Cipta Agung, CV
TABLE OF CONTENTS
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.
8.3.1 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
These working procedures apply to the Thermal Spray Aluminium (TSA) according to …
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.
5.0HEALTH AND SAFETY REQUIREMENT
Properties & Applications
Particularly suitable for applications where resistance to corrosion is required
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
8.1. 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.
8.2.1. 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.
8.7.1. 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.
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.
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