船用油漆工程师FR考试.doc

Day 1
Specification: A document defining what is wanted and what shall be done to achieve this.
标书:一个关于我们想做什么和将要完毕什么的定义文献
Procedure: A detailed description of how to perform the tasks called for in the specification.
工艺:一个具体记录了如何执行配套规定的条款
Specification ---- “what” to do.
标书---做些什么
Procedure ---- “how” to do.
工艺---怎么去做
Coatiog system specification
油漆配套标书
l Area部位
l Substrate基层
l Surface preparation表面解决
l Coating system涂装系统
Coating work specification
油漆工作标书
l Coating system specification油漆配套标书
l Procedure工艺
Standard: Definitions and procedures made by third party authority used as a common reference.
标准:政府或有关权威部门统一制作的定义和程序
Why do we use standards为什么我们要使用标准
l Uniform understanding统一理解
l Normative procedures and equipment标准化的程序和设备
l Rationalization of production合理的产品
l Avoidance of discussions避免不同的意见
Five levels of standards标准的5个等级
l Company standards 公司标准
l Industry standards 行业标准
l National standards 国家标准(BS英国标准 ,DIN德国标准,ASTM美国标准)
l Regional standards 地区标准(CEN)
l International standards (ISO)国际标准
Quality assurance (QA): Implementation of all the systematic and planned actions necessary to ensure that a product or service is delivered is the required quality.
质量保证: 根据计划的施工规定执行所有体系来保证产品和服务在协议规定范围内的质量.
Quality control (QC): Checking of individual operations to ensure conformity with the specifications.
质量控制:保证得到标书规定品质的独立检查
One of the actions in QA是质量保证的一部分
Surface treatment inspector inspection phases表面解决检查人员的检查范围
l Before surface preparation表面解决前
l Surface preparation表面解决中
l Before paint applications表面解决后
l Paint application申请涂装
l After paint application在涂装后
Inspector duty检查员的职责
l Observe , monitor观测,监控
l Advice建议
l Check检查
l Report报告
l Stop of work requires (given authority)有必要的停止工作(需要授权)
How to perform怎么样执行
l Technically authoritative技术上的权威
l Flexible 灵活掌握(within the limits of specifications在标书范围内的)
l Well behaving /diplomatic良好的行为/老到
Why use coating为什么使用涂层
l Protection保护
l Signal ownership标注所有人, company colour给予颜色, image图象
l Warning警告, attention注意
l Ease of cleaning容易的清洁
Substrates基层
l Steel钢材
l Non-ferrous metals非铁金属
l Concrete混凝土
l Wood木材
l Plastics塑料
Coatings涂层
l Paint油漆
l Metallizing金属
l Glass玻璃
l Powder coating粉末涂料
l Wax coating (soft coating)蜡涂层(软涂层)
Considerations注意事项
l Substrate基材
l Environment环境
l Surface preparation表面解决
l Coating quality涂层质量
l Coating type涂层类型
l Paint application油漆施工
l Paint film thickness油漆厚度
Day 2
Surface preparation: The process making a surface suitable for application of a coating.
