Online Training and Certification Programme. For the Institute of Corrosion Coatings Inspector Levels 1, 2 and 3. corrodere-tti.

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1 Online Training and Certification Programme For the Institute of Corrosion Coatings Inspector Levels 1, 2 and 3 corrodere-tti.com

2 Contents Page Introduction 3 Corrodere Online Training 3 Pre-requisites for the Training 3 ICORR REQ Doc 3 ICorr Syllabus 4 Levels of Certification 8 Minimum Training Hours 8 Qualification Examinations 8 Practical Examinations 9 Examination Invigilator 9 Practical Assessment Workshop 9 Training Units 9 Student Study Material 10 2

3 Welcome to Traintheinspector Introduction This document details how a student, who is using the Corrodere Online Coating Inspector Training programme, can progress through the Institute of Corrosion Coating Inspector Certification Levels 1, 2 and 3. The document will assist the student in the knowledge requirements for each particular level. Corrodere Online Training The Corrodere online training programme is a unique, approved and endorsed method of training for the Coating Inspector. The student simply registers for the training programme and is then allowed unlimited access to the training. Full access to the training is offered 24/7 for 12 months per level. The Corrodere online training has been developed by Industry experts in the Corrosion Control Industry and uses a voice activated method of training which is supported by text, animation, video and handout notes. Various tools accompany the training which assist the student as he / she progresses The programme automatically monitors the progress made during the training period. ICORR REQ Doc The ICORR REQ Doc is the requirements for the certification of personnel engaged in painting and coating inspection, cathodic protection and related fields. The document is wholly owned and administered by the Institute of Corrosion. The ICORR REQ Doc is a document which establishes a system for the qualification and certification and sets out the requirements common to all parts of the scheme. The Corrodere online training programme works in accordance with the ICORR REQ Doc. A quality system approved by Lloyds training ensures that procedures are available and managed in accordance with ISO A student may progress directly onto ICorr level 2 if they an demonstrate they have coating experience, practical instrument experience and completed the full online training programme. If a student fails level 2 hey will not get a level 1 certificate by default. Pre-requisites for the Training There are pre-requisite requirements for all levels that the student must possess before attempting the training programme. ICorr Level 1 Coating Inspector The student must have twelve months industrial experience in the Coatings Industry. This experience may be obtained by working for painting / coating contractors as protective coatings applicator, abrasive blast cleaning operative or spray painter. Alternatively the student could have industrial experience within paint / coating sales, technical service, chemist etc. The student could also be an unqualified coatings inspector or have some supervisory or management role in the Coatings Industry. ICorr Level 2 Coating Inspector The student must possess ICorr Level 1 Coating Inspector or have twelve months experience of having Coating Inspector experience or Supervisory / Management experience in the Coatings Industry. ICorr Level 3 Coating Inspector The student must possess ICorr Levels 1 and 2 and have twenty four months of Coating Inspection experience. 3

4 ICorr Syllabus LEVEL 1 1 Quality assurance philosophy 2 Ethics 3 Inspection 3.1 Philosophy 3.2 Duties and authority 3.3 Procedures and written instructions 3.4 Meetings 4 Normative documents 4.1 Awareness of types of normative document 4.2 Information contained within normative documents 5 Corrosion 5.1 Nature of corrosion 5.2 Factors influencing corrosion 5.3 Effects of scale and contamination 5.4 Methods of corrosion prevention 5.5 Assessment of corroded substrates 6 Surface preparation (ferrous) 6.1 Reasons for surface preparation 6.2 Characteristics of prepared surfaces 6.3 Weathering for scale removal 6.4 Assessment of surfaces prior to cleaning 6.5 Methods of surface preparation Degreasing Dry abrasive blast cleaning a Abrasive types b Effect of abrasives c Surface profiles d Measurement and assessment of profiles e Assessment of blast cleaning grades f Blast cleaning equipment i Pressure blast cleaning ii Wheel abrators iii Vacuum / suction blast cleaning g Safety of blast cleaning h Pressure measurement during air blast cleaning Wet blast cleaning a Methods b Use of inhibitors Hand and power tool cleaning a Chipping b Scraping c Sanding d Grinding e Wire brushing f Needle gunning Flame cleaning Chemical cleaning 6.6 Assessment of prepared surfaces 7 Surface preparation of non-ferrous surfaces (awareness) 7.1 Methods used 7.2 Precautions 7.3 Weathering for adhesion purposes 8 Weathering for adhesion purposes 8.1 Dust 8.2 Oil / grease 8.3 Soluble iron salts 8.4 Mill scale 9 Coating categories / types 9.1 Paints containing solvent (including water) 9.2 Solvent free paints 9.3 Powder coatings 9.4 Metallic coatings 9.5 Bitumen and coal tar enamels 9.6 Tapes and wrappings 9.7 Compatibility issues 10 Paint constituents and basic chemistry 10.1 Binders Types Polymers / polymerisation Resins and oils 10.2 Pigments Opaque pigments Rust inhibitive pigments Metallic pigments Extenders Laminar pigments 10.3 Solvents 10.4 Other main constituents 10.5 Solutions and dispersions 11 Paint drying and curing 11.1 Solvent evaporation 11.2 Oxidation 11.3 Chemical curing 11.4 Coalescence 12 Corrosion protection methods 12.1 Barrier principle 12.2 Passivation 12.3 Cathodic protection 13 Layers of a paint system 13.1 Etch primers (coupled to surface preparation) 13.2 Primer 13.3 Intermediate coats 4

