Digital Data Management For Coating Inspection Tasks On Steel Structures

Presented by: Joe Walker, Elcometer

Learning Outcomes• Define digital data management• Define key sections where project

information is recorded within a digital data management software package

• Define surface profile, ambient conditions, and dry film thickness

• Recognize how to perform profile, ambient conditions, and dry film thickness measurements

Introduction• Optimum corrosion protection and

rigorous inspection is required – on both new build and existing structures

• Protective coating maintenance costs for steel structures continue to rise

• Accurate records of inspection measurements and procedures provide assurances to the owner or the purchaser that the coating is being applied properly

Inspection• Independent inspection provides

quality assurance to the owner• The time needed to perform quality

inspections will impact overall project• Inspections are necessary to meet the

required standard

Inspection• The key therefore is to minimize the

time spent writing the reports, so more time can be spent inspecting

• This is where digital data management comes in

What is Digital Data Management?

• What are the issues?

• Not all inspections are with digital gauges• Surface condition – SA2½ • Surface cleanliness

– soluble salts– beading – weld spatter

• Surface contaminants– Oil, grease, dust– abrasive inclusions

• Edge radii• Surface profile• Climate conditions• Dry film thickness• Film continuity• Damage & inclusions

• Some use ‘mark 1 eyeball, others mechanical, and some have a digital display but no data output or memory

Digital Data Management Software for Inspection

• Advantages:– Significantly speeds up measurement

and recording time- by as much as 70%– Minimizes (and in most cases removes)

human error- transcribing or keying in errors

– Reduces paperwork– Provides real time inspection data to the

customer

What is Digital Data Management?

• Digital Data Management comes in many forms:

• Hand written reports – scanned into the computer and stored• Hand written reports – manually keyed into the computer• Inspections using digital test equipment and downloaded into a

computer• Inspections carried out using a PDA and digital test equipment

emailed to the PC• Total paperless QA – with inspection task planning

Total Paperless QA• Provides a framework for planning and

recording coating inspection tasks• Provides a single point of reference for all

coatings applied – and in which location• Provides a daily activity log• Generates a complete inspection report –

automatically• Provides an electronic method for

recording both digital and non-digital inspections

• Maximises inspection time

Using Digital Data Management

• Provides a framework for planning and recording these coating inspection tasks on large projects.

Key Components of Digital Data Management Software– A coating library– Defined coating systems used throughout the

structure– A register of inspectors and their certifications

(e.g. PCI and NBPI)– A list of individual inspection check/hold points– Details of the structure being coated (including

drawings)– A list of individual inspection tasks, along with

areas to record results and links to rework– A daily log that contains inspection information

recorded by the system administrator

Coating Library• Repository of information from the manufacturer’s

product data sheet– Manufacturer– Product name– Product ID– Specified wet film thickness/dry film thickness– Specified surface profile– Ambient conditions for application

Defined Coating Systems• Unique IDs in the coating library tying

each coating system to structure area

Defined Coating Systems: Application

• Once the coating system’s unique identification is created, the steps for proper coating application are specified

Register of Inspectors• Holds the records for approved

inspectors:– Photograph of inspector– Copy of inspector’s certificate– Record of certificate expiration date– Details of where inspector has permitted

access

Inspection Regime• Area in the digital data management

system that groups inspection check points together, for example:– Surface Preparation Check Points

• Removal of oil and grease• Removal of surface contaminants• Surface profile• Abrasive cleanliness• Cleanliness of abrasive blasting air

Steel Structure Details• A record of the steel structure and

steel parts • Provides a basis for planning the job

and inspection tasks

Steel Structure Details• Example:

– Ship Structure• Record of:

– Hull number/IMO number– Customer’s name– Ship’s name– Contract date– Keel-laying date– Planned launch and delivery dates– Gross tonnage– Deadweight– Length of ship– The beam– The draft and depth

