Projects

Standard Application Procedures
Thermal Spray Aluminium / TSA
 Cipta Agung, CV

Prepared By

 Cipta Agung, CV

 Approved By

 

Name

 Larasanto

 Name

 

Signature

 

 Signature

 

Date

 

 Date

 

 

TABLE OF CONTENTS

1.0           OVERVIEW

2.0           REFERENCE OF SPECIFICATION

3.0           PRINCIPLE OF ARC SPRAY PROCESS

4.0           EQUIPMENT TO BE USED

5.0           HEALTH AND SAFETY REQUIREMENT

6.0           MATERIAL TO BE USED

7.0           PROCEDURE QUALIFICATION TEST

8.0           WORKING INSTRUCTION

8.1           Inspection – Work piece

8.2           Masking before blasting.

8.3           Pre-treatment

8.3.1      Mechanical de-scaling (as required).

8.3.2      Degreasing with solvent (as required).

8.4           Surface Preparation

8.4.1      Abrasive blasting with grit blast.

8.4.2      Surface cleaning with compressed air.

8.5           Inspection of Surface Roughening and Dust Removal

8.6           Remove the blasting tape.

8.7           Spray coating

  9.0         APPLICATION AND INSPECTION PLAN DIAGRAM

10.0        REPAIR PROCEDURE

11.0        MEASUREMENT

 

1.0   OVERVIEW

These working procedures apply to the Thermal Spray Aluminium (TSA) according to …

2.0   REFERENCE OF SPECIFICATION

3.0   PRINCIPLE OF ARC SPRAY PROCESS

In the Arc spray process, the raw material in the form of a pair of metallic wires is melted by means of an electric arc. The molten material is atomised by compressed air and propelled towards the work piece.

The molten spray solidifies on the component surface to form a dense, strongly adherent coating suitable for Corrosion Protection or Component Reclamation. Sprayed coatings may also be used to provide Wear Resistance, Electrical and Thermal Conductivity or Free Standing Shapes.

Major advantages of the Arc spray Process are that the coatings are available for almost instant use with no drying or curing times and there is no risk of damaging the component. In addition, the deposits possess a higher degree of bond strength then most other thermally sprayed deposits and the use of compressed air and electricity alone mean more economic coatings.

4.0   EQUIPMENT TO BE USED

  • Compressed Air.
  • Arc spray Machine

5.0HEALTH AND SAFETY REQUIREMENT

  • CV. Cipta Agung commits to follow safety regulation and particular at Project Facilities Design Safety requirement and dictated on Project HSE Manual. Listed following are listed safety hazard expected during application and countermeasures provided as minimum to protect from potential risk. Personnel work for Project Facilities are those having experiences and qualification on application of TSA. The personnel will be identified with ID and job function, a list of personnel who have been recognized in previous project. Project Manager will lead the overall activities and he will be stationed on site during main application.
  • Noise – Foam earplug.
  • Dust and Fumes – Half mask, using chemical cartridge is not advisable to be used however in highly toxic atmosphere or where there may be a deficiency in oxygen.
  • Flash – Dark glasses.
  • The entire process shall be done in line with the requirements of HSE and Specification.

6.0   MATERIAL TO BE USED 

  • 99.5% Aluminium Wire.

    Chemistry
    Wire Size
    Morphology
    Processes
    Properties & Applications
    :
    :
    :
    :
    :
    Al 99.5%
    1.2/1.6/2/2.4 mm
    Alloy Wire
    Electric Arc
    Particularly suitable for applications where resistance to corrosion is required

7.0   PROCEDURE QUALIFICATION TEST (PQT)

7.1. Procedure Qualification Test on preferably same material specification,as being actually used in job shall be grit blasted accordance Specification or Pre-Job Meeting.

7.2.  The test coupons shall be arc spray as per preceding working instructions; TSA thickness of the layers accordance specification. The Dry Film Thickness (DFT) of the coating surfaces shall be checked by DFT meter / gauge.

7.3. The entire process shall be done in line with the requirements of  NORSOK M-501/SSPC CS-23 or Client request.

7.4.  Adhesion test to check the soundness of  TSA, sealer coat and top coat layer on the test coupons shall be checked as per provisions of NORSOK M-501/SSPC CS-23 or Client request, with the help of adhesion pull off tester and results documented.

7.5. Special assessment the effect of TSA application to normal paint pre-applied on the other side (inner side) of the material will be also conducted. Plates to be applied with normal paint similar to project paint system on the backside and allow sufficient time for curing prior to TSA application. After completion of application and curing, both sides of the plates to be examined with both visual and mechanical inspection

8.0   WORKING INSTRUCTION

8.1. Inspection – Work piece

Visual inspection of surface oxides, oil, paint, scale, dust, etc. on surface of parts. Set up for spraying. Assure easy access and good visibility of all work surfaces.

8.2.Masking before blasting.

Using a proper masking tape –strong adhesive- to protect of neighboring the areas to-be-coated in order to avoid from any surface damaged.

8.3. Pretreatment

8.2.1.     Mechanical de-scaling (as required).

8.2.2.     Degreasing with solvent (as required).

8.4. Surface Preparation

8.4.1.     Abrasive blasting with grit blast.

8.4.2.     Surface cleaning with compressed air.

8.5. Inspection of Surface Roughening and Dust Removal

8.5.1.  The Surface has to be sprayed maximum 6 hours after grit blasting, the faster spraying after grit blasting the better bonding strength achieved.

8.5.2.  The abrasive shall be checked periodically to see that it conforms to the requirements, i.e. sharp, clean, dry and free of fines

8.5.3.  The blasted surface shall be visually inspected on roughness and cleanliness proper for spray coating by comparing it with standard comparison surface (Keane-Tator Surface Comparator, Press-O-Film Tape, and  SSPC-VIS 1).

8.5.1.  To remove the blasting tape and changed by high temperature resistant (up to 500°C) tape in order to protect of the areas neighboring the areas to-be-coated against heating and molten metal during spraying.

8.6. Spray Coating

8.6.1.  Spray coating must begin as soon as reasonably possible after blasting for surface roughness. At least one layer must be applied within 4 hours of blasting and the prepared surface completely covered to specified thickness within 10 hours of blasting.

8.6.2.  Thickness per pass “one way” should be measured; coating will be done in multi layers.

8.6.3.  The overall thickness of TSA accordance specification.

8.7.     Inspection.

8.7.1.  The coating is inspected by visual examination after thermal spraying.

8.7.2   Checking the thickness of thermal spraying as above by using Dry Film Thickness Gauge.

8.7.3   Mark substandard area for later attention or repair.

9.0   APPLICATION AND INSPECTION    PLAN CHART

10.0   REPAIR PROCEDURE

10.1.Inspection – Work piece

Visual inspection, analyze damage area.

10.2.Grinding / Turning

Using hand-grinding tool to clean the damage area and roughness surface preparation.

10.3.Protect the outside damage area by masking.

10.4.Spray coating on spot damage area.

10.5.Inspection, immediately after last layer coating  thickness shall be inspected.

11.0  MEASUREMENT

Please contact us for detail procedures......