5 13.4 Finish 14 Types of paint systems 14.1 Sacrificial systems 14.2 Powder coatings 14.3 Moisture tolerant 14.4 Moisture curing 14.5 Water borne coatings 15 Metal coatings 15.1 Common types 15.2 Terminology 16 Paint data sheets 17 Paint milling (awareness) 18 Paint / paint film testing 18.1 Sampling 18.2 Flashpoint 18.3 Viscosity 18.4 Density and specific gravity 18.5 Wet film thickness 18.6 Dry film thickness Non-destructive gauges Awareness of destructive test gauges Calculation Test panels 18.7 Hardness tests Awareness of test methods Pencil scratch test 18.8 Adhesion / cohesion V cut test X cut tape test Cross cut test Tests using dollies 18.9 Pinhole detection High voltage Low voltage 19 Weather conditions and environment 19.1 Types of environment 19.2 Effects on operations 19.3 Relative humidity 19.4 Dew point 19.5 Temperature effects and measurement 19.6 Whirling hygrometer RH/dew point calculator RH/dew point charts 20 Storage of materials 21 Paint application 21.1 Paint data sheets 21.2 Mixing and stirring 21.3 Overcoating times 21.4 Intercoat preparation 21.5 Brush application 21.6 Roller application 21.7 Conventional spray 21.8 Airless spray 21.9 Electrostatic spray Other methods 22 Application coating faults 22.1 Recognition 22.2 Causes 22.3 Rectification (awareness) 22.4 Standards 23 Health and Safety 23.1 Health and Safety at Work etc. Act Toxicity COSHH regulations Risk assessment Occupational exposure limits Monitoring methods 23.3 Explosive limits 23.4 Flammability 23.5 Labelling and packaging 24 Environmental considerations (introduction) 24.1 Waste disposal 24.2 Environmental Protection Act 24.3 VOC 25 Reporting 26 Standards applicable LEVEL 2 The level 2 training syllabus shall review the subject areas for Level 1 and include new subject areas as listed. The examination for Level 2 shall include questions relating to subjects for Level 1 in addition to the subjects listed for Level 2. Any subjects which are repeated indicates a greater depth of knowledge is required compared to Level Quality assurance 27.1 Document control 27.2 Equipment control and calibration 28 Inspection and quality control 28.1 Definitions 28.2 Production of written instructions 28.3 Supervision of Level 1 inspectors 29 Normative documents 29.1 Types of normative instructions 29.2 Interpretation of normative documents 5

