector to the
screening equipment discharges the mixture. Usable powder passes through the screens to the
fluid bed. Unusable powder is rejected in the screening process.
Figure 6-7 Example #1 of powder system, all powder is screened and reclaim ratio is
controlled.
Advantages:
Controlled ratio of virgin to reclaim powder. Some specifications set a maximum ratio.
All material is screened just prior to the fluid bed.
Disadvantages:
Some extra equipment required.
Example #2
Virgin powder is fed into the virgin hopper. Reclaim material is drawn from the coating booth by
the reclaim collector. A rotary valve discharges reclaim powder to the screen system. Level
controls in the fluid bed start and stop a screw conveyor that adds virgin material to the reclaim
prior to entering the screen system. Useable powder is passed through the screens to the fluid
bed. Unusable material is rejected at the screens.
Figure 6-8 Example #2 of powder system. All powder is screened, reclaim continuously
used.
Advantages:
Minimum equipment required.
Reclaim powder continually used up.
All material screened just prior to the fluid bed.
Disadvantages:
No quick way to determine virgin to reclaim ratio.
Example #3
Virgin material is fed into a fluid bed storage bin. Reclaim material is picked up from the coating
booth by the reclaim collector. A rotary valve discharges the reclaim into the screen equipment.
Useable powder is passed into the fluid bed storage and unusable powder is rejected. The main
collector draws the mixture of virgin and reclaims powder from the storage bin. This mixture is
then discharged through a rotary valve into the fluid bed that feeds the electrostatic guns.
Figure 6-9 Example #3 of powder system Virgin material is not screened.

Advantages:
If storage bin is fluidized with dry air, there may be additional moisture control in the
system.
Disadvantages:
Excess equipment.
Virgin material entering the fluid bed is not screened.
Example #4
Virgin material is loaded into the virgin hopper where it is gravity fed through a rotary valve into
the screen equipment. Reclaim is drawn from the coating booth by the reclaim collector and is
fed through a rotary valve to the screen equipment. Useable powder is passed to the fluid bed and
unusable powder is rejected.
Figure 6-10 Example #4 of powder system. Virgin material is screened.

Advantages:
Minimum equipment required.
All material screened just prior to fluid bed.
Disadvantages:
No quick way to determine virgin to reclaim ratios.
SCREENS
The majority of screens found in powder application systems are the vibrating type. A typical
unit is the SWECO Vibro-Energy Separator. The purpose of this equipment is to remove
oversized particles from the material being fed to the fluid bed that supplies the electrostatic
guns.
Figure 6.11 The SWECO Vibro-Energy Separator

The SWECO Separator vibrates about its center of mass. Vibration is accomplished by eccentric
weights on the upper and lower ends of the motor shaft. Rotation of the top weight creates
vibration in the horizontal plane, which causes the material to move across the screen to the
periphery. The lower weight acts to tilt the machine in the vertical plane. The angle of lead given
the lower weight provides variable control of the spiral screening pattern. The actual lead and
spiral pattern is established by trial and error: The optimum pattern would be similar to that
shown for a 35-degree lead.
Product A is manufactured in such a way that less than 1% by weight will not pass through an 80
mesh screen. 45 - 60% of the material will pass a 325 mesh screen. During the reclaim process,
some of the powder particles may fuse together or agglomerate. In addition, foreign material may
be picked in the hoppers, ductwork, rotary valves or other equipment in the recycle/reclaim
system. The screen equipment rejects all unsuitable particles.
Sieve Designation
Sieve Opening
Nominal Wire Diameter*
Standard
Alternativel
y
mm
in. (approx
equivalents)
mm
in. (approx
equivalents)
107.6 mm
4.24 in.
107.6
2.24
6.40
0.2520
101.6 mm
4 in.**
101.6
4.00
6.30
.2480
90.5 mm
3-1/2 in.
90.5
3.50
6.08
.2394
76.1 mm
3 in.
76.1
3.00
5.80
.2283
64.0 mm
2-1/2 in.
64.0
2.50
5.50
.2165
53.8 mm
2.12 in.
53.8
2.12
5.15
.2028
Tyler
equivalent
designation
50.8 mm
2 in.**
50.8
2.00
5.05
.1988
45.3 mm
1-3/4 in.
45.3
1.75
4.85
.1909
38.1 mm
1-1/2 in.
38.1
1.50
4.59
.1807
32.0 mm
1-1/4 in.
32.0
1.25
5.23
.1665
26.9 mm
1.06 in.
26.9
1.06
3.90
.1535
25.4 mm
1 in.**
25.4
1.00
3.80
.1496
22.6 mm
7/8 in.
22.6
0.875
3.50
.1378
0.883 in.
19.0 mm
3/4 in.
19.0
.750
3.30
.1299
.742 in.
16.0 mm
5/8 in.
16.0
.625
3.00
.1181
.624 in.
13.5 mm
0.530 in.
13.5
.530
2.75
.1083
.525 in.
12.7 mm
1/2 in.**
12.7
.500
2.67
.1051
11.2 mm***
7/16 in.
11.2
.438
2.45
.0965
.441 in.
9.51 mm
3/8 in.
9.51
.374
2.27
.0894
.371 in.
8.00 mm***
5/16 in.
8.00
.312
2.07
.0815
2-1/2 mesh
6.73 mm
0.265 in.
6.73
.265
1.87
.0736
3 mesh
6.25 mm
1/4 in.**
6.35
.250
1.82
.0717
5.66 mm*** No. 3-1/2
5.66
.223
1.68
.0661
3-1/2 mesh
1.050 in.
4.76 mm
No. 4
4.76
.187
1.54
.0606
4 mesh
4.00 mm***
No. 5
4.00
.157
1.37
.0539
5 mesh
3.36 mm
No. 6
3.36
.132
1.23
.0484
6 mesh
2.83 mm***
No. 7
2.83
.111
1.10
.0430
7 mesh
2.38 mm
No. 8
2.38
.0937
1.00
.0394
8 mesh
2.00 mm***
No. 10
2.00
.0787
0.900
.0354
9 mesh
1.68 mm
No. 12
1.68
.0661
.810
.0319
10 mesh
1.41 mm***
No. 14
1.41
.0555
.725
.0285
12 mesh
1.19 mm
No. 16
1.19
.0469
.650
.0256
14 mesh
1.00 mm***
No. 18
1.00
.0394
.580
.0228
16 mesh
841
No. 20
0.841
.0331
.510
.0201
20 mesh
707 ***
No. 25
.707
.0278
.450
.0177
24 mesh
595
No. 30
.595
.0234
.390
.0154
28 mesh
500 ***
No. 35
.500
.0197
.340
.0134
32 mesh
420
No. 40
.420
.0165
.290
.0114
35 mesh
354 ***
No. 45
.354
.0139
.247
.0097
42 mesh
297
No. 50
.297
.0117
.215
.0085
48 mesh
250 ***
No. 60
.250
.0098
.180
.0071
60 mesh
210
No. 70
.210
.0083
.152
.0060
65 mesh
177 ***
No. 80
.177
.0070
.131
.0052
80 mesh
149
No. 100
.149
.0059
.110
.0043
100 mesh
125 ***
No. 120
.125
.0049
.091
.0036
115 mesh
105
No. 140
.105
.0041
.076
.0030
150 mesh
88 ***
No. 170
.088
.0035
.064
.0025
170 mesh
74
No. 200
.074
.0029
.053
.0021
200 mesh
63 ***
No. 230
.063
.0025
.044
.0017
250 mesh
54
No. 270
.053
.0021
.037
.0015
270 mesh
44 ***
No. 325
.044
.0017
.030
.0012
325 mesh
37
No. 400
.037
.0015
.025
.0010
400 mesh
* These specifications are primarily for testing sieves. Many commercial screen cloths employ
wire diameters considerably different from those of the standard series.
** These sieves are not in the fourth root of 2 series but they have been included because they
are in common usage.
*** These sieves correspond to those proposed as an international (ISO) standard. It is
recommended that whenever possible these sieves be included in all sieve analysis data or
reports intended for international publication.
Table 6-1. U.S. Sieve Series and Tyler Equivalents (Courtesy of SWECO Inc.)
MAGNETS
In addition to a screen separator, the system should include a magnetic separator. These are
common in nearly all bulk handling systems such as the food, industry, chemicals, and
pharmaceuticals.
"Grate" magnets should be installed at the powder inlet of the fluid bed, or bar magnets can be
suspended in the fluid bed. Magnet manufacturers offer a wide variety of magnets to suit most
applications.
ROTARY VALVE
The rotary valve function is to provide an air seal at the collector while permitting material to be
discharged. Typical construction is shown in fig 6-15. The rotor contains multiple blades,
uniformly spaced similar to a paddle wheel. At any position on the rotor the valve is closed.
Material in the collector cannot flow from the inlet to the outlet. As the rotor turns, material
dropping from the collector enters the inlet side and fills the voids between the blades. As the
blades rotate, the material is gravity discharged into the outer section.
Figure 6-12 Exploded view of a rotary valve assembly.

Rotary valves are available in various sizes. Capacity is rated as volume discharge per
revolution. Speeds are kept low to minimize heating. Heat will cause the powder to melt,
resulting in partially cured powder buildup on the end plate faces and other internal surfaces.
Eventually, this partially cured powder will break loose and be discharged with usable material.
The result is chunks of solidified coating in the coating system. They can cause abnormalities in
the pipe coating and can clog coating lines, etc. This is a good reason for final screening before
the powder enters the fluid bed and coating guns.
POWDER FLOW/GUN OUTPUT
Equipment described in this section is the heart of the powder application system.
FLUID BED
The purpose of the fluidizing bed is to change its state from bulk form to a fluidized state where
individual particles are suspended in an air stream. In this condition, the powder tends to flow
more like a liquid and is easily transported. The bed consists of a container divided into two
sections by a porous membrane that is sealed at the edges on both sides. Air passes uniformly
through the membrane and up through the powder.
Figure 6-13 The heart of the powder application system consists of a fluidized bed, a
venturi feed, and the electrostatic gun.
Figure 6-14 The fluid bed makes the powder more easily transportable.
Potential problems with a fluid bed are:
Leaks in either chamber, particularly at the membrane.
Non-uniform air distribution through the membrane.
Need for extremely dry non-contaminated air.
PUMP/VENTURI
This device picks up powder from the fluidizing bed and mixes it with an air stream, which
transports it through the feed lines to the electrostatic guns. Pump/Venturi assemblies come in
different shapes and configurations, but all work on the venturi principle. Air leaving the nozzle
is directed into the flared opening of the venturi insert. Due to the velocity change, the pressure
in the area around the nozzle is reduced. As a result of this reduced pressure, an air/powder
mixture is drawn from the fluid bed. The quantity of powder drawn is a function of the nozzle
opening, supply air pressure, venturi design, and the location of the venturi insert relative to the
nozzle. The assembly is usually made of steel, aluminum or brass, except for the venturi insert,
which is a low friction material such as Teflon.