表面解决:解决需要涂装的基材表面
Increase adhesion – long term
增长附着力-长时间的保护
l Removal of contaminants (cleanliness)去除污染物(清洁)
l Increase of contact area (anchor pattern)增长接触面积峰状表面
Contaminants ---General污染物-常规
l Dust灰
l Oil/grease油/油脂
l Moisture水痕迹
l Salt ----Osmosis盐-可溶解的
l Non-intact, old coating不完整的旧涂层
Contaminants ---Substrate污染物-基材
l Millscale ---steel (battary), St2,St3 have millscale.氧化皮—钢材
l Red rust ---steel红锈-钢材
l White rust ---galvanizing, zinc coating白锈-镀锌或锌层
l Laitance ---concrete浮浆皮-混凝土
Methods for removal (ISO8504)去处方法
l Chemical化学解决
l Thermal热解决
l Mechanical机械解决
Chemical methods化学解决
l Water (<700bars) ---soluble salts
小于700ars的水冲洗---可溶性盐
l Alkaline solutions ---grease ( not mineral oil)
碱性液体----油脂(没有矿物的油)
l Emulsifying solutions ---oil, grease
乳化液---油,油脂
l Solvents ---oil, grease
溶剂---油,油脂
l Pickling (acid treatment) ---millscale, rust
酸洗(酸解决)---氧化皮,锈
l Electrolytic descaling ---rust
电解除锈---锈
l Phosphatizing ---protective layer, adhesion, promoter, phosphate layer protect corrosion
磷化---形成磷酸盐,给予保护

Thermal methods热解决
l Flame cleaning ---millscale, rust, oil火焰除锈---氧化皮,锈,油
Mechanical methods机械解决
l Needle gunning, chipping ---rust针枪,敲铲---锈蚀
l Grinding (ISO8501) ---rust, old coating打磨---锈,旧涂层
l Wire brushing ---rust, old coating (not millscale)钢丝刷---锈,旧涂层(没有氧化皮)
l Sanding ---rust, old coating (roughening)砂纸打磨---锈,旧涂层(粗糙的)
l Abrasive blasting ---millscale, rust, old coating喷砂---氧化皮,锈,旧涂层
l Water jetting ---rust, old coating (does not roughening)
高压水除锈---锈,旧涂层(没有粗糙度)
Sequence of cleaning清洁顺序
1. Oil, grease ---emulsifying solutions油，油脂---乳化溶解
2. Soluble salts ---water hosing, water jetting可溶性盐份---水管清洗，高压水喷射
3. Millscale ---blasting, sanding, water jetting, etc.氧化皮---喷砂，打磨，高压水喷射
4. Dust ---blowing, vacuum cleaning灰---排风，吸尘
5. Moisture ---heating潮湿---加热
Methods –relative durability, C-steel
l No preparation ---------
l Flame cleaning -------------
l Power tool ------------------------
l Blasting --------------------------------------------------
l Water jetting --------------------------------------
Standards标准
l Cleanliness ---ISO8501-1清洁度
l Contaminants ---ISO8501-1, ISO8502污染度
l Methods ---ISO8504方法
l Roughness characteristics ---ISO8503粗糙度特性
l Water jetting ---SSPC –SP12/ NACE5高压水喷射
Equipment for abrasive blasting喷砂设备
l Centrifugal force ---wheel abrator离心力---叶轮抛丸
l Pressurized air (open blasting加压喷射（开放式）
Wheel abrator –characteristics叶轮抛丸-特性
l Almost exclusively on line大部分用于生产线
l Typically arranged insets ---2, 4, …
l Low to medium roughness较低的粗糙度
Wheel abrator –what to look for?叶轮抛丸-应当期待什么？
l Result效果
l Refill frequency再装频率
l Type and mix of abrasives混合磨料的类型
l Synchronizing of wheel abrators同步抛丸
Nozzle –choracteristics喷嘴-争论
l On-site在现场
l Versatile多样性
l High roughness possible (pressure, distance)高粗糙度（压力和距离）
Nozzle –what to look for?喷嘴-应当期待什么？
l Result效果
l Oil油
l Water水
Nozzle –variants喷嘴-不同类型
l Dry干
l Wet湿
l Vacuum真空
Abrasive –types磨料类型
l Metallic金属
l Non-metallic非金属