6 30 Corrosion 30.1 Types of corrosion 30.2 Anodic and cathodic reactions 31 Surface preparation 31.1 Properties of abrasives 31.2 Sizing of abrasives 31.3 Checking of contamination of abrasives 31.4 Compressors 31.5 Chemical cleaning 31.6 Preparing non-ferrous surfaces 32 Tests to detect surface contamination 32.1 Qualitative tests 32.2 Quantitative tests 33 Paint constituents 33.1 Binders, pigments, solvents (review) 33.2 Pigment volume concentration 33.3 Plasticisers 33.4 Driers 33.5 Anti-skinning agents 33.6 Anti-settling agents 33.7 Other constituents 34 Coating systems 34.1 Coating systems 34.2 Plastic coatings 34.3 Cementitious coatings 34.4 Fire proof coatings 34.5 Anti-foulants 35 Paint manufacturer 35.1 Types of paint mill 35.2 How dispersion is achieved 36 Paint / paint film testing 36.1 Interpretation of results 36.2 Understanding of paint properties 36.3 Fineness of grind 36.4 Volatile / non-volatile matter 36.5 Volatile / non-volatile matter Flow cups Rotation viscometers 36.6 Density Use of density cup Calculation 36.7 Dry film testing Non destruction gauges Destructive test gauges Calculations 36.8 Weathering and artificial weathering Tropical box Salt spray box Water soak Temperature cycling Cold check testing Prohesion 36.9 Mechanical testing Abrasion resistance Hardness Flexibility Impact resistance Drying and curing tests Ballotini test Stylus test Print free test Mechanical thumb Sag resistance test Opacity Degree of gloss Adhesion (review) Cathodic disbandment test 37 Hygrometers 37.1 Types 37.2 Usage 38 Paint application 38.1 Conventional spray 38.2 Airless spray 38.3 Electrostatic spray 39 Application of metal coatings (awareness) 39.1 Hot dip galvanizing 39.2 Sherardising 39.3 Electroplating 39.4 Calorising 39.5 Anodising 39.6 Thermal spraying 40 Coating faults 40.1 Recognition 40.2 Causes 40.3 Rectification 40.4 Standards 41 Paint colours 41.1 Terminology 41.2 Coding systems 6

7 42 Cathodic protection (awareness) 42.1 Sacrificial anodes 42.2 Impressed current 42.3 Determination of adequate protection 42.4 Cathodic disbondment 43 Scaffolding 44 Standards applicable LEVEL 3 The level 3 training syllabus shall review the subject areas for Level 1 and Level 2 and include new subject areas as listed. The examination for Level 3 shall include questions relating to subjects for Level 1 and 2 in addition to the subjects listed for Level 3. Any subjects which are repeated indicates a greater depth of knowledge is required compared to Level Quality assurance 45.1 Systems 45.2 Auditing 45.3 Standards 46 Supervision 46.1 Leadership requirements 46.2 Technical skills 46.3 Team work 47 Planning 47.1 Methods 47.2 Pre-work meetings 48 Standardisation 49 Production of procedures 49.1 Aims 49.2 Format 49.3 Content 50 Basic metallurgy and materials 50.1 Conditions 50.2 Properties 50.3 Effect on corrosion behaviour 51 Corrosion (awareness) 51.1 Corrosion mechanisms 51.2 Interpretation of chemical symbols and chemical formulae 52 Structural design 52.1 Surface preparation and coating considerations 52.2 Corrosion considerations 53 Imperfections on surfaces to be coated 53.1 Types (awareness) Castings Wrought products Welds 53.2 Significance 53.3 Action to take 54 Paint technology 54.1 Polymers 54.2 Corrosion protection mechanisms 54.3 Recent developments 54.4 Compatibility issues 55 Optical aids for inspection 55.1 Magnifiers 55.2 Fibrescopes 55.3 Lighting conditions 56 Paint shop layout 57 Health and Safety 57.1 Scope 57.2 Statutory requirements 57.3 Responsibilities 58 Environmental considerations 58.1 Waste disposal 58.2 Environmental Protection Act 58.3 VOC 59 Assessment of inspection reports 60 Records 61 Standards applicable The Corrodere online training covers all aspects to the above syllabus for Levels 1, 2 and 3. 7

