What Is Surface Preparation?

Surface preparation
What
is surface preparation?
Surface preparation is the process in which
the surface of work piece is been cleaned for
next process like painting, coating etc.
Why it required?
With proper surface preparation we can make the
work piece corrosion free.
With this process we can providing more efficiency
to next processes.
Types of surface preparation

Blasting
Water jet cleaning
Surface preparation
Hand & power

tool cleaning
Acid-cleaning
BLASTING
Blasting is a one kind of surface preparation
activity in which surface is cleaned by
Impacting of abrasives
Blasting
Blasting is a process in which abrasives are blasted

on the surface of work-piece.
Types of blasting
1) Wheelabrators
2) Air blasting
Blasting is most common & applicable method in

industry so blasting is most preferable in a heavy
engineering industry, shipping & fabrication
industry
Wheelabrators
Wheelabrators
are centrifugal blasts units Which is

mobile & fixed m/c types
Quality
is maintained by conveyer in fixed m/c. In

mobile unit traveling speed maintain good quality
Generally
recycled type abrasive used in this

blasting e.g. steel shots, grits
Wheelabrators
Maintain
a shot speed of 220mile/hour by rotor

speed of 2500 to 3500 rpm
Very
This
effective in a batch or mass production
types of process is most commonly used in

flat steels & long products in plate yard & ship-
yard
Equipments
Hopper
( blasting storage ):To store the abrasive

Blasting wheel with elect. Motor : Give kinetic
energy to abrasive
Screw conveyors & elevator: To movement of
abrasives for recycling
Blowing or suction unit: To clean dust & abrasives
from the w/p after blasting
Separator: To refine & separate abrasives
Dust collector : To separate dust particle & air
collect from unit.
Blasting m/c
Portable wheelabrater
Wheelabrator
Generally
this types of blasting is better result on

flat types of steel
This blasting is more preferably in long products &
piping also.
This blasting is generally done in ship yard.
Abrasives used in this blasting is always recyclable
e.g. steel shots, steel grits
This blasting is very effective in batch & mass
production
Does
Blasting
m/c should be proper sealed

Blasting operator, rigger & other work men should
wear safety goggles
While doing maintenance, proper safety device
should be operated while going inside the m/c
Leakage in m/c should be attended as early as
possible
Rotor blade, blasting chamber liner ,bolts
&conveyor sleeves should be replaced by periodic
time as per manual
Don'ts
Dont
bypass any safety limit switch while entering

in m/c
Dont mix wet abrasive in m/c for increasing the
m/c efficiency
Dont bypass the limit switch while doing operation
or maintenance .
Air blasting
-This types of blasting is also known as a manual
blasting. Abrasive is blasted with compressed air
- If Blasting done on 100 psi (7kg/sq.cm) it gives

100% efficiency then reducing 1 psi we get 1.5%
less efficiency .
-We can do this blasting on any type of surface but
very effective for a pressure vessel It is
-very effective in a job production
Equipments
Compressor
is used for giving the high

compress air 7 kg/sq.cm
Blasting
pot store abrasive & mix