--Mineral矿石
--Organic有机物
--Others其它
Abrasives磨料
l Grir ---angular菱角砂---多角的
l Shot ---round钢丸---圆的
l Wire cut ---cylindrical钢丝段---圆柱型
Metalloc金属
l Chilled iron grit硬铁粗纱
l High-carbon, cast steel grit/shot高碳，铸铁菱角砂/钢丸
l Low--carbon, cast steel shot低碳量铸铁钢丸
l Wire cut钢丝切段
Non-metallic非金属
l Natural minerals自然矿石
Garnet, Olivine, Staurolite 石榴石，橄榄石，十字石
l Synthetic minerals (slags)合成矿石（矿渣）
Copper slag, Nickel slag, Coal furnace slag, Iron furnace slag, Glass,
Aluminium oxide
铜矿砂，镍矿砂，煤矿砂，铁矿砂，玻璃，氧化铝
l Organic有机物
Ground walnut shells
Ground cherry stones
l Other其他
CO2 ice, Baking soda (NaHCO3), Plastic granulates
Surface characteristics for abrasive blasting磨料喷砂表面特性
l Profile ---sharp or dimpled轮廓---锋利或酒窝状态
l Roughness ---high or low粗糙度---高或低
l Density ---high or low密度---高或低
Ry5 : Mean of five max. Peak to valley measurements in five adjoining
sampling length
Ry5:5个最大值的平均值。测量5个临近的波峰到波谷的距离值
Ry5 = 1/5 (Ry①+Ry②+Ry③+Ry④+Ry⑤)
Ry (Rmax.) : Max. Distance peak to valley in sampling length
Ry (Rmax.) ：最高测量的临近波峰到波谷的距离值
Rz : Rz = 1/5 (y1+y2+ …+y9+y10)
Rz velue near Ry5
Ra : Ra * L = ( Area above + Area below)
Summary
l Ry > Rz
l Ry5≈Rz however, 5 and 1 sampling length respectively
l Rz >> Ra Rz≈6 * Ra
l Roughness ---increased area粗糙度----增长的面积
l Area increase ( %)≈0.9 *Rz (micron)
Density : Number of peaks above the arithmetical mean line per unit
Length
密度：单位面积内波峰数量的算术平均值
! Peaks exceeding a chosen minimum
Assessment for surface characteristics表面特性的评估
l Profile ---visual轮廓---肉眼查看
l Roughness ---comparator (Testex)粗糙度---对比测试
l Density ---stylus密度---触针检测
Comparator对比设备
l ISO Comparator (Grit and shor) ---means for Ry5
l Rugotest NO.3 (Grit and shot) ---Ra
l Testex ---Ry
l Needle gauge针式测量仪---Ry5
Day3
Paint : A liquid material which can be applied on the substrate.
油漆:一种外加在基层表面的液体材料
Why use paint?为什么要使用油漆
l Protection (the main funtion)保护（重要作用）
Steel and other metals ---against corrosion
钢铁和其它金属---防止腐蚀
Wood ---against rot / decay
木材---防止腐烂/腐朽
Concrete ---against carbo
混凝土---防止风化
Other valuable structures ---against …其它有价值的表面---防止
---fouling (ships underwater areas)---污垢（船底部位）
---contamination of commodities (cargotanks)日用品污染（船货仓）
---abrasion (ships decks)磨损（船甲板）
l Decoration装饰
l Warning / safety警告/安全标志
l Comouflage伪装
l Image图象
Composition for paint油漆的组成
l Binders树脂
l Pigments颜料
l Extenders填料
l Solvents溶剂
l Additives助剂
Binders ---characteristics树脂---特性
l Non-volatile part不可挥发部份
l Adhesion附着力
l Cohesion ---strength of the paint内聚力---油漆内部强度
l Paints prominent properties体现油漆重要性能
Examples for binders树脂实例
l Bitumen, tar沥青，焦油
l Chorinated rubber, Acrylic, Vinyl氯化橡胶，丙烯酸，乙烯基
l Silicone, Silicate硅有机树脂，硅酸盐‘酯’
l Alkyd, Modified alkyd醇酸树脂，改良]醇酸树脂
l Epoxy, Polyurethane环氧，聚氨酯
Pigments ---characteristics颜料---特性
l Non-volatile part不可挥发部分
l Colour颜色
l Opocity (hiding power)功能（隐藏能力）
l Other functional properties其它性能
Examples实例
l Prime or hiding (white)
l Black碳黑
l Other coloured, Organic and inorganic其它的颜色，有机和无机