8 Levels of Certification The ICorr Req Doc has three levels of certification which are defined as follows: Level 1 Level 1 personnel are qualified to carry out operations according to written instructions. ICorr Level 1 certified personnel have demonstrated the competence to: Set up and calibrate specific inspection or test equipment Carry out tests and perform inspections against written criteria: Record and classify the results of tests and inspections against written criteria: Report the results Level 1 personnel have not demonstrated competence in selecting the extent of inspection or testing required, appropriate inspection or test methods to be used, nor for the interpretation of specification requirements. Level 2 Level 2 personnel are qualified to perform and direct inspection or testing operations according to established or recognise procedures and they have demonstrated competence to: Choose the extent of inspection or testing to be used (where agreed procedures allow) Choose the inspection and test methods to be used (where agreed procedures allow) Set up and calibrate inspection or test equipment Perform and supervise inspection or testing tasks Interpret and evaluate results according to applicable normative documents Define the limitations of application for common test methods Understand and transform normative document requirements into practical instructions adapted to the actual working conditions Prepare written test instructions Organise and report the results of inspections or tests Level 3 Level 3 personnel are qualified to: Direct any inspection or test operation for which they are certified Assume full responsibility for an inspection or test facility and staff Establish and / or validate work instructions or procedures Interpret normative documents Designate the extent of inspection and the particular test methods and procedures to be used Level 3 personnel have demonstrated: Competence to interpret and evaluate inspection or test results in terms of existing normative documents Possession of a cope and level of knowledge sufficient to enable the individual to select inspection methods and tests, and to assist in the establishment of inspection and test criteria where non are otherwise available A general familiarity with all coating materials, application methods and associated areas The ability to guide personnel below level 3. Minimum Training Hours The minimum number of training hours for the Coating Inspector is: Level 1 40 hours Level 2 40 hours Level 3 40 hours Qualification examinations The ICorr Req Doc outlines the examinations which consist of general, specific and practical. The general and specific examinations consist of both multichoice and essay type questions. The time allocated will be 1.5 minutes per multi-choice questions and 15 minutes per essay questions. General questions technology, principles, physics chemistry and mathematics Specific questions equipment, operating procedures and test techniques LEVEL Level 1 Level 2 Level 3 LEVEL Level 1 Level 2 Level 3 NUMBER OF GENERAL QUESTIONS Multi-choice Essay Multi-choice Essay Multi-choice Essay 40 - Maximum 60 minutes 5 - Maximum 75 minutes 40 - Maximum 60 minutes 5 - Maximum 75 minutes 60 - Maximum 90 minutes 10 - Maximum 150 minutes NUMBER OF SPECIFIC QUESTIONS Multi-choice Essay Multi-choice Essay Multi-choice Essay 30 - Maximum 45 minutes 4 - Maximum 60 minutes 30 - Maximum 45 minutes 4 - Maximum 60 minutes 40 - Maximum 60 minutes 5 - Maximum 75 minutes 8

9 Practical Examinations There is a different type of practical assessment for all three levels: Level 1 Hands on practical assessment of inspection equipment: Environmental equipment Wet and dry film thickness gauges Holiday detection Surface profile Surface contaminants (salt, dust etc) Preparation identification Visual standards Types of abrasives Level 2 Preparation of written instructions for Level 1 personnel (1 hours) Level 3 Preparation of a written procedure involving inspection and testing for a work situation (4 hours). Examination Invigilator LEVEL 1 KEY Core training units. Questions for ICorr Level 1 will be selected from these training units. No questions for ICorr Level 1 will be selected from these training units. LEVEL 2 KEY Questions for ICorr Level 2 are likely to be asked on these training units, however these will be in greater depth than ICorr Level 1. Questions for ICorr Level 2 will be selected from these training units. No questions for ICorr Level 2 will be selected from these training units. LEVEL 3 KEY Questions are likely to be asked on these training units for ICorr Level 3, however these will be in greater depth than ICorr Level 1 and 2. Questions for ICorr Level 3 will be selected from these training units. All exams will be conducted in strict accordance with control procedures and with the use of an ICorr Approved Invigilator. The student must obtain at least 70% in both general and specific parts of the examination and 80% on the practical. Practical Assessment Workshop Corrodere have developed a one day training course for students who wish to have a practical training session on all the Coating Inspection Instruments that will be found in the practical assessments, specifically for ICorr Level 1Coating Inspector. Training Units There are 248 training units in the Corrodere online training programme which covers all the requirements contents of ICorr Levels 1, 2 and 3 Coating Inspector. The student must complete all the online training units and complete all the online test 100% before applying for examination at any level. The student will also have to meet the pre-requisite requirements for every level. 9