Since the powder is abrasive, the venturi insert wears rapidly, and the pressure drop around the
nozzle is affected. This reduces the quantity of material drawn from the fluid bed and can result
in gun surging and loss of thickness control.
Figure 6-15 The venturi pulls the powder out of the fluid bed and transports it to the feed
lines.
FEED LINES
The size and length of the feed lines also play a role in the quantity of powder delivered to the
spray guns. At a given air pressure, a longer line or one with a smaller diameter will increase the
resistance and result in reduced powder flow. Too large a diameter will cause pulsating flow.
To assure the system is operating at peak efficiency, a flow test should be run on each gun or at
least a representative example of guns with new venturi inserts. The results should be saved for
comparison to later test results. An alternate procedure is the use of the Venturi Tester .
POWDER FLOW VS VENTURI PRESSURE AND LINE SIZE
Figure 6-16 Increasing line diameter or air pressure increases the amount of powder fed to
the guns. Increasing the length of the feed lines decreases powder output.
The ideal condition is to operate with venturi supply pressure as low as possible. This results in
lower powder velocity, less over spray, better electrostatic charge, less venturi wear and
generally improved coated surface appearance. There is no specific value for pressure used, as
systems vary in number and location of guns, desired coating speeds, etc. Each system must be
tuned by trial and error for optimum conditions.
AIR DRYERS AND OIL FILTERS
During the reclaim process, the powder is mixed with a large quantity of ambient air. Moisture is
absorbed during the process. To prevent porosity and fish eyes, this moisture must be removed.
Moisture removal is efficiently accomplished through the use of dry air to operate the fluidizing
bed and powder feed lines. A dew point of 20F. or lower is suggested for the compressed air
used in the powder handling system.
To remove oil that may be introduced in the air compressors, coalescing filters must be installed
prior to the system air dryers. These filters must be properly maintained to be effective.
SUMMARY
Use time-to-cure curves vs. wall thickness to establish coating speeds.
Check for tracking at first wheel past the coating booth.
Periodically run gun flow tests to confirm powder output.
Store bulk powder at 80F or lower.
Check air dryer to assure proper dew point.
Check vibrating screens for holes or other damage.
Frequently clean any magnets in the powder system.
Check and maintain satisfactory differential pressure across collector media.
Check fluid bed levels and amount of fluidization.

Holiday Detection Through the Outbound Rack

Objective
The overall continuity of the fusion bond coating on the exterior pipe surface needs to be verified
as part of the coating inspection process. The method used to determine this continuity is done
electrically or as more commonly know in the industry, holiday detection. The holiday detection
process is not intended to determine coating resistivity, bond, or physical characteristics of the
overall coating quality. Holiday detection is intended to find voids, cracks, foreign inclusions or
contaminants in the coating that are of such size, number or conductivity to significantly lower
the electrical resistance or dielectric strength of the coating.
Definitions
The following terms are used in the detection process:
Continuous D.C. Voltage Detector
A detector that supplies a continuous D.C.
test voltage. This detector should only be
used in very dry areas and no moisture
should be present on the pipe surface.
Ground Wire
The ground wire attached to the pipe that
permits the circuit to be formed if bare
pipe is exposed to the search electrodes.
Holiday
A holiday is a discontinuity in the coating that exposes the unprotected pipe surface to the
environment.
Holiday Detector
Electrical device used to locate holidays or discontinuities in the pipe surface.
Jeeping
Another term used to describe electrical inspections.
Pulse Type Holiday Detector
A pulse type detector is one that supplies a D.C. voltage pulse for a very short duration. Most
commonly used in plant operations and is not as sensitive to damp surfaces.
Search Electrode
A search electrode may be conductive rubber or brass bristle crescent shape device that is
placed on the pipe to search for holidays. This search electrode may also be a straight device if
the pipe is rotated or a roller spring attachment if the pipe is supported on both ends. Roller
springs are more commonly used in the field after the pipe has been welded together prior to
lowering in.
Tracking
Tracking is a false indication that occurs when the search electrode has conductive material,
usually moisture, between it and a holiday at another location on the pipe. The conductive
material will permit the voltage to leak back to the holiday generating a signal.
Procedures
Prior to startup of production, all equipment must be checked. The detector must be checked
with an appropriate type and properly calibrated voltmeter to determine that the proper output
test voltage is being generated at the search electrode. This test must be recorded and signed off
by the person conducting the test. All runners and kickers should be inspected and wiped down
to remove any residual foreign matter such as grit or dirt. The output voltage should be checked
against the customers requirements and the condition of the search electrode inspected for
proper conformance to the pipe. The ground wire and all supporting electrical connections
should also be inspected.
Proper Test Voltage
The test voltage used to detect pipe is generally spelled out in the customers specification.
However, a general rule of thumb is 125 volts per mil. Another test method of proper voltage is
to create a 1/32" holiday in the coating and pass the search electrode over this holiday, increasing
the voltage with each pass, until a consistent signal is established.
Pipe Temperature
Pipe temperature is an important factor to determine prior to holiday detection. Normally the
pipe surface should be below 200F. In some cases, the customer will indicate the maximum
allowable temperature in his specifications.
Travel Speed
The proper travel speed of moving the search electrode on the pipe can be determined as follows:
Make a known holiday on the pipe,

usually 1/32" in diameter. Move the
search electrode to the known holiday and
determine the best rate that permits
efficient travel speed of 100% detection
coverage of the holiday. Faster pulse rate
detectors will permit faster travel rates.
The search electrode should be placed first
on the bare cutback area of the pipe to
determine proper operation. The detector
must be equipped with a horn of sufficient
volume that it is easily heard at either end
of the pipe and above the normal plant
noise. The area around the pipe being
detected should be free from any debris
that could cause the operator to loose his
footing. A patch man should accompany
the person doing the detection to help
locate holidays quicker and execute the
repair promptly.
During the detection process, the indication
of holidays needs to be observed to
determine their cause. A spiral indication
on the pipe with embedded particles could
be steel shot or grit falling on a tire being
pressed into the soft coating. A straight line
indication usually is a steel surface
condition such as raised slivers or steel
imperfections. Submerged arc welded pipe
may have indications along the weld seam
that could be pinholes in the weld, undercut
welds or hydrogen outgassing. Repetitive
indications usually establish a pattern that
can be traced to either coating mill
conditions or steel conditions. In either
circumstance a solution to excess holidays
needs to be solved as quickly as possible to
minimize repairs and possible rejected
coating. One common solution to
overcoming raised slivers is to build a
greater distance between the slivers and the
search electrode by applying additional
coating. The latter solution has economic
factors that have to be addressed between
the applicator and his customer. Also care
must be exercised not to exceed the

customer's allowable maximum thickness.
In some cases a metal screen or mat can be
placed on the pipe to ride the pipe and
scrape the slivers off just prior to entering
the powder booth. This screen or mat is
called a drag mat.
The number of holidays usually allowed on the pipe surface is normally spelled out in the
customers specification.
Repairs
Repair of holidays fall into two categories; small repair or large repair. Small repairs (areas less
than 1 in diameter) are the most common and are repaired as follows:
A. Surface of the holiday and surrounding
coating film is lightly abraded with 125
mesh sandpaper.
B. The abraded area is cleaned of all loose
residue and preheated with a noncontaminating heat source such as a
propane or butane torch.
C. A 100% solids patch stick is then
heated next to the cleaned surface and
melted into the abraded area. A small
puddle will form and flow out over this
area.
D. Heat the melted puddle to achieve final
cure.
Large areas (greater than 1 in diameter) are repaired using a liquid two-part epoxy as supplied
by the powder manufacturer. The repairs are completed as follows:
1. Lightly abrade the area to be coated. This abrasion should extend at least one inch beyond
the affected area into sound coating.
2. Mix equal parts of the liquid in a small container and apply to the abraded area. You must
be careful to mix the proper proportions per the manufacturers recommendation to
ensure proper cure. Adding extra catalyst will not always accelerate cure, if fact, it may
retard the cure. Final thickness should be according to manufacturers recommendations.
3. Liquid repairs are temperature sensitive. Application should only be done if the
temperature is above 55F.
Due to the longer cure time of the liquid epoxy, it may be necessary to take the repaired pipe off
the outbound rack and be separated from the stacking or shipping operations until the curing is
complete.
Liquid repairs may not be allowed on ends of the pipe usually for a distance of 12" from each
end. This is due to the joint coating that the customer will use in the field. If the customer elects
to put fusion bond epoxy on in the field, the liquid will not hold up under the heat of the
induction coil.
Pipe Handling
INTRODUCTION
This lesson focuses on the recommended handling and storage procedures for bare and FBE
coated pipe. Safe handling practices must be used at all times, using equipment that will safely
lift and transport the loads associated with the various activities. This lesson will not address the
necessary safety practices required; reference the applicators safety program for this information.
In addition to this lesson, it is recommended that the student obtain and review the following
industry guidelines on pipe handling and loading procedures:
American Petroleum Institute Recommended Practice for Railroad Transportation of

Line Pipe (RP 5L1-96)
Association of American Railroads Section 2
American Petroleum Institute Recommended Practice for Transportation of Line Pipe

on Barges and Marine Vessels (RP 5LW-90)
National Association of Pipe Coating Applicators Bulletins 1-65-94 through 16-94
RECEIVING AND HANDLING OF BARE PIPE

1. INSPECTION AND DOCUMENTATION OF PIPE UPON ARRIVAL
At time of arrival at the applicators facility, the responsibility for the care and custody of the
pipe transfers to the applicator. It is necessary to fully inspect the pipe, prior to off loading
from the truck, railcar or barge and identify items that are outside of the applicators
contractual responsibilities and to alert the client of the findings. This inspection should
include the following:
Confirm that the pipe has legible and correct pipe identification data so that each
individual pipe can be tallied and tracked through the coating process.
Pipe damage, such as dents, scrapes, excessive marks on bevels, ovaling, gouges, flat
spots, etc., is identified and marked with a non-contaminating chalk. Findings should
be recorded on the bill of lading and as well on the applicators documents.
Surface contaminates such as oil, grease, tar, ferrosalts, etc should also be noted on
the bill of lading and the applicators documents.
2. OFF LOADING OF BARE PIPE
Conventional Transport Trucks: Bare pipe loads are generally configured in either a
pyramid stack, stripped with wood spacers between vertical rows or stripped bundles.
These various configurations require that specific off loading procedures be considered
with each type of equipment used. A forklift truck can be employed to lift off the stripped
rows and stripped bundles as shown in Fig.8.1 and permit transport to the storage pile.
Figure 8.1 Offloading from racks of coated pipe.