l Metallic金属
Extenders ---characteristics填料---特性
l Non-volatile part不可挥发部分
l Mechanical strength机械性能
l Application properties施工性能
l Cost reduction减少成本
Example
l Carbonates, Silica, Silicates碳酸盐，硅土，硅酸盐
Solvents ---characteristics溶剂---特性
l Volatile part可挥发部分
l Dissolution (liquification) of binder分散（液化）数值
l Application properties施工性能
l Drying time干燥时间
l Flash point闪点
Example
l Hydrocarbon
---Aliphatic (white spirits)
---Aromatic (naphtha, toluene, xylene)
l Oxygenated
---Alcohols (n-bulanol)
---Ester (n-butyl acetate)
---Ethers (monoethyl, ethylene, glycol)
---Ketones (MEK, MIBK)
Type Example Resin
Aliphatic White spirit Alkyds
Aramatid Toluene, Xylene CR, Vinyl
Alcohols Ethanol, Butanol Zinc ethyl silicate
Epoxies
Ketones MEK Epoxies
Acitates Ethyl acetate
Butyl acetate
Epoxies, Polyurethane
Examples for additives
l Anti-settling, anti-skinning agent
l Driers
l Plasticizers
l Wetting agent, coalescing agents
l Preservative, fungicides
Production for paint油漆的生产
1. Raw (materials)准备
2. Premix (millbase)预混合
3. Dispersion (grinding)分散
4. Final mix (binder, solvents, additives let down)最终混合
5. Filling and packaging包装
Dispersion stage ---Grinding (wetting of agglomerates)
l High speed disperser: up to 3600 liters/batch
l Dynomill: up to 1500 liters/hour
Generic type : A member of a family with properties distinct from other
members of the family. ---binder decide paint property
一般类型：树脂决定油漆类型
l Physically drying物理干燥
l Chemically curring化学固化
l Oxidatively curing氧化固化
Physically drying (solvent borne)
Common properties Generic type
l Thermoplastic
l Reversible
l Solvent sensitive
l Excellent recoatability
l Temperature independent for
film formation
Bitumens, Tars,
CR,
Acrylic,
Vinyl,
Physically drying (water borne)
Common properties Generic type
l Thermoplastic
l Reversible (to a certain degree)
l Solvent sensitive
l Excellent recoatability
l Temperature independent for
film formation
Acrylic copolymer,
Styrene-butadiene copolymer,
Vinyl acetate copolymer,
Vinyl chlorinated copolymer,
Chemically curing
Common properties Generic type
(solvent borne)
Generic type
(water borne)
l Non-thermoplastic
l Irreversible
l Resistant to solvent
(own)
l Critical recoating
interval
l Temperature
dependent for film
formation
Epoxies,
Polyurethane, (one or
two-pack)
Zinc-silicate,
Silicones,
Polyesters (hempel
3592),
Epoxies,
Zinc silicates,
Oxidative curing (Solvent-borne and water-borne)
Common properties Generic types
l Generally similar to chemically
curing paint
l Poor alkali resistant
Oil based, Oleoresinous,
Alkyds,
Multified ---epoxyester
Physically drying
l Solvent-borne ---binder ∽∽∽∽
l Water-borne ---binder globules ●●●●
Pot life : Maximum time, at a given paint temperature, the mixture of
base and curing agent should be used after mixing.
Induction time : Minimum time, at given paint temperature , necessary
to allow pre-reaction of the components for optimum film formation.