10 Student Study Material Protective coatings application 1 Health and safety 1.1 Company induction 1.2 Accident prevention 1.3 House keeping 1.4 First aid 1.5 Electricity and air supply 1.6 Permit to work 1.7 Risk assessment 1.8 Material data sheets 1.9 LEL, TLV, OEL MEL 1.10 PPE 1.11 Basic access requirements 1.12 Safety in surface preparation 1.13 Safety in paint application 1.14 Method statements 2 Access, plant and equipment 2.1 Erecting and dismantling platforms Erecting and dismantling platforms Safe use of ladders 2.2 Types of mobile access Access platforms 3 Surface preparation 3.1 Surface preparation requirements Types and methods of surface preparation Types of substrates and materials Previously painted and coated substrates 3.2 Surface preparation standards Mechanical and hand preparation standards Pre-surface condition Pre-surface preparation and cleaning 3.3 Hand and power tool equipment Chipping hammer Hand wire brush Scraper Needle gun Power wire brush and grinding 3.4 Pre-cleaning methods Steam cleaning Water washing Solvent cleaning 3.5 Auxiliary equipment Compressors Heaters Lighting Grit removal and hoppers De-humidification 4 Coating types 4.1 Coating types and systems 4.2 Products data sheets - review 4.3 Single and two part materials 4.4 Paint mixing 4.5 Pot-life and induction 4.6 Storage 4.7 Batch numbers 4.8 Volume solids 4.9 Coverage 4.10 Compatibility 5 Paint application 5.1 Environmental conditions Relative humidity and dew point Steel temperature 5.2 Types of paint application equipment Brush application Roller application Airless spray (introduction) Air assisted spray (introduction) 5.3 Paint film thickness Wet film thickness Dry film thickness Drying and re-coating Stripe coating 5.4 Paint application procedures Surface cleaning Coatings damage and repair Materials and equipment handling 5.5 Paint locations and types Shop painting Site painting General maintenance - plant and equipment Equipment cleaning 6 Quality control 6.1 Environmental conditions inspection equipment Specialist Equipment 6.2 Inspection standards BS, EN, ISO etc Visual standards 6.3 Specification Equipment, Standards and Specifications 7 Metallic coatings 7.1 Thermal metal spray for corrosion protection 7.2 Galvanizing 10

11 Abrasive blast cleaning 8 Intumescent coatings 8.1 Thin film intumescent coatings 8.2 Thick film intumescent coatings 9 Concrete 9.1 Concrete basics 9.2 Concrete moisture 9.3 Concrete preparation 9.4 Concrete coatings 10 Environmental 10.1 Volatile organic compounds 10.2 Hazardous waste 11 Coating failure 11.1 Coating failures 12 Management and supervision 12.1 Management and supervision 13 Offshore and marine 13.1 Offshore Offshore construction Offshore maintenance 13.2 Dry docking procedures In-docking specification and surface preparation Coating application and undocking 13.3 Marine coating systems Outside shell coating systems Cargo tank coating systems Cargo hold coating systems Superstructure coating system Main deck coating system 14 Speciality units 14.1 Specialist coatings 14.2 History of pipe coatings 14.3 Fusion bonded epoxy coatings for pipeline protection 14.4 Miscellaneous pipeline coatings and field joints 1 Introduction 1.1 General overview 1.2 Basic corrosion 1.3 Mill scale 1.4 Substrate materials 1.5 Pre-surface condition 1.6 Mechanical blast cleaning equipment 1.7 Types of air blast equipment 1.8 Wet abrasive blast cleaning 2 Health and safety 2.1 Health and safety (introduction) 2.2 Method statements / risk assessments 2.3 Personal protection equipment (PPE) 2.4 Breathing air / helmets 3 Blast media 3.1 Types of abrasives 3.2 Surface profile 4 Standards and quality control 4.1 Visual (photographic) standards 4.2 Surface cleanliness 4.3 Environmental conditions 5 Operational procedures 5.1 Compressed air and air requirements 5.2 Blast hose and associated equipment 5.3 Types of nozzle 5.4 Ventilation and lighting 5.5 Communication 6 Process control 6.1 Equipment set-up and testing 6.2 Abrasive blast cleaning process 6.3 Abrasive blast cleaning standards/ guides 14.5 Rubber linings 14.6 Special coatings and linings 14.7 Powder coatings 15 Visual standards 15.1 BS EN IOS BS EN ISO BS EN ISO BS EN ISO SSPC VIS SSPC VIS SSPC VIS 4 - NACE VIS SSPC VIS 5 - NACE VIS 9 11

