The Company has two levels of partial inspection, Level 2 being the more limited.
Partial Inspection Level 1. Partial Inspection Level 1 (Figure 100-3) differs from a complete inspection not only in the inspector’s qualifications and time on the project, but also in the number of tests required.
The inspector examines or tests particular items—highlighted on the checklist—
during and on completion of the work. Time and cost permitting, the inspector may III. Application—First Coat
❏ A. (c) Check surface for flash rusting.
❏ B. (c) Check ambient conditions.
❏ C. (n) Check steel temperature.
❏ D. (c) Check proper mix ratio observed.
❏ E. (n) Check for proper thinner addition (when necessary).
❏ F. (a) Check wet film thickness.
IV. Application—Subsequent Coats
❏ A. (c) Check dry film thickness of preceding coats.
❏ B. (c) Check recoat times observed.
❏ C. (c) Check intercoat cleanliness.
❏ D. (c) Check ambient conditions.
❏ E. (n) Check steel temperatures.
❏ F. (c) Check proper mix ratio observed.
❏ G. (n) Check for proper thinner addition (when necessary).
❏ H. (a) Check wet film thickness.
❏ I. (c) Repeat for every coat.
V. Final Inspection
❏ A. (c) Check visual appearance.
❏ B. (c) Check dry film thickness.
❏ C. (c) Holiday test. (Required only for interior coatings)
❏ D. (c) Cure test.
❏ E. (c) Verify all touch-up and repair work.
❏ F. (c) Complete records and copy Chevron OPCO.
❏ 1. Verify compliance to specification.
❏ 2. List work, if any, not in compliance and why.
Fig. 100-2 Inspection Checklist—Complete Inspection (2 of 2)
also verify the critical and necessary items on the Checklist For Complete Inspec-tion (Figure 100-2) as any extra inspecInspec-tion improves the coating’s reliability.
Partial Inspection Level 2. Partial Inspection Level 2 (Figure 100-4) is the minimal inspection for any tank or vessel coating project and is recommended only if the Company is willing to accept the risk of premature failure of the coating
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Caution Select Level 2, the lowest recommended level, only after evaluating the project carefully and considering the risks of a premature failure.Fig. 100-3 Inspection Check List—Partial Inspection—Level 1 (1 of 2)
All items listed are critical to Level 1 Partial Inspection and should be conducted by someone familiar with coat-ings inspection. This person may be a qualified inspector, an experienced Chevron inspector, or an engineer with a good knowledge of coatings inspection. The inspector should keep records (using the Company's Standard Form COM-EF-844 or another form agreed upon by the Chevron representative and the inspector) and should file a copy of the report with the Chevron OPCO.
I. Pre-Job Check Out
❏ A. Review Chevron OPCO Specification.
❏ B. Check tank for inaccessible areas, laps, patches, rough welds, weld spatter, etc.
❏ C. Check surface for grease, oil, moisture, etc.
❏ D. Check abrasive for cleanliness, dryness, etc.
❏ E. Check to see the coating has not passed its shelf life.
II. Surface Preparation
❏ A. Check degree of surface cleanliness.
❏ B. Check dust and abrasive removal.
III. Application—First Coat
❏ A. Check surface for flash rusting.
❏ B. Check ambient conditions.
❏ C. Check steel temperature.
IV. Application—Subsequent Coats
❏ A. Check dry film thickness of preceding coats.
❏ B. Check recoat times observed.
❏ C. Check intercoat cleanliness.
❏ D. Check ambient temperatures.
❏ E. Check steel temperatures.
❏ F. Repeat for every coat.
V. Final Inspection
❏ A. Check visual appearance.
❏ B. Check dry film thickness.
❏ C. Holiday test.
❏ D. Cure test.
❏ E. Complete records and copy Chevron OPCO.
❏ 1. Verify compliance to specification.
❏ 2. List work, if any, not in compliance and why.
Fig. 100-4 Inspection Checklist—Partial Inspection—Level 2 (1 of 2)
All items listed are critical to Level 2 Partial Inspection. This is the minimum inspection to be performed when lining a tank or vessel. With a little planning and thought, an OPCO engineer or construction representative can carry out all of these tests. The inspector should keep records (using the Company's Standard Form COM EF-844 or another form agreed upon by the Chevron representative and the inspector) and should file a copy of the report with the Chevron OPCO.
I. Pre-Job Check Out
❏ A. Review Chevron OPCO Specification
Know what the specification requires so you can discuss it with the coating contractor.