Steel Structure Details• Store drawings of the structure as “jpg.”• Highlight individual areas of the structure

as part of the structure definition• Assign the proper coating system to be

applied to individual areas as well as the appropriate registered inspector

Steel Structure Details

Steel Structure Details

Inspection Tasks• The inspection record (inspection

tests and results) is created after the structure part, coating system, and assigned inspector are identified

Daily Log• Documentation of inspection tests

performed on a given day as well as any scanned documents

• Should include supporting photographs as well as measured data

Reporting Inspection Test Results

• Written on a hard copy printout of the inspection task

• Transferred electronically to a Smart Phone/PDA

• Entered directly into a computer

Reporting Using a Hard Copy Printout

• Finished written document is scanned to create an electronic file within the digital management software

Reporting Using a Smart Phone/PDA

• Transfers the inspection test results along with any photographs to the portable device

Reporting Using a Computer

• Enter testing results directly into the computer

The Three Digital Inspection Techniques

• Surface Profile• Ambient Conditions• Dry Film Thickness

Surface Profile• The roughened surface that results

from abrasive blast cleaning or power tool cleaning to bare metal

• A measurement of the peak-to-valley height of the surface roughness

Surface Profile• ASTM D 4417, Standard Test Method

for Field Measurement of Surface Profile of Blast Cleaned Steel– Method B

Surface Profile• ASTM D 4417, Method B

– The depth of profile is measured using a fine pointed probe at a number of locations and the average is determined

Ambient Conditions• Weather conditions at a specific place

and time or time period: – air temperature– relative humidity– dew point– wind velocity

• Monitored on the job site

Ambient Conditions• Measured using:

– Electronic dew point meters

Ambient Conditions

Ambient Conditions• Maximum relative humidity of 85%• Surface temperature typically must be

at least 5°F/3°C above the dew point in order for final surface preparation and/or coating work to begin or to continue

Dry Film Thickness• Depth of cured film usually expressed

in mils (0.001 inch) or microns (millionths of a meter)

Dry Film Thickness• Measured with:

– Type II Gage (Non-Destructive)

Dry Film Thickness Gages

Dry Film Thickness Standards

– ASTM D 7091, Standard Practice for Non-Destructive Measurements for Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nonconductive Coatings Applied to Non-Ferrous Metals

Dry Film Thickness: SSPC PA 2

• Measurement of Dry Coating Thickness with Magnetic Gages– Type II Gages– Describes how many measurements to

take in a given area

SSPC-PA 2• Provides guidance on:

• Frequency of verifying gage accuracy• Frequency of measurements (number

of measurements to obtain based on the size of the coated structure

• Places limits on thickness readings vs. specified thickness

• Procedures supplement manufacturers’ operating instructions but do not replace them

SSPC-PA 2• Gage Reading- a single reading at one

point• Spot Measurement- the average of at

least three gage readings made within a 1.5 inch diameter circle

SSPC-PA 2• Make five separate spot

measurements spaced arbitrarily over each 100 ft2 area to be measured

• For structures NOT exceeding 300 ft2, each 100 ft2 area shall be measured

• For structures NOT exceeding 1000 ft2, three 100 ft2 areas shall be arbitrarily selected

SSPC-PA 2• For structures exceeding 1000 ft2, the

first 1000 ft2 shall be measured as stated in previous slide

• Each additional 1000 ft2 of area or increment thereof, one 100 ft2 area shall be arbitrarily selected

SSPC-PA 2

Conformance • Minimum Thickness

– No single spot measurement in any 100 ft2 area shall be less than 80% of the specified minimum thickness

• Note- it is possible for any single gage reading to under-run by a greater amount

Conformance• Maximum Thickness

– No single spot measurement in any 100 ft2 area shall be more than 120% of the specified maximum thickness

• Note- it is possible for any single gage reading to over-run by a greater amount

Summary

• Using digital data management can reduce time spent on the inspection process and overall project costs while providing an electronic record of the job in all its stages.

Conclusion• This concludes our webinar for today.

Please join us for our next webinar, Coating Selection for the Wastewater Industry on October 20th at 1 pm EST