12 Spray painting 1 Introduction 1.1 Paint application (introduction) 1.2 Basic corrosion 1.3 Surface preparation 1.4 Coating types and systems 2 Health and safety 2.1 Material safety data sheets 2.2 Risk assessments 2.3 Method statements 3 Paint materials 3.1 Product data sheets - review 3.2 Paint storage and paint mixing 3.3 Quality control 4 Airless spray equipment 4.1 Airless spray painting equipment Airless spray painting equipment - A Airless spray painting equipment - B 4.2 Equipment set-up, testing and general use 5 Conventional air spray 5.1 Conventional air spray equipment 6 Plural component spray 6.1 Plural spray Specialist Units 1 Coating Inspection and Inspection Equipment 1.1 Inspection and Testing Equipment 1.2 Duties of a Painting Inspector 1.3 Low Voltage Holiday Detector 1.4 High Voltage Holiday Detector 1.5 Practical Arithmetic 1.6 Pre-Job Conference 1.7 Navigating Coating Specifications 1.8 Inspection Plans 1.9 The Roles of QA and QC Inspector 1.10 Inspection Documentation 1.11 Coating Inspectors Safety 1.12 Advanced Non-destructive Tests 1.13 Advanced Destructive Tests 2 Corrosion, Cathodic Protection and Coatings 2.1 Corrosion Fundamentals 2.2 Forms of Corrosion 2.3 Engineering Materials 2.4 Environments 2.5 Cathodic Protection in the Marine Environment 2.6 Cathodic Protection of Pipelines 2.7 Cathodic Protection and Coatings 3 Marine General 3.1 IMO Regulations Ballast Tanks Performance Standards for Protective Coatings: Part Performance Standards for Protective Coatings: Part Performance Standards for Protective Coatings: Part Performance Standards for Protective Coatings: Part High Pressure Water Jetting on Sea Going Vessels 3.3 IMO Regulations Cargo Oil Tanks 3.4 IMO Regulations Void Spaces 3.5 IMO Guidelines for Maintenance and Repair of Coatings 3.6 Coating Survey Guide for ballast tanks 4 Marine PSPC 4.1 Role of the Inspector 4.2 International Standards 4.3 Coating Technical File 4.4 Ventilation and De-humidification 4.5 Pre-job Conference 5 Design & Construction 5.1 Material Design and Type 12

13 6 ISO and other International Standards 6.1 ISO Standards EN ISO (Parts 1-8) EN ISO EN ISO 4628 (Parts 1-6) BS EN ISO 8502 Part BS EN ISO 8502 Part BS EN ISO 8502 Part BS EN ISO 8502 Part BS EN ISO 8502 Part BS EN ISO 8502 Part BS EN ISO 8502 Part BS EN ISO 8502 Part BS EN ISO 8502 Part BS EN ISO BS EN ISO BS EN ISO BS EN ISO BS EN ISO BS EN ISO BS EN ISO BS EN ISO BS EN ISO 2409 (BS3900-E6) ISO Miscellaneous 6.2 SSPC Standards SSPC VIS SSPC PA SSPC PA SSPC Miscellaneous 6.3 ASTM Standards ASTM D ASTM D ASTM D ASTM D ASTM Miscellaneous Standards 6.4 NORSOK Standards NORSOK M Quality Management 7.1 Quality Management System 8 Paint Testing 8.1 Laboratory and Field Testing Laboratory and Field Testing Part Laboratory and Field Testing Part Paint Testing, Paint Constituents and Paint Chemistry Paint Testing, Paint Constituents and Paint Chemistry Part Paint Testing, Paint Constituents and Paint Chemistry Part 2 9 Soluble Salts 9.1 Soluble Salts 10 Specialist Tests 10.1 Specialist Tests and Test Equipment 11 Coating Surveys 11.1 Coating Surveys 13

14 MPI Group, Peel House, Upper South View, Farnham, Surrey, GU9 7JN, UK. Tel +44 (0) Fax +44 (0) corrodere-ttcs.com