Pipe stacked in a pyramid fashion may require a crane to lift the pipe free from the stack
without damage. Properly designed hooks can prevent damage to the bevels and not leave
a metal contaminate that will impact the welding process in the field. Pipe lifted from the
truck may be placed directly in the storage pile or placed on a temporary rack for a
forklift to transport to storage.
Railcars: Typically pipe is shipped in either a gondola or flat bed type railcar. Off
loading of gondola type railcars normally utilizes a crane and a temporary rack adjacent
to the railcar for transport to the storage pile by forklift. The stacks on or within the
railcar may be a pyramid configuration or stripped. A crane or forklift may be used to off
load flatbed type railcars. The unloaded pipe may be brought directly to storage racks if
a forklift is used; otherwise a temporary rack may be used.
Figure 8.2 Coated pipe stacked on railcar.
Barges: Off loading of pipe from a barge may require a crane with considerable reach,
depending on the width of the barge. Normally the pipe is stacked in a pyramid fashion
with bulkheads placed to prevent pipe movement in transit. Pipe is lifted from the barge
and placed on a rack for transport to the storage pile. If the storage pile is remote from the
barge location, the pipe may be placed on a truck, secured with straps and transported to
the storage pile where a second crane or a forklift will place the pipe.
3. PLACEMENT OF BARE PIPE IN STORAGE

Storage areas must be prepared to prevent structural damage to the pipe and minimize
areas where accelerated corrosion can take place. Sand berms, covered with polyethylene
sheeting, or solid wooden timbers are commonly used to support pipe stacks. The choice
is generally defined by the diameter of the pipe, the height of the stack, and the required
bearing area to prevent excessive stressing of the pipe. Over stressing of the pipe may
cause ovaling, flat spots and dents. The client generally specifies the allowable stacking
height and they will normally also provide dimensions for a minimum bearing area. The
height of the berm or timber off the grade level is important to prevent the pipe from
sitting in water during wet periods, which may contribute to excessive corrosion of the
bare pipe.
Bare pipe is placed on the storage racks with either a forklift truck or a crane. Pipe stored
is stabilized with the use of end chocks. This should prevent shifting which may result in
damage to the pipe or injury to workers in the area. Stacking configurations can be
pyramid or a stripped fashion.
4. HANDLING OF BARE PIPE FROM THE STACK TO THE COATING PROCESS
The bare pipe is removed from the stack with a forklift truck or crane and transported to
the in feed racks. The pipe is lowered and placed on the rack where it will be staged for
inspection and coating. Personnel must exercise care to prevent damage to pipe or
equipment.
Figure 8.3 Loading of bare pipe on to incoming racks.
HANDLING OF FUSION BONDED EPOXY COATED PIPE

1. THE COATING PROCESS
The coated pipe will be rolled out on the out going coating racks. These racks will have
padding over the steel surface to prevent damage to the coating. At this point, rope rings
or separators will be positioned along the coated pipe length to prevent handling and
transportation damage to the applied coating. Forklifts used in this operation must have
padded forks. The forklift truck operator needs to frequently inspect the fork padding to
ensure bare spots have not developed which will damage the coating.
Figure 8.4 Handling coated pipe from the rack to the storage process.
2. FROM THE COATING PROCESS TO STORAGE

The coated pipe is transported with the forklift truck to the coated pipe storage area to a
sand berm covered with polyethylene sheeting or padded timbers. The coated pipe can be
stored in either a pyramid or stripped fashion. Separators will prevent pipe to pipe
contact. The location of the stored coated pipe may be noted on the inventory sheet.
3. LOADING OUT OF FUSION BOND COATED PIPE
CONVENTIONAL TRUCKS: The truck bed must be prepared with wooden bunks
(commonly referred to as dunnage) to prevent the coating from contacting the irregular
surface of the bed prior to the coated pipe being loaded. The trucking contractor normally
provides the dunnage. Prior to the pipe being loaded onto the truck, the dunnage should
be inspected to ensure that there are not any nails or other projections that could tear or
damage the coating. The dunnage may or may not have padding depending on the
preference of the client. The coated pipe is stacked in either a pyramid or stripped
fashion.
The truck operator secures the load, preferably using nylon straps. If steel bands or chains
are used, padding between the coating and the strap is required.
The applicator should provide a pipe tally for the bills of lading. These documents are
used in the commercial transport and the invoicing process.
RAILCARS: Flatbed railcars or gondolas are normally used to ship coated pipe. The
Association of American Railroads (AAR) Section 2, provides loading specifications
for coated pipe defining the load configurations, required dunnage, strapping procedures
and loading capacities. These specifications address the various pipe diameters and
lengths used in the preparation and loading of the coated pipe. A typical railcar load is
shown in figure 8.5. Rope separators are required on these loads to prevent pipe to pipe
contact.
Figure 8.5 Loading out of coated pipe on to railcars.

.
BARGES: Barge decks are prepared by the placement of dunnage to prevent the coating
from making contact with the deck. The customer or his representative will determine the
number of rows, the heights, and location of the pipe on the barge, as well as the tie down
requirements. It is especially helpful if a loading diagram is provided. The pipe is loaded
to this program for barge stability and then secured with the specified lashing that may
require padding to prevent damage to the coating.
SUMMARY:
Line pipe requiring anti-corrosion coating can be shipped to or from a pipe coating facility by
the means of ground, rail or water transportation methods. The customer normally arranges
the means of transportation to/from the coating facility. The facility is responsible for
establishing and maintaining documented procedures for the control, verification, storage,
and maintenance of customer supplied line pipe. Any pipe damaged or otherwise unsuitable
for use should be recorded. Each pipe coating facility is responsible for its own quality
management system that will ensure that the customer-supplied pipe is handled and stored
safely and properly while in the custody of the pipe coating facility.
Handling Coated Pipe:
After coating and

quenching, FBE coated
pipe should be rolled onto
padded bearing racks for
inspection and repairs.
Coated pipe should be

transported with suitable
padded to prevent damage
to the coating.
Coated pipe should be

stored on wooden racks or
on sand berms covered
with polyethylene
sheeting.
Figure 8.6 Padded forks for the handling of coated

pipe.
Pipe interiors should be kept clean and free from mud splashing or dirt deposits during
storage..
Coated pipe should be stored in such a manner to prevent damage to the pipe, pipe ends,
bevels and applied coating.
All stacked pipe should be stored in a safe manner to avoid uncontrolled movement.
All pipe should be stored at an angle to allow water to drain from the interior.
Coated pipe should be stored on berms or on lumber skids at least 10 inches wide, and no
closer than 1 pipe diameters from the end of the skid. The skid should be equipped with
wedges or a similar device to prevent the pipe from rolling off the stack.
Coated pipe, when stored or shipped, should have three to four company approved
separators, such as polypropylene rope rings, completely encircling the pipe for each 40
foot length. Separators should be made to fit the circumference of the pipe. They should
be evenly spaced on each pipe joint.
Coated pipe should be handled using web slings, end hooks, or padded lift forks. Coated
pipe that has been nested in storage should be handled using a crane with end hooks and a
lifting beam (spreader bar).
Coated piped should be protected from damage during

shipping using padded dunnage and non-abrasive straps.
Coated pipe should be loaded in compliance with API RP
5LW and RP 5L1 shipping standards and government
regulations. Loading and transportation by other means
should be in compliance with applicable standards and
government regulations.
Figure 8.7 Setting of dunnage and
banding of coated pipe on load out of
railcar.
The coating on all pipe joints should be visually inspected for damage during load-out.
Coating damage, if not exceeding the requirements of the applicable specification, must
be repaired. Damaged coating that exceeds the allowable limits of this specification at
load-out should be stripped, and the pipe should be recoated.
Quality Control
Quality control is sometimes viewed as the testing that takes place at the completion of a
manufacturing process. Effective quality control requires continuous monitoring of the
process to insure successful production. This chapter follows the sequence of coating steps
and suggests monitoring procedures in each. It also includes discussion on methods and
background for appropriate tests.
Application Process
Inspection of inbound pipe
Blast cleaning
Heating
Powder application
Coating cure
In-plant inspection
Coating appearance
Blowholes, pinholes, fisheyes
Coating thickness
Holiday detection
Repair
Destructive testing of ring samples
Bend
Porosity
Backside contamination
Cathodic disbondment test
Hot water soak test
The goal of this chapter is to outline procedures to prevent problems, or, to define the
techniques that will determine the cause of a problem. Corrective measures will then be
suggested. Tests and testing procedures will be handled in a following chapter.
INSPECTION OF INBOUND PIPE

Check the condition of the pipe before blasting. If wet, preheat to
dry prior to the final blast. Look for grease or oil on the pipe. A
no rust area on an otherwise rusted pipe joint is an indication of
oil. Oil or grease must be removed prior to blasting to prevent
abrasive contamination. Alternatively, consider precleaning the
pipe or adding an acid wash step after the blast cleaning process.
Mill lacquer should be removed before blast cleaning - otherwise
it will contaminate the abrasive. Dirt on pipe will not necessarily
contaminate the steel, but it will significantly increase
maintenance costs by wearing out both equipment and blast
abrasive.
Figure 9.1 Quality control of

the inbound pipe.
If there is any question of salt contamination due to seaside storage, ocean shipment, or
transport over salt laden winter roads of either the pipe or the plate, check for salt using
potassium ferricyanide paper. (Quality Control Test 3: Detection of Salt Contamination.)
Scrape or sand away the mill scale or outer layer of rust prior to the application of the
potassium ferricyanide paper.
In the event that the potassium ferricyanide test indicates the presence of soluble chlorides,
quantification of contaminate should be done. To do so, use the ASTM D 512, Test Method
for Chloride Ion in Water, Method A is recommended. Chlorides equal to or exceeding
5g/cm found on pipe prior to blast cleaning or 2g/cm found after blast cleaning should be
pretreated with a phosphoric acid wash. This will neutralize the soluble chlorides found on
the pipe.
BLAST CLEANING
The first step in quality control of the blast cleaning process is the maintenance of the
equipment itself. Check that the air curtain is full length. Check the fines refuse tube. The
presence of larger sized abrasive indicates sufficient airflow for cleaning. Check amperage
and line speed - is there sufficient time in the blast cabinet to achieve cleaning? Check
wheels after the machine exit for dirt or grease. Check manometer or magnehelic gage on the
dust collector to assure that bags are in place and not clogged. Check the dust collector. Is the
expansion chamber essentially empty?
If an air knife is used, check water, oil traps and filters. As a rough test, blow air through a
clean white rag to check for oil contaminated air. Oil in the line means that filters must be
replaced or the filtration system improved.
An evaluation of the blast abrasive also provides information on the cleaning operation.
Check the appearance of the grit. If it is rounded to a form similar to shot, check the original
container to insure that the hardness is greater than Rockwell C 55.
Rub the blast abrasive between hands. Significant discoloration of the skin indicates that the
air screen is not working properly.
In the laboratory, perform a screen analysis (QC Test 6: Blasting Abrasive - Screen
Analysis). Too much large abrasive indicates the need to add new abrasive in smaller
increments. Too many fine particles indicate that more frequent addition of new abrasive is
required.
A conductivity check (QC Test 5: Blasting Abrasive - Conductivity Analysis) of the abrasive
provides clues about salt contamination of the incoming pipe. Abrasive contaminated by
salty or oily pipe should not be reused on clean pipe. A backside contamination evaluation
can be made on the underside of coating removed from the pipe.
The pipe surface should meet the requirements of NACE No. 2 Near-White Blast Cleaned
Surface Finish or as per the customer's requirement. Rubbing the pipe surface with a lint-free
white rag will provide information on the amount of mill scale and spent abrasive imbedded
in the steel surface. A tape test, while subjective, will normally provide more information
than a white rag.
Check the surface profile using replica tape (QC Test 7: Profile Measurement - Replica
Tape).
HEATING
The goal is to heat pipe as uniformly as possible at the optimum coating application
temperature.
The optimum application temperature depends upon a number of factors such as the tendency
of the powder to form porosity and the time to quench. The powder manufacturers' "Time to
Cure" chart should be referenced to determine the application window for their product.
RULE OF THUMB:
For best performance, coat at the
highest possible temperature that
does not result in foam bond.
Figure 9.2 Heating pipe prior to the coating process.