Minimum temperature for film formation
Physically drying (solvent borne) -10℃
Alkyds 5℃
Epoxy (in general) 10℃
Polyurethane -10℃
Water borne 5℃
Zinc silicate (solvent borne) -10℃
Application must give the paint film the following properties:
l Durability in service environment
l Protection of substrate for suitable peried
l Formation of coherent film with low permeability to substrate
l Impact and mechanical resistant
Brush
l Good penetration
l Cheap
l Slow
l Uneven films (brush marks)
Roller
l Poor penetration
l Cheap
l Slow
l Very thin and uneven films
Checklist for application of paints
l Stirring /mixing /thinning
l Correct wet film thickness
l Adequate ventilation
l Temperature limitations
l Avoidance of too high RH
l Good workmanship
l Safety, health and environment
Chicklist application of 2-pack paints
l Correct mixing of components
l Mechanical mixing
l Induction time
l Minimum and maximum overcoating times
l Pot life
l Curing time
l Temperature limitations during application and curing
Loss factors during application
l Wind [ > 2m/sec (7.2km/h) –inadvisable to apply by spray]
l Application method (e.g. spray, brush, roller)
l Surface profile (dead volume)
l Access (e.g. narrow spaces, long distances)
l Design
l Equipment (e.g. nozzle size, gun)
l Left in can or equipment
Day4
Corrosion : A degradation of a metal through interaction with the
environment.
腐蚀：由于外界因素产生对金属材料从外到内的降解。
Galvanic series电位差
（Noble惰性）
1.25 C (graphite)石墨
0.95 SS (passive)被动的
0.7 Cu铜
0.68 Millscale氧化皮
0.5 SS (active)积极的
0.4 Fe铁
0.0 Zn锌
-0.6 Mg镁
（Ignoble活泼）
Type for steel钢材类型
l Mild steel低碳钢, carbon steel碳钢
l Cast iron铸铁
l Corten steel低合金高强度钢
l Stainless steel不锈钢
All can corrode都能被腐蚀
Corrosion for steel (in air) 钢铁腐蚀（空气中）
l Relative Humdity湿度（湿度大于60%时，湿度越高腐蚀越快）
l Dirt, dust泥土，灰
l Salt, sulfur dioxide 盐，二氧化硫
Steel + Air (Oxygen) + Water → Rust 钢铁+空气（氧）+水 → 铁锈
Corrosion for steel (in water) 钢铁腐蚀（水中）
l Air, oxygen 空气，氧气
l Salinity of water 水中含盐量，重量比（4%为最高腐蚀点，由于含氧量减少）
l Non-alkaline water 非碱性水
Steel + Air (Oxygen) + Water → Rust 钢铁+空气（氧）+水 → 铁锈
Steel + Oxygen + Water ---mechanism 钢铁+氧气+水 --- 原理
Steel + Acid → Iron salt + Hydrogen
钢铁+酸 → 铁盐+氢
Steel + “Other metal” ---Zinc, Copper
钢铁+“其他金属”---锌，铜
l Corrosion product +groove
l Water + salt ---Electrolyte
Design –Avoid计划---避免
l Dirt / dust traps
l Water traps
l Combination of metals, without insulation
Corrosion types腐蚀类型
l General / Uniform corrosion典型/均匀腐蚀
l Galvanic / Bimetallic corrosion电化学/双金属腐蚀
l Pitting corrosion深度腐蚀
l Crevice / Deposit corrosion裂缝/沉淀腐蚀
l Erosion / Turbulence corrosion冲击/空气或液体流动腐蚀
l Selective / De-alloying corrosion选择性/脱合金成分腐蚀
l Stress corrosion cracking应力腐蚀开裂
l Microbiologically induced corrosion微生物感染腐蚀
G / U : Even corrosion spread all over the substrate of the corroding metal. Reduction of metal thickness at a slow and constant rate evenly over the surface.
G / U：遍及表面传布使腐蚀金属平均的腐蚀。 金属的厚度慢的并且平均地减少数值速率。
G / B : Direct contact between two metals having different electrical potentials in an electrolyte.
Intensity of attacks depends on:
l Difference in electrical potential
l Relative area sizes of anode and cathode
1. A small cathode will not offect a large anode very much (General
corrosion)
2. A large cathode will affect a small anode very much (Pitting
corrosion)
May be reduced through:
1. I