Efficient Digital Data Management for Coating Inspection on Steel Structures

1. Digital Data Management For Coating Inspection Tasks On Steel StructuresPresented by: Joe Walker, Elcometer

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. Using Digital Data Management Provides a framework for planning and recording these coating inspection tasks on large projects.

11. 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

12. 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

13. Defined Coating Systems Unique IDs in the coating library tying each coating system to structure area

14. Defined Coating Systems: Application Once the coating system’s unique identification is created, the steps for proper coating application are specified

15. 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

16. 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

17. Steel Structure Details A record of the steel structure and steel parts Provides a basis for planning the job and inspection tasks

18. 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

19. 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

20. Steel Structure Details

21. Steel Structure Details

22. Inspection Tasks The inspection record (inspection tests and results) is created after the structure part, coating system, and assigned inspector are identified

23. 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

24. 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

25. Reporting Using a Hard Copy Printout Finished written document is scanned to create an electronic file within the digital management software

26. Reporting Using a Smart Phone/PDA Transfers the inspection test results along with any photographs to the portable device

27. Reporting Using a Computer Enter testing results directly into the computer

28. The Three Digital Inspection Techniques Surface Profile Ambient Conditions Dry Film Thickness

29. 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

30. Surface Profile • ASTM D 4417, Standard Test Method for Field Measurement of Surface Profile of Blast Cleaned Steel • Method B

31. 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

32. 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

33. Ambient Conditions • Measured using: • Electronic dew point meters

34. Ambient Conditions

35. 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

36. Dry Film Thickness Depth of cured film usually expressed in mils (0.001 inch) or microns (millionths of a meter)

37. Dry Film Thickness • Measured with: • Type II Gage (Non-Destructive)

38. Dry Film Thickness Gages

39. 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

40. 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

41. 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

42. 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

43. 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

44. 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

45. SSPC-PA 2

46. 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

47. 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

48. 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.

49. 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