Melt crayons are normally used to measure temperature. They are available in different melt
temperatures and are used to bracket the temperature of the pipe. For example, the
temperature might be stated as, "good melt on the 450F (232C), none on 463F (239C)."
That indicates that the pipe temperature is between 450F (232 degrees C) and 463F
(239C). Melt indicators affect coating adhesion, therefore, use sparingly.
Thermocouples, optical pyrometers, infrared guns, etc. are alternate methods of measuring
pipe temperature. When using these methods, great care must be taken to assure that these
instruments are properly calibrated. Using melt sticks in conjunction with one of these
instruments is a common practice.
Both induction coils and direct impingement flame ovens are high intensity heaters. Either
heating process can result in a higher temperature of the pipe wall - the heat transfer through
steel is not instantaneous. Allow time for the pipe wall temperature to reach equilibrium
before measuring. This can take several seconds. As a double check, on an uncoated lead
joint, measure the temperature of the pipe before and after the coating booth and note the
time for the pipe to travel between the measuring points. Compare the measured temperature
change with the expected change for pipe of that wall thickness using a cool down chart. A
loss greater than predicted indicates that the pipe wall temperature had not come to
equilibrium by the time of the first measurement. Adjust heat so that the pipe joint is at
equilibrium and at the correct temperature at time of powder application.
TEMPERATURE UNIFORMITY
Temperature variation is unavoidable along the length of the pipe and circumferentially
around the pipe. However, some variance factors can be minimized.
INCOMING PIPE
Direct impingement ovens and electrical induction coils raise the

pipe temperature by a given number of degrees to attain coating
application temperature. Therefore, uneven inbound pipe
temperature will be mirrored at the oven exit.
Figure 9.3 Testing

pipe with ammeter.
LINE SPEED VARIATION
A line speed change directly affects the temperature of pipe because it affects the time
available in either the induction coil or in a direct impingement oven. Most conveyor systems
are slowed when the weight of a new joint of pipe is added to the line. A second line speed
change occurs when the new joint is mated with the chain of joints already on the line.
Lastly, the speed can increase when a coated joint disengages from the train and kicks off the
system. These factors are unavoidable but can be minimized by balancing the system.
WALL THICKNESS VARIATION
Wall thickness can vary around the pipe as well as down the length of the joint. This is
especially true of seamless pipe. Also, weld thickness can cause a cool area on the pipe.
While steel is a fairly good conductor of heat, these variations can take quite some time
before evening out.
EMISSIVITY
The heat up rate in impingement ovens is directly related to the emissivity (dark surfaces
absorb heat faster than light surfaces) of the steel surface. The better the overall cleaning
process, the less the variation in emissivity will become. The largest change occurs on pipe
that has been blasted a second time. To avoid significant variance, twice-blasted joints should
be coated at the same time and not mixed with joints blasted only once.
INTERRUPTIONS
Interruptions can be especially important when the pipe is preheated prior to blast cleaning.
Preheat temperature decays at a regular rate. If the time from preheat to the heating step
varies due to either a shut down or delays between the two steps, the temperature of the pipe
entering the heating system will vary. That means the application temperature will vary if
interruptions occur when induction coils or direct impingement ovens are used for pipe
preheat.
IR GUNS
Infrared measurement devices are ineffective on bare steel because of varying emissivity.
However, the emissivity of the coated pipe is uniform and that can be quite useful at this
point. The use of an IR gun placed at the coating booth exit combined with the cool down
curve results in a good indication of the pipe temperature at the time of application.
POWDER APPLICATION
The powder supplier tests the powder quality at time of manufacture. While history shows it's
unlikely, the powder can become unusable due to improper storage, shipment, or age and
should be checked prior to use. Powder that is several years old, but has been properly stored
often is quite useable. On the other hand, new material improperly shipped or stored can be
unusable. Powder suitability is determined by age and (more importantly) by handling.
Customer specifications merely stating material of a maximum age are ineffective, as they do
not address the base issue. Specifications requiring a powder suitability test before use make
sense.
CHECK THE INCOMING POWDER
The two primary tests for material suitability are:
Gel Time
Appearance Test
The gel test is very easy to perform and requires only a hot plate and a stopwatch. However,
attention to detail and practice is required to obtain reproducible results, and this can be a
serious shortcoming. Because test temperature is critical, and the end point is based on
operator judgement, test variance can result. For fast-gel materials, the test temperature is the
greatest cause of variability. Small changes in temperature can result in significant changes in
gel time. Stable hot plates are expensive. Also, the method for measuring temperature can
significantly affect the results.
For longer gel materials, the end point is more difficult to determine. Therefore, operator
error is the most significant cause of variation.
Does this variation mean that the gel time is not useful? No. The reason for the above
discussion is to point out that obtaining results that are the same as those on the
manufacturer's data sheet is difficult. The objective of the test is to find out if the material is
usable and not "advanced," i.e. the gel time has not been shortened by heat or age. Therefore
the important detail is the comparison of gel time to previous shipments that were "good."
With a little care and one operator using the same equipment, these comparisons are easily
made.
Caution: comparable gel time results between plants or laboratories are difficult to achieve
without well-calibrated equipment, a well-defined test procedure, and operator training.
The primary cause of advanced powder is high temperature experienced during
transportation. Check the gel time at least once per truckload of coating material. If there are
any questions about storage conditions, also check the gel time. If the gel time is shorter than
expected or the coating material is more viscous than normal, conduct an appearance test
(QC Test 2: Coating Appearance)
The powder manufacturer, with every shipment of material, supplies a powder certificate.
This document certifies that the supplied material complies with their published standards. It
includes a particle size or sieve analysis, gel time, percent of total volatiles or moisture
content, a DSC or thermal analysis, and an infrared scan (may or may not be included).
Typically a review of this information is sufficient to determine suitability of the product for
application. Coating applicators must familiarize themselves with the manufacturers' release
parameters and what works best in their particular situation.
COATING (APPLICATION)
The equipment used in the application process is the most complex in the plant. It includes
electrostatic guns, power packs, powder pumps, venturis, screens, dust collectors, air dryers,
and more. As such it requires a significant amount of care and maintenance.
OVERSPRAY
Too much over spray can result in powder build up in the shroud, excessive moisture pick up
by the reclaim powder, and clogged guns. Minimize over spray by using the minimum air
pressure required to effectively convey powder through the guns to the pipe. Using a larger
number of guns at lower pressure results in less over spray. Pumps with new venturi inserts
require less air pressure to convey the same amount of powder when compared to those with
worn inserts. Check all of the electrostatic guns to ensure that they are charging properly.
BUILD RATE
Build rate is important when the number of guns available controls the rate of pipe coating.
The volume of powder conveyed by all of the guns primarily affects the build rate. Check the
throughput rate for individual guns. A worn venturi insert will reduce the amount of powder
a gun can spray.
POROSITY
All coatings applied at the proper temperature will contain some entrained bubbles. Excess
porosity is defined as a coating with a sufficient number of bubbles to reduce the physical
strength of the coating. Porosity is affected by several factors:
Powder coating characteristics
Moisture content of powder
Gun arrangement
Pipe surface contamination
Application temperature
The moisture content of the powder is a function of:
Moisture content of the virgin powder
Moisture content and quantity of recirculated powder
Dew point of air used to supply the fluidized bed and electrostatic guns
Recirculated powder quickly picks up moisture from the plant air used to transport it to the
dust collector. The moisture must be removed from the powder in the fluidized bed by using
feed air with a low dew point That is, the feed air must be very dry, dew point less than 2OF (29C).
Each powder coating has a unique tendency to form porosity. The greater the tendency
towards porosity, the lower the allowed application temperature. Porosity is also directly
related to the moisture content of the powder coating material .
CURE
Cross-linking and cure are terms used to describe the complex chemical reaction that changes
the melted powder material into a tough coating. Sufficient cure is critical to the attainment
of physical properties required for corrosion protection.
Cure has a time/temperature relationship that means that it takes the coating less time at high
temperature to cure and longer time at a lower temperature. Once sufficient cure is achieved,
continued exposure to the hot pipe has a minimum effect on properties.
Cure curves can be obtained from the various powder manufacturers. To use them, find the
minimum temperature along the length of the pipe joint. From that, minimum quench time
can be calculated. For example, if the pipe temperature varies from 425F (218C) to 463F
(239C) along the pipe length, use the 425F (218C) curve. This curve shows the minimum
time to quench.
Time to quench is the time from the last gun to the point where water is sprayed onto the
coating. Under normal circumstances, the cooling effect of the wet tires is negligible and can
be ignored.
PICK-UP TIME
Measure pick-up time from the last gun to the first wheel. The
coating does not need to be completely cured to attain the strength
to support the weight of the pipe on a wet wheel. However, it does
require time to obtain sufficient cross-linking to develop
Figure 9.4 Pipe on
compression strength. The amount of time depends on several
factors such as the coating formation and gel time, weight and size wet wheel shortly
after leaving the
of the pipe, alignment/synchronization of the conveyer wheels,
coating booth.
and application temperature.
If the coating is wrinkled after the first wheel, or tracks (tears or leaves coating on the
wheel), then either more time or a higher application temperature is required. Solutions
include slower line speed, higher application temperature, or an increase in the distance to the
first wheel.
IN-PLANT INSPECTION
APPEARANCE
Orange peel or rough coating is not necessarily detrimental to coating performance or an
indication of a problem. Orange peel will result when a fast-gel powder is applied to pipe
moving slowly through a coating booth. If that is the case, then lowering the application
temperature may improve the appearance, but it may also reduce performance properties and
will lengthen cure time.
On the other hand, it could be an indication of a problem:
Advanced powder due to age or high temperature storage
Porosity
Prior use of the powder from the same shipment or gel/appearance testing should provide
information on powder advancement. Of a more serious nature is the possibility of porosity.
A simple knife test of the rough coating can provide early warning of a porosity problem.
Test coupons can also be removed from the pipe.
To perform the knife test, gouge the coating with the tip and push through the coating for an
inch or two (2 to 5 cm) if the coating cuts easily or peels, that is an indication of porosity.
Verify with a 30X-magnification pocket microscope - look for close-packed large bubbles
near the substrate.
If porosity is the cause of orange peel, check:
Application temperature
Salt contamination
Air drying system (moisture in powder)
BLOWHOLES
A complete discussion of blowholes and other surface anomalies will be discussed in a later
chapter.
THICKNESS
Measure the coating thickness with a magnetic or magnetic flux gage. Calibrate the gage
daily using National Bureau of Standards non-magnetic coating standards with a thickness
within 20% of the specified coating thickness. If the thickness on the pipe varies
significantly, check for a clogged gun or uneven heating. Check arrangement of electrostatic
guns.
Attempt to achieve a uniform coating. Most specifications contain a minimum thickness
value as well as an average value. Not meeting the specification may mean stripping and
recoating the pipe. Non-uniform thickness also means wasted coating material.
Quality Control Tests

Table of Contents
This chapter deals with the acutal testing associated with quality control in a fusion bonded
epoxy facility. Not only are the tests described in detail, the reasons for these tests and the
interpretation of the results is dealt with as well.
QC Test 1 - Gel Time
QC Test 2 - Coating Appearance
QC Test 3 - Detection of Salt Contamination (Potassium
Ferncyanide)
QC Test 4 - Chloride Measurement
QC Test 5 - Blasting Abrasive - Conductivity Analysis
QC Test 6 - Blasting Abrasive - Screen Analysis
QC Test 7 - Profile Measurement - Replica Tape
QC Test 8 - Bend Test
QC Test 9 - Porosity Rating and Interfacial Contamination
QC Test 10 - Cathodic Disbondment Test
QC Test 11 - Hot Water Soak Test
QC TEST 01 - GEL TIME

SCOPE
This test measures the amount of time from powder melt to coating gel at a given temperature.
SIGNIFICANCE
A significant change in gel time is an indication of powder advancement or aging. Gel time will
vary depending on the type of powder being used. Advanced powder can cause an orange peel
appearance, poor flow out, or a dull, sandy finish in the applied coating. Because the test is
somewhat subjective, care is required to obtain reproducible results. Especially important is
temperature measurement. A l0F (6C) change in temperature can result in a 20% change in gel
time.
EQUIPMENT
Hot plate capable of maintaining 400 2F (204 1C)
PTC Model 314F Surface Thermometer
Stop watch with 0.1 second intervals
Spatula or wood stirring stick.
TEST SPECIMEN
Powder sample (about 0.1 gm - a quantity of powder about the volume of three match heads).
PROCEDURE
1. Stabilize hot plate at 400F (204C). Using the spatula or stirring stick, spread the 0.1 gm
sample over an area of approximately 1 in2 (650 mm2) in a uniform thickness.
2. Start the timer as soon as the coating material is melted.

3. Stir the coating with the spatula or wood stick.
4. Stop the clock when the coating becomes unstirrable.
5. Run the test in triplicate. Record the three results and the average.
CORRECTIVE ACTION
If the gel time is more than 30% below the expected range, conduct the coating appearance test.
QC TEST 02 - CHLORIDE MEASUREMENT

SCOPE
This test provides a procedure to measure the amount of chloride in an aqueous sample.
SIGNIFICANCE
Salt contamination of steel cannot be reliably detected by visual inspection. While the potassium
ferricyanide paper technique provides an indication of salt contamination, it does not give a
precise measurement of the amount. This test provides a measure of the amount of chloride
removed by water from the steel sample.
EQUIPMENT
HACH(TM) Chloride Test Kit. Model 8-P, Cat. No.144
Available from:
HACH Co.
P.O. Box 389
Loveland, CO 80539
800/227-4224
PROCEDURE
The following is from the Model 8-P direction set:
Low Range, 0-100 mg/L Chloride
1. Fill the mixing bottle to the 23-ml mark with the water that is to be tested.
2. Add the contents of one Chloride 2 indicator Powder Pillow. Swirl to mix.
3. Add the Silver Nitrate Titrant drop by drop to the water in the mixing bottle. Hold the dropper
in a vertical position and swirl the bottle to mix after each drop is added. Count each drop as it is
added until the water changes from yellow to red-brown in color.
4. The chloride content of the water in mg/L as Cl is found by multiplying the number of drops
that were added by 5."
REFERENCE TESTS:
QC Test 03 - Blasting Abrasive - Conductivity Analysis
QC TEST 03 - BLASTING ABRASIVE - CONDUCTIVITY ANALYSIS

SCOPE
This test provides a procedure to estimate the level of inorganic salt contaminants on the blast
abrasive used to clean the pipe.
SIGNIFICANCE
Abrasive media can contaminate the pipe surface. Usually, this is caused by blast media which
has been fouled by pipe surface contaminants. If contaminated abrasive is suspected, this
procedure can provide an early warning that the pipe may require an additional chemical
cleaning step.
EQUIPMENT
Eight-ounce (240 ml) bottle.
Two-ounce (60 ml) bottle.
ml graduated cylinder.
Distilled/deionized water.
Conductivity Calibration Standard* - Cat No. 256-916.
Conductivity meter* - Cat. No. 244-350.
*Available from:
Curtis-Matheson Scientific
470 Valley Drive
Brisbane, CA 94005
415 /467-1040
PROCEDURE
1. Measure 100 ml abrasive into eight-ounce (240 ml) bottle.
2. Follow with 100 ml of distilled/deionized water.
3. Cap the bottle and shake vigorously for 60 seconds.
4. Pour water into two-ounce (60 ml) bottle.
5. Using the meter, measure conductivity and record.
6. If desired, run the chloride measurement test.
CORRECTIVE ACTION
The level of conductivity indicating a detrimental level of contamination of either the pipe or the
abrasive has not been determined. Levels above 70 ohms suggest that other tests for salt
contamination should be considered or the water wash.
QC TEST 04 - BLASTING ABRASIVE - SCREEN ANALYSIS

SCOPE
This test provides a procedure to measure the particle size profile of the abrasive.
SIGNIFICANCE
Proper balance of the abrasive work mix and removal of contaminants is necessary for effective
pipe cleaning. The work mix must be clean and contain a mixture of small, medium, and large
abrasive particles. At a minimum, check weekly.
EQUIPMENT
Stack of U.S. Standard Sieves with the following screen numbers: 20, 30, 40, 50, 70, pan.
50 ml graduated cylinder.
PROCEDURE
1. Obtain sample getting a full "cut" of abrasive from the air wash curtain.
2. Place 50 ml sample on top screen. If sample is larger than 50 ml, make successive
measurements and average the results.
3. Cover and shake by hand for one minute. More accurate results can be obtained with longer
shaking times, but for this test 60 seconds should be adequate - consistency is important for
comparison purposes. Use the same amount of shaking time and effort for each test.
4. Accurately measure the volume of material on each screen and in the pan.
5. Convert to percentages and graph using chart in attached screen analysis profile. If there is
significant variance from expected, resample and repeat. Sampling technique can be critical to
the results since abrasive tends to segregate during handling.
INTERPRETATION
Operating practices and equipment condition can generally be divided into two classes:
Those that increase the percentage of large size abrasive.
Those that increase the amount of fines.
Loss of usable abrasive, such as to the dust collector or to the separator discharge, tends to
increase the percentage of large size abrasive. Conditions that retard removal of fines inoperative separators, reduced airflow - tend to increase the level of small particles in the
operating mix.
Infrequent additions of abrasive will result in an increase in larger size particles if sampled
shortly after addition and an increase in smaller size abrasive if sampled near the time of the next
addition.
CORRECTIVE ACTION
1. Maintain equipment: check the separator and ventilating system frequently, check to see that
air wash curtain is full width, check for dust build-up in collector pipes, check baffle settings
and manometer. Is collector emptying?
2. Add new abrasive Frequently (once per shift). Maintain hopper level above 3/4 full.
3. Return spillage to machine daily.
QC TEST 05 - PROFILE MEASUREMENT - REPLICA TAPE

SCOPE
This test provides a procedure to measure the peak-to-valley height of the surface profile.
SIGNIFICANCE
Profile roughness is important to coating performance. While this procedure does not measure
roughness, it provides information on the size of the steel grit in use and changes in the blast
cleaning equipment performance.
EQUIPMENT
Spring Micrometer
Press-O-Film(TM) Tape - X-Coarse
PROCEDURE
The following excerpts the Press-O-Film(TM) Replica Tape direction set:
1. Locate a clean representative surface site.

2. Apply film to blasted surface.
3. Rub burnishing tool or other blunt object over the round cut-out portion of Press-OFilm(TM) until the entire circular area has uniformly darkened.
4. Remove replica and place between anvils of spring micrometer. Subtract 2 mils from the
gage reading to compensate for the mylar. The gage reading is the maximum peak to valley
height of the test area.
CORRECTIVE ACTION
If the reading is outside the expected range, check the blast media for size, QC Test 04: Blasting
Abrasive - Screen Analysis, and check abrasive labels for hardness. Check blast cleaning
equipment.
QC TEST 06 - HOT WATER SOAK

SCOPE
This test determines the adhesion retention of the powder to the steel.
SIGNIFICANCE
Poor adhesion is a result of either contamination of the substrate or low application temperature.
Contamination can include inorganic salts or organic oils.
EQUIPMENT
The equipment required shall be as follows:
Slow cooker or other controlled temperature water bath
De-ionized water
Thermometer
Utility knife
TEST SPECIMEN
The test specimens need to be large enough to accommodate the test area and to facilitate
evaluation. A convenient size for laboratory coated test specimens is approximately 6.4 X 100 X
100 mm. For specimens from test rings, panels should be approximately 100 mm X 100 mm X
pipe wall thickness.
PROCEDURE
Place the test specimen in the slow cooker and add sufficient de-ionized water to submerge it
fully. Heat the water to 167F (75C) for of 24 hours ( one half hour). Remove the samples.
While the specimen is still warm, use the utility knife to scribe an approximate 30 X 15 mm
rectangle through the coating to the substrate. Cool the sample to 68F (20C). Within one hour
after removal from the heat, insert the tip of a utility knife under the coating at a corner of the
scribed rectangle. Use a levering action to remove the coating. Continue inserting the tip of the
knife and levering under the coating until either all of the coating in the rectangle is removed or
the coating demonstrates a definite resistance to the levering action.
Rate the adhesion of the coating within the rectangle as follows:
Rating 1- coating cannot be removed cleanly
Rating 2 - less than 50% of the coating can be removed
Rating 3 - more than 50% of the coating can be removed but the coating demonstrates a definite
resistance to the levering action.

Rating 4 - the coating can be easily removed in strips or large chips.
Rating 5 - the coating can be completely removed as a single piece.
CORRECTIVE ACTION
An adhesion rating of greater than 3 indicates an adhesion problem that needs to be corrected.
Check application temperature and backside contamination. If both are in an acceptable range,
check the pipe for contamination in the form of inorganic salt, smut or oil. Take steps to remove
the contaminants.
QC TEST 07 - CATHODIC DISBONDMENT TEST
24 HOUR, 150 F (66C), 3% NACL, 3.5 VOLT

SCOPE
This test provides a measure of pipe coating adhesion.
SIGNIFICANCE
Poor adhesion is a result of either contamination of the substrate or low application temperature.
Contamination can include inorganic salts or organic oils.
EQUIPMENT
power supply.
Platinum anode wire.
Electrolyte - 3% salt - (3 gms NaCl in 97 ml distilled or deionized water).
Plastic tubes 4" ( 10 cm) long and suitable diameter for pipe size.
Cover.
Dow Corning 732 Multi-Purpose sealant.
High resistance volt/ammeter.
Hot plate or oven capable of maintaining 5 F(3C) at 150F (66C).
Calomel reference electrode.
Utility knife.
TEST SPECIMEN
1. Cut the specimen from the coated pipe. A convenient size is 4" on a side.
2. Drill a hole in one comer to attach negative lead or grind the coating away from the steel.
3. Drill a 1/8" (3 mm) hole through the coating in the center of the test panel. The depth should
be the minimum required to provide a 1 /8" diameter hole completely through the coating.
4. Center plastic tube over holiday and glue to specimen.
PROCEDURE
5. Fill tube to within half inch of top with 3%
NaCl electrolyte preheated to about 150 F
(66C).
6. Assemble test cell as shown in the figure
below. A heat transfer medium such as shot or
grit in a pan provides uniform temperature on
a hot plate.
7. If the test is run on a hot plate, use an
immersion thermometer resting on the coating
for temperature measurement.
8. Connect the negative lead from the power
supply to the test panel and the positive lead
to the platinum anode. Turn on the power
supply.
9. Adjust the voltage to 3.5 volts with respect to the calomel electrode. Make the measurement
by connecting one end of the voltmeter to the calomel electrode and the other end to the negative
test panel connection.
10. The 24-hour test period starts at this point. Note the time.
EVALUATION PROCEDURE
11. At the end of the 24-hour period, disconnect and remove the test cell, drain the electrolyte,
remove the tubing and allow the specimen to air cool to ambient temperature. Evaluate the test
within one hour of removal from the hot plate.
DISBONDMENT
12. Insert the blade of the utility knife under the coating starting at the intentional holiday. Using
a levering action, chip off the coating. Continue until the coating resists the levering action.
l3. Measure the radius of the disbanded area from the holiday edge to the coating. If the
disbanded area is not a uniform circle, take several measurements and average the results.
OUTSIDE ADHESION
14. At a point midway between the disbondment and the outside of the test cell, cut an "X"
through the coating to the substrate. Insert the utility knife point at the intersection and lever the
coating from the substrate. Rate the adhesion based on the following scale:
1=Well adhered coating that cannot be stripped from the substrate.
3=The coating can be pried from the substrate in small pieces, but will leave some coating
residue in the anchor pattern.
5=The coating is attached to the substrate, but peels easily and leaves no coating residue behind.
15. Report disbondment diameter in mm and adhesion rating.
CORRECTIVE ACTION
A disbondment radius of greater than 1-6 mm and/or an adhesion rating of greater than 3
indicates an adhesion problem that needs to be corrected. Check application temperature and
backside contamination. If both are in an acceptable range, check the pipe for contamination in
the form of inorganic salt, smut or oil. Take steps to remove the contaminants.
QC TEST 08 BEND TEST

SCOPE
This test measures the flexibility of the applied coating.
SIGNIFICANCE
Under curing of fusion bonded epoxy coatings results in reduced flexibility. This test normally provides a good indication of cure.
Foam bond and a contaminated substrate may also negatively affect flexibility.
Equipment
1.
2.
3.
4.
Four point bend apparatus (Procedure A)

Bending mandrels of fixed radii (Procedure B), with bend appratus
Freezer, dry ice, or ice bath
Thermometer
TEST SPECIMEN
Cut a test specimen approximately 1 by 8 (2.5cm by 20 cm) from the pipe to be tested, with the 8 (20 cm) dimendion parallel to the
length of the pipe.
PROCEDURE
Chill the specimen to 32F (0C) by immersion in an ice water bath for at least 10 minutes. An alternate method is to chill the
specimen below the freezing into in a freezer or with dry ice and allow it to warm to 32F (0C).
Procedure A - Four Point Bend
1. Position the test panel in bending apparatus; make marks approximately (6 mm) from each pin.
2. Start bending within thirty seconds of the specimen being removed from the ice bath or when it reaches 32F (0C), using the
freezer or dry ice method, as determined by the thermometer.
3. As the bend proceeds, visually check for cracks in the coating. Ignore those within 1/8 (3mm) of strap edge; stress risers
may cause these. Those within the (6mm) of pin contact points should also be ignored, overbend due to bar breakover may
cause this.
4. At the first signs of cracks, stop the test and remove the panel.
5. Calculate the permanent strain with the following equation:
/pd = (57.3) (t)
R t/2
R = bend radius of outer curve of test specimen
t = effective strap thickness
/pd = strain or deflection expressed in degrees per pipe diameter
6. The resulting bend should be, at a minimum, 2.5/pd.
Procedure B Mandrel Bend:

1. Calculate the required mandrel radius using the following formula to :
R = (57.3) (t) - t
/pd
2
R = mandrel radius
T = effective strap thickness
/pd = 2.5 (strain or deflection expressed in degrees per pipe diameter)
2. After placing the mandrel that approximates a 2.5/pipe diameter in the bending apparatus, clamp the coated specimen to
the mandrel.
3. Bend the coated sample so that it matches the arc formed by the mandrel.
4. Remove the bend specimen and visually inspect the strained surface for cracks or tears in the coating that expose the steel
surface.
5. The bend passes if the coating shows no visible signs of cracks or tears. Should the bend exhibit any of these indications,
it will be considered a failure. Cracks or tears that occurs within 1/8 (3 mm) from the edge of the specimen will be
disregarded.
CORRECTIVE ACTION:
A cured coating should pass at least 2.5/pd at 32F (0C) using either Procedure A or Procedure B. If the results are less than this,
check the application temperature and pipe wall thickness to assure that the time to quench meets the product cure requirements. Also
check for foam bond or backside contamination. Contamination from salt or oil may also reduce flexibility.
QC TEST 9 - POROSITY RATING AND INTERFACIAL

CONTAMINATION
SCOPE
This method of rating provides a numerical value for the level of porosity in a coating applied in
powder form to a heated metal substrate. It also provides an indication of the amount of visible
residue left on the metallic substrate by the abrasive cleaning process.
SIGNIFICANCE
These tests are combined because they use the same specimens.
Increased moisture levels in plant coating systems and high application temperatures
correspondingly increase porosity of the cured coating. Moisture adsorbed by the powder during
the recycling process must be removed by using dry air in the fluidizing and powder transport
systems. The dew point of the compressed air should be -20'F (29'C) at 60 psi or dryer. A high
level of large interfacial bubbles next to the substrate results in a reduction of structural strength
of the coating which makes it more susceptible to damage during handling and installation of the
pipe.
Abrasive cleaning always leaves residue on the cleaned surface; high residue levels may reduce
long-term durability and installation characteristics of the coating and therefore indicate that
improvements in the cleaning process are in order. This test is useful only for contaminants
visible under 30-40X magnification. Contaminants such as inorganic salts or organic oils which
may be detrimental to coating performance, may not be detected by this method. Due to the
severity of this test, even properly applied coatings will separate from a well prepared substrate.
The visual examination is necessary to determine the level of contamination.
SUMMARY OF METHOD
This method utilizes the rapid bending of a chilled specimen over a short radius mandrel to
remove a coating chip. The cross section of the coating is then examined under magnification to
compare to a pictorial chart to estimate the level of porosity.
If there is cohesive failure of the coating near the substrate, the interfacial porosity level is also
estimated using a second pictorial chart.
The backside (substrate side) of the coating is then examined under magnification to estimate the
percentage of contamination.
EQUIPMENT
Microscope - 30 to 40 power
Bend equipment
Freezer or dry ice
Copper sulfate solution - 5 % (5 gms CU504 in 95 ml distilled or deionized water)

TEST SPECIMEN
Cut a strap with dimensions of approximately I" X 8" (2.5 cm X 20 cm) with the 8" (20 cm) side
parallel to the axis of the pipe.
PROCEDURE
l. Chill sample and bend rapidly over a short radius mandrel to cause coating to delaminate. The
combination of chilling technique and mandrel radius should be tested to verify adequate chip
removal. One normally acceptable combination is dry ice and a mandrel with 1 /2" (I 3 mm)
radius.
2. Porosity Rating: Examine the coating film in cross section under magnification and rate the
foam level based on the cross-section porosity chart (a) shown below. See Figure C for example
of coating chip.
3. If the cross sectional porosity rating is 2 or less, no interfacial test is required. If 3 or greater or
if the bulk of porosity is within 20% of the coating nearest the substrate, the coating may fracture
near the substrate leaving areas of the porosity visible for observation from the backside of the
coating. Interfacial porosity rating is then possible using the chart shown below.
4. If there is no fracture plane within the coating that exposes porosity on the underside of the
coating, it will be necessary to remove a thin layer of the coating. This can be done using a sharp
razor blade.
5. Interfacial contamination rating: Observe the backside of the coating under magnification and
estimate the amount of non-coating material as a percentage of total viewed area using the
following comparison charts as a guide.
6. Record this as "Percent of area which is contaminated."
7. If sufficient samples are available, repeat three times and average the results.
8. Dip a delaminated coating chip in the copper sulfate solution for 10 seconds. Again observe
the backside of the coating under magnification for change to copper color. These are areas
where the contaminant is primarily steel. Estimate the percent of the contaminants that have
changed color. Record as "Percent of contaminated area which is steel."
CORRECTIVE ACTION
For excessive porosity, check for salt on pipes. Check application temperature - is it higher than
normal? Check air-drying system.
Contamination levels of 30% or greater indicate a need for blast machine adjustment or
maintenance. Check the separator and air curtain used to remove the fines from the blast media.
Appendices
Each appendix offers detailed information on certain tests and procedures.The appendices may
be reached by clicking on the links below.
Appendix 1: Fusion Bonded Epoxy Plant Application Trouble-Shooting Guide
Appendix 2: Fusion Bonded Epoxy Anomalies Trouble Shooting Guide
Appendix 3: Routine Shot Blaster Maintenance Inspection
Appendix IV
Fusion Bonded Epoxy Plant Application Troubleshooting Guide
PIPE INSPECTION
Oil, grease, lacquer - Clean Pipe Per SSPC-SP-1-63.
Structural defects, excessive metal imperfections - Cull out and report to proper people.
CLEANING
Rust or dark color after cleaning.
Pipe forward line speed too high for capacity of blaster
Blasting wheel or control cage improperly adjusted.
Abrasive feed rate too low - feed system too small or plugged. Is system low on
blast media?
Blotchy appearance of cleaned pipe.
Oil, grease, or lacquer on the pipe prior to blasting.
Grit possibly contaminated.
Wash chemicals not evenly applied or removed.
Surface dust, dirt, or embedded grit on cleaned pipe surface.
Cleaning machine air sweep out of adjustment.
Contaminated grit-should be replaced.
Brush or final cleaning mechanism not working properly, or not making contact
with the pipe surface.
If air knife is used, make sure an adequate oil filtration system is in place.
HEATING
Hot spots on pipe.
Uneven heating, check calibration of heating process.
Burner malfunction.
Line speed variation.
Uneven pipe temperature due to the blast cleaning preheating step.
Plan ahead - with direct impingement heating, pipe that has been blasted twice
will not heat up as quickly as pipe blasted only once. Check for variation in pipe
wall thickness.
Cold ends - couplings as heat sinks. Induction heat results in cool ends.
Oxidation of the steel prior to coating (bluing).
Oven dwell time too long.
Preheat too high.
COATING - ELECTROSTATIC SPRAY
Guns not spraying.
Improper fluidization.
Check and clean gun tips and resin feed pumps.
Is Venturi insert in place?
Check pressure of air supplying pumps.
Feed rate falling off at same pressures - clean gun tips and venturi pumps. Check feed
hoses for leaking or plugging. Also, inspect venturi insert for wear. Replace if needed.
Impact fusion.
Reduce air pressure to guns.
Moisture in powder - check dew point of air to guns.
Buildup of powder on gun tips.
Check air supply for oil and moisture, service dryer and oil traps.
Reduce air pressure to guns.
Gun position. If too close, radiated heat from pipe will cause fusion buildup on
tips.
Buildup of resin in coating chamber
Check reclaim collector. Is there enough suction?
Too high air pressure to gun will cause excessive overspray.
Check temperature of coating chamber, if above 130oF (54oC) do not operate.
Cob-webbing in coating chamber
Powder concentration in coating chamber too high. Reduce resin velocity.
Guns too near pipe or too close together?
Check electrostatic voltage. Try lower voltage.
Surface imperfections on the coated pipe (pockmarks and blowholes).
Service air traps and dryer.
Check air dryer for effectiveness. Air/dew temperatures should be at or lower than
-20oF (-29oC) at 60 psi.
Are couplings and/or drive rolls wet or contaminated?
Possible oil or grease on the pipe. Review cleaning system.
Does water or steam run back through the pipe interior and discharge into the
coating unit?
Clean fluidized bed magnets.
Is powder screen system intact? Agglomerates of resin can cause blowholes.
Check the position of the blowholes - if they are aligned, it indicates a problem
with the steel, such as out-gassing, or a contaminant on the surface.
Coating appears lumpy.
Check and clean fluid bed screen and magnet.
Has reclaimed powder been screened before loading into fluid bed?
Is dust collector operating at too high a temperature (above 130oF or 54oC) or