❏ B. Check tank for inaccessible areas, laps, patches, rough welds, weld spatter, etc.
Linings will not cover irregular or rough surfaces adequately. Welds should be ground smooth and sharp corners rounded. If not possible, apply a stripe coat of the lining material after surface preparation.
❏ C. Check surface for grease, oil, moisture, etc.
The biggest cause of premature lining failures is a contaminated surface. Cleanliness is the single most important step in the lining of a tank or vessel.
❏ D. Check to see the coating has not passed its shelf life.
This is a simple step; old coatings are hard to apply and will not perform properly.
II. Surface Preparation
❏ A. Check degree of surface cleanliness.
Linings require abrasive blast cleaning the surface to a “White Metal Blast” (SSPC-SP5).
See Abrasive Blast Coating Guide for Aged or Coated Steel Surfaces in the Coatings Manual for a visual guide to judging degrees of abrasive blast cleaning.
❏ B. Check dust and abrasive removal.
Visually check to see there is not any dust or abrasive residue on the surface to be lined.
Dust or residue can cause the lining to have poor adhesion.
III. Application—First Coat
❏ A. Check surface for flash rusting.
After abrasive blasting, the surface can flash rust due to high humidity or salts on the surface. Linings applied over a rusted surface will fail prematurely.
❏ B. Check surface for moisture.
Do not apply linings if the surface is damp. This usually happens when the surface is below the dew point. Linings applied over moisture will not adhere.
Fig. 100-3 Inspection Check List—Partial Inspection—Level 1 (2 of 2)
163 Inspectors
To carry out a thorough inspection, the inspector may be a Company employee or a contractor but must be trained, experienced, and familiar with a variety of coating methods and equipment.
Whether full- or part-time, the inspector should participate in all inspections at the completion of the coating contract and must inspect the finished project before the end of the contractor’s guarantee.
Qualifications
Full-time Inspector. A qualified, full-time coatings inspector must have one of the two backgrounds below:
Certified and experienced.
• National Association of Corrosion Engineers (NACE)-certified Level III
• Experience inspecting tank and vessel coatings IV. Application—Subsequent Coats
❏ A. Check recoat times observed.
Most linings have a maximum and minimum recoat time. The times are dependent on the temperature; higher temperatures equal shorter times. The lining manufacturer’s data will give you the recoat time at a standard temperature. If your temperature is different, call the manufacturer’s representative.
❏ B. Check intercoat cleanliness.
Make sure the first coat has not been contaminated before applying subsequent coats.
❏ C. Repeat Sections III & IV for every subsequent coat.
V. Final Inspection
❏ A. Check appearance.
Visually check for runs, sags, skips, etc. If the job looks good, then the contractor probably did a good job. If not, you might want to do some of the testing listed in Partial Inspection, Level 1.
❏ B. Check dry film thickness.
While present, have the contractor calibrate his dry film thickness gage and randomly check the lining to see if it meets the specified dry film thickness.
❏ C. Final Cure.
Check with the lining manufacturer on how long to wait before putting the tank or vessel in service. Circulating hot air through the tank or vessel will shorten the time.
❏ D. Verify all touch-up and repair work.
There will usually be some touch-up or repair work, so verify that it has been done.
❏ E. Complete records and copy Chevron OPCO.
❏ 1. Verify compliance to the specification.
❏ 2. List work, if any, not in compliance and why.
Fig. 100-4 Inspection Checklist—Partial Inspection—Level 2 (2 of 2)
Uncertified, trained, and experienced.
• No certification
• Some industry-accepted training
• At least five years of verifiable experience inspecting coatings on tanks and vessels
Example: Industry training coating courses are offered by KTA-Tator, S.G.Pinney, or Bechtel.
Part-time Inspector. A qualified, part-time inspector must be:
• Familiar with the different methods of inspection
• Capable of identifying potential problems and analyzing results
• Experienced in coating inspections This inspector may be
• A qualified third-party inspector
• An experienced Company inspector
• An engineer familiar with coating inspections
Responsibilities
Full-time inspector. The full-time inspector reviews the project prior to start up and is present whenever the fabricator is working offsite or the contractor onsite and during hold points in the project, normally:
• Prior to starting work
• After preparing the surface
• Prior to applying each coating
• Following application of the final coating
• Following the final cure
Part-time inspector. The part-time inspector must be available to examine the coating during the project's hold points.