sucking in moisture. Are couplings and drive rollers clean?
Check pipe for cleanliness and surface defects.
Is powder falling from coating chamber onto the pipe?
Check the diffusers in the gun tips.
Try lower air pressure to guns.
Coating has heavy orange peel appearance.
Pipe temperature should not be higher than maximum specified for product.
Check for porosity - is there salt contamination on the pipe.
Is reclaim to virgin powder ratio too high?
Check temperature of powder in fluid bed. It should be near ambient temperature.
Check gel time and coatability of powder. Powder storage should be at 80oF
(27oC) or lower and used within shelf life period.
Dew point of fluidizing air should be at -20oF (-29oC) or lower
QUENCH (FORCE COOLING)
Roller marks on the coating after the pickup wheel.
Application temperature too low.
Pickup time not being met. Adjust line speed or first wheel distance from coating
unit.
Are first wheels contacted continuously wet?
Watermarks or mottled (blotchy) appearance.
Pipe quenched before coating is cured. Check cure time.
Water splashing out of quench contacts pipe before complete cure of the coating.
Coating rough at leading end of pipe - powder on couplings tracking onto rollers and
being redeposited on the pipe.
COATING INSPECTION
Excessive jeeps.
What is operating voltage of holiday detector? Use 125 volts/mil as guide for
proper voltage.
Is contacting electrode tracking to ground through pipe surface water supply or

discharge water?
Visually check for contamination or blowholes in the coating.
Check for unusual pipe conditions (metal imperfections).
Is coating thickness adequate?
Jeeper not detecting holidays, but instrument okay.
Is unit set at the proper voltage?
Does the contacting electrode give complete coverage of the coated surface?
With in-line jeeper, check for adequate grounding through the couplings.
Is travel speed too high?
Thickness variation.
Guns not properly adjusted or feeding erratically. Check and clean guns and feed
pumps, replace venturis if needed. Too few guns in operation, add more.
Guns not charging. Check high voltage supply.
Pipe speed varying.
Pipe temperature varying.
Powder wet causing resin to build rapidly on tips and/or pumps. Check air dryer
and air dew point.
Low impact; poor adhesion.
Check underside of released chip. If black or discolored, pipe is not clean.
If honeycombed or foamy, pipe may be too hot or powder moisture content too
high. Check pipe application temperature and air dryer. Check for salt
contamination on pipe.
Coating too thick. Measure thickness.
Coating quenched before it was cured. Check cure curves for this coating
material.
Application temperature too low. Measure pipe temperature.
REPAIR
Patch sticks - patches easily removed.
Improper surface preparation. Clean and roughen surface, remove dust and
filings, before applying patch stick.
Pipe-coating surface not preheated enough to wet out patch stick material.
Two-part liquid repair material - patches do not cure.
Improper mix ratio used, or resin not thoroughly mixed before using.
Atmospheric temperature too low. Do not use below 55oF (13oC) unless pipe
temperature is high enough to ensure cure.
FBE Anomalies
Trouble-Shooting Guide
NAPCA has produced pictures of different FBE Anomalies commonly found in coating plants.
We have also narrowed down the areas where we believe these anomalies will be found. This is a
guide to be only used to help locate the source of the anomaly.
The National Association of Pipe Coating Applicators assumes no responsibility for the
interpretation or use of this trouble-shooting guide.
POSSIBLE CONTAMINANTS IN FBE
POSSIBLE
CAUSES
W
RU
OTHER
OI
B-STAGED IMPACTED SILIC
EQUIP
AT
BBE
CONTAMINA
L
POWDER POWDER ONE
MENT
ER
R
NTS
Air Hoists
Air-Lock Seals
Airborne Particles
Airlocks
Atmospheric Air
Bearings
Blast Machine Seals
Bugs
Compressed Air Stream - Air
Compress
X
X X
Condensation in bin
Condensation in ducting
Conveyor
Couplings
Duct Work
Dust
X
X
X
X
X
X
X
Dust Collector
Fog
X
X
Forklift
Gaskets - Seals
Heat Affected Powder

High Humidity moisture in powder
X
booth
High Temp
Hoses
Insulation
Lubricants
Manufacturer
Paint Chips
Pipe Handling Equipment
Powder Booth
Powder gun Tips - electrostatic
Powder Guns
Powder gun Tips - Electronic Grease
Powder Pumps
Powder-duct work
Powder-humidity, moisture
Powder-process
Powder-storage
Rain
Release Agents
Rust
Scale
Squeegee
Steam Quench water couplings
X
X
Storage - improper
Transfer Systems
Vibratory screener
Wheels
B-STAGED POWDER
PLACES WHERE B-STAGED POWDER MAY BE
FOUND:
Powder System
Dust Collector
Powder Booth
Air Lock
Duct Work
Gun Tips (electrostatic)
Transportation
Improper Storage
High Temp
Heat Affected Powder
Pipe Handling
Couplings
Conveyor
10X Magnification
30X Magnification
Cross Section
IMPACTED POWDER
PLACES WHERE IMPACTED POWDER MAY BE
FOUND:
Impacted Powder
Powder Pumps
Hoses
Guns
Transfer Systems
Airlocks
Duct Work
Vibratory Screener
Manufacturer
10X Magnification
30X Magnification
Cross Section
RUBBER
PLACES WHERE RUBBER MAY BE FOUND:
Wheels (conveyor)
Blast Machine Seals
Air-Lock Seals
Squeegee
Couplings
10X Magnification
30X Magnification
Cross Section
OIL
PLACES WHERE OIL MAY BE FOUND:
Compressed Air Stream (Air Compressor)
Powder Guns (Electronic Grease)
Hydraulic Oil
10X Magnification
Conveyor
Air Hosts
Bearings
Pipe Handling Equipment
30X Magnification
Cross Section
SILICONE
PLACES WHERE SILICONE MAY BE FOUND:
Gaskets - Seals
Lubricants
Release Agents
10X Magnificaton
30X Magnification
Cross Section
WATER
PLACES WHERE WATER MAY BE FOUND:
Compressed Air Stream
Atmospheric Air (high humidity moisture in powder

booth bin and ducting)
Rain (fog)
Steam Quench Water (couplings)
Powder
Process
Humidity Moisture
Storage
Transportation
10X Magnification
30X Magnification
Cross Section
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ROUTINE SHOT BLASTER MAINTENANCE INSPECTION

The routine inspection of equipment is the basis of preventive maintenance. Among the purposes
of the inspection routine are:
1. To detect minor necessary repairs and forestall major ones.
2. To anticipate repairs by locating probable causes - PREVENTIVE.
3. To plan repairs for convenient times.
4. To prevent BREAK DOWNS.
5. To be certain equipment is being operated at the highest possible efficiency.
To assist in planning such a maintenance routine, we have classified the items to be inspected
into three groups: daily, weekly, and monthly.
CABINET
DAILY
WEEKL
Y
The cabinet should be free of leaks. Flying abrasive is

dangerous to personnel and nearby equipment. Lost
abrasive is expensive.
1. Inspect cabinet interior for evidence of abrasive
wear
2. Clean loose abrasive from roof areas and return it to

system. Determine and eliminate the source of loose
abrasive.
3. Inspect wheel housings and liners. Replace as

necessary.
4. Check entrances, exits, loading doors, and seals for

abrasive losses.
WORK CONVEYOR
Flights, belts, and/or rolls should be checked for:
1. Tension
2. Alignment
3. Worn or missing bolts, etc. Check sprockets and
MONTH
LY
drives for tension, alignment, keys, loose set screws,

and bearings.
ABRASIVE HANDLING SYSTEM
DAILY
WEEKL
Y
X
1. Storage hopper, feed spouts, screws, etc. Inspected

and scheduled for repairs or replacement, if the
cycling of the abrasive is retarded in any way.
2. Elevator belt check for:
a. Tension
b. Alignment on pulleys
c. Worn or missing buckets
d. Splice condition
X
X
X
X
3. Check sprockets and drive for tension, alignments.,

keys, loose set screws, and bearings.
4. Check abrasive control valve for free operation and

desired opening.
WHEEL UNITS
DAILY
1. Check wheel for vibration.
2. Check blades or vanes.
WEEKLY MONTHL
Y
3. With blades removed, close housing and run

wheel.
Check for vibration.
4. Inspect and replace impellers if badly worn.
5. Inspect control cage. If bevel edge of the opening

has worn in way, should be replaced.
6. Inspect wheel housing liners and deflectors,

change as necessary
7. Check blast pattern for correct setting.
*8. Record Ammeter reading.
MONTH
LY
9. Check ammeter for accuracy with Tong ammeter.

10. Check wheel belts.
X
X
*Ammeter should be steady at full load (or determined setting). Violent fluctuations indicate
improper belt tension, bearing trouble, inadequate supply of abrasive, or drag in some moving
machine part.
SEPARATORS
DAILY
1. Clean scalping screen.
2. Check scalping screen for holes.
3. Check shed plates, baffles for wear.
4. With machine in blasting cycle, check abrasive flow

at point of separation (orifice) to make sure it is
uniformly spread over the entire orifice.
5. Make sure dribble valves are in place on refuse

pipes or tubes from separator and are working
properly.
WEEKL
Y
MONTHL
Y
(Check separator discharge for usable abrasive.)
DUST COLLECTOR
1. Inspect atmosphere around blast cleaning unit to see
that it is free of dust.
DAILY
WEEKLY MONTHLY
2. Check all ductwork for leaks.
X
X
3. Inspect blast gate settings to see that they are

unchanged.
4. Take manometer reading.
5. See that hoppers are empty.
X
X
6. Check fan belts.
7. Inspect fan vanes for wear.
8. Check shaker or rapper mechanism while in

operation.
9. Check bag house or filter compartment while

shaking or rapping.
Lubrication - Follow manufacturer's instructions.
SUMMARY
Check daily: Wheel components, ammeter wheel flow readings, dust collector
manometer readings, abrasive curtain at separator and blast patterns.
Adjust pipe rotation so that forward travel of pipe through blast machine does not exceed
length of blast pattern.
Maintain a full abrasive curtain in the air wash separators.
abrasive feed hopper go below 2/3 full.
Glossary of Terms
Abrasion
Mechanical damage to a coating, usually caused by rubbing together of two surfaces.
Adhesion
Attraction of unlike materials such as an organic coating to steel pipe.
Ambient Temperature
Temperature of the surrounding environment.
Anchor Pattern
The microscopic peaks and valleys on the pipe surface caused by blasting. Also, the amount
of surface roughness.
Applicator
The company or organization which applies coatings.
Blast cleaning
Removing contaminants from the surface of pipe with propelled abrasives. Usually relies on
compressed air and grit or shot.
Blow-back
Reflection or rebound of a spray.
Bonding
Creating adhesion.
Bright Blast
A white metal finish.
Cathodic Protection
Preventing corrosion by an impressed current or with sacrificial anodes.
Checking
Appearance of cracks or cracking in a coating.
Cleaner
Chemicals or solvents used for removing soil, grease, oils, and other contaminants from the
pipe surface.
Coating
A surface covering or barrier to prevent corrosion and extend life expectancy of the pipe.
Cohesion
The sticking together of similar materials.
Commercial Blast
A surface finish from which all oil, grease, rust, scale, soil, and other contaminants have been
removed except for light streaks, discolorations, or shadows. (Also called NACE No. 3
Finish)
Continuity
Free of pores or holes; intact
Corrosion
Deterioration of the pipe by electrochemical means.
Cracks or Cracking
Splitting of a coating.
Cratering
Deep holes or depressions in a coating.
Cross-Linking
Combining of chemicals to form a protective coating or film.
Cure
To harden or set up
Damp
Moist, wet to the touch.
Degreaser
A solvent or chemical used to remove grease or oil.
Delamination
Separation of a coating into layers
Density
Weight or Mass per unit volume. Example: 5.1 Lbs. Per Cubic Ft.
Detergent
A chemical or combination of chemicals used for cleaning.
Deterioration
Breaking down of a coating or loss of original properties.
Dew Point
The temperature at which moisture condenses from the atmosphere.
Disbondment
Physical separation of the coating away from the pipe.
Electrostatic
An application system, which uses an electric charge, attracts the coating to the surface.
Epoxy Coatings
Coatings formed from an epoxy resin and a curing agent.
FBE
Fusion Bonded Epoxy Coating
Field Coating
Applying coating at the job site.
Film Thickness or Build
Thickness of a coating when dry or fully cured.
Film Integrity
Overall continuity of a coating
Film Thickness Gage
A device for measuring thickness of a coating either wet or dry.
Fish Eye
Formation of holes or craters in a coating resembling the eye of a fish.
Flexibility
The ability of a coating to be bent without cracking, splitting, or disbonding.

Gel
To form a jelly-like mass
Grit
An abrasive used to roughen the pipe surface. Usually has sharp-pointed shape.
Gun
The spray device, which transfers the FBE powder to the surface of the pipe.
Hardness
The amount of force a coating can withstand before deformation or scratching.
High Build Coating
A coating, which produces a thick dry film.
Holiday
A pinhole or skip in the coating. Voids. Pores.
Holiday Detector
An electro-conductive device for detecting holidays or pinholes.
Humidity
Measure of moisture content in the air.
Hydrogyl
A chemically combined ion of oxygen and hydrogen (OIH).
Impact Resistance
Resistance of a coating to a blow or dropped weight.
Jeeping or Jeep Test
Testing a coating for continuity at low voltage.
Mil
One thousandth of an inch (0.001 in.)
Mill Scale
An oxide layer formed on steel pipe by hot rolling at the steel mill.
Misses
Voids, holidays, or skips.
NACE No.1 White Metal Blast Cleaned Surface Finish (SSPC-SP5)
A gray-white, uniform colored finish which is slightly roughened to form a suitable anchor
pattern for coatings. The finish is free from all oil, grease, dirt, mill scale, rust, corrosion
products, oxides, paint, or other contaminants.
NACE No. 2 Near White Blast Cleaned Surface Finish (SSPC-SP10)
A finish which has all oil, grease, dirt, mill scale, rust, corrosion, corrosion products, oxides,
paint, and other contaminants removed except for light streaks or slight discolorations. At
least 95% of the surface is NACE No.1 White Metal Finish as described above.
NACE No. 3 Commercial Blast Cleaned Surface Finish (SSPC-SP6)
This finish has oil, grease, dirt, rust, scale, and other matter removed from the surface except
for slight shadows or streaks and discolorations. If pitted, slight residues of rust or coatings
may be found in the bottom of the pits. At least two thirds of the surface shall be free of
visible residue and the remainder limited to slight discolorations or staining.
NACE No. 4 Brush-Off Blast Cleaned Surface (SSPC-SP7)
This finish has oil, grease, dirt, scale, rust, and loose mill scale removed completely but some
light mill scale or tightly adhering rust or paint remains on the surface.
Near-White Blast Cleaning
Same as NACE No. 2 Near-White Blast Cleaned Surface Finish.
Nozzle
An outlet or orifice such as a spray gun nozzle.
Orange Peel
A dimpled, roughened appearance in a dried coating.
Outgassing
Releasing of a contained gas.
Oxide
A chemical compound formed by combining with oxygen.
Pass
Moving of the spray gun in one direction only.
Peeling
A physical detachment of the coating, which results in a bending away from the pipe.
Permeability
A property of a coating which allows liquids or vapors to pass through it.
pH Value
The measure of acidity or alkalinity. A pH of 4 is acidic; 7 is neutral; 11 is alkaline. The
scale ranges from 1 to 14.
Polymer
A large molecule formed by combining smaller ones.
Profile
Contour of a surface when viewed from the side.
Rust
Corroded iron or steel formed by oxidation.
Shot Blasting
Blast cleaning with hard steel balls as an abrasive.
Skips
Voids or holidays in the coating.
Solvent Wash
Cleaning with a substance which will dissolve other substances.
Spark Testing
Holiday Testing using an electric spark
Specific Gravity
Ratio of the weight of a material when compared to an equal volume of water.
Squeegee
A stiffbar applicator or tool for applying or removing liquids from the surface.
Streaks
A surface condition, which has parallel lines of different colors or shades.
Tack
The amount or degree of stickiness of a coating.
Tape Test
Test of the cleanliness of the pipe surface.
Tensile Strength
Resistance to being stretched or elongated. The greatest horizontal stress a material can
withstand before rupturing or being permanently elongated.
Thermosetting Resin
A coating component, which becomes hard and rigid under heat and cannot be remelted.
Void
Holidays, skips, pinholes, or holes. A disruption in the coating.
Wet Film Gage
A device for measuring thickness of a coating while it is uncured or wet.
Epoxy Final Exam

For accreditation you will need to pass the final exam. You should be ready to take the exam
after you feel competent with the interactive practice exam that came with your password.
Contact NAPCA at:
National Association of Pipe Coating Applicators
Deposit Guaranty Bank Building
333 Texas Street, Suite 717
Shreveport, Louisiana 71101-3673
Telephone (318) 227-2769
Telefax (318) 222-0482
The final exam will be sent to you.
If you haven't received the practice CD, please contact NAPCA.

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Fusion Bonded Epoxy Operational Training Course

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Credits and Acknowledgements

Chemistry of Fusion Bonded Epoxy Coatings

Mechanical Pipe Cleaning

Abrasive Blast Cleaning Machine

ABRASIVE BLAST CLEANING MACHINE

Figure 1.1 Abrasive blast cleaning machine.

Vestibule and seals

Combination brush and sheet

Control system packages

Abrasive level monitoring

Abrasive flow control systems

Automatic magnetic variable abrasive flow control

Wheel Drives and Speed Control

Cabinet liner packages

Cast chrome molly

Figure 1.2 Exploded view of a wheel unit.

Figure 1.4 Direct driven wheel assembly.

Figure 1.5 Bi-directional wheel assembly.

2. Check blades or vanes.

3. With blades removed, close housing and run

5. Inspect control cage. If bevel edge of the opening

6. Inspect wheel housing liners and deflectors,

7. Check blast pattern for correct setting.

*8. Record Ammeter reading.

9. Check ammeter for accuracy with Tong ammeter.

Excessive vibration at the wheel usually indicates worn

If squeaking/squawking occurs while starting motor on

The leading edge of the control cage opening is

If grinding noises occur in the wheel during start-up, it

When replacing worn blades, replace the complete set.

Wheel blades are considered worn out when grooves or

Figure 1.7 Up-blast cleaning theory of operation.

Figure 1.8 Down-blast cleaning theory of operation.

The cabinet should be free of leaks. Flying abrasive

2. Clean loose abrasive from roof areas and return it

3. Inspect wheel housings and liners. Replace as

4. Check entrances, exits, loading doors, and seals for

If the elevator makes clanging noise while operating, it

Cast malleable iron buckets are most efficient on

Multi-ply heavy-duty rubber belting 3/8" to 1/2" thick is

Figure 1.9 Cycle of abrasive through blast cleaning system.

3. Check sprockets and drive for tension, alignment,

4. Check abrasive control valve for free operation and

Figure 1.10 Gravity type abrasive screening system.

ROTARY SCREEN TYPE

Figure 1.11 Rotary type abrasive screening system.

Maintain a full-length curtain for effective cleaning of

All abrasive in storage hopper should be free of fines and

If good abrasive is discharged from fines, trash or rotary

If excessive dust is coming from blast cabinet, it usually

Figure 1.12 CFS (Compensating Flow Separator) abrasive separator.

1. Clean scalping screen.

2. Check scalping screen for holes.

3. Check shed plates, baffles for wear.

4. With machine in blasting cycle, check abrasive flow

5. Make sure dribble valves are in place on refuse

(check separator discharge for usable abrasive.)

Figure 1.14 Schematic of a typical dust collection system.

Figure 1.15 Dust collector up draft concept of operation.

Shaker-type bag houses should have hopper emptied two

Anytime dust collector has a sealed fines container under

If no sealed container exists under the slide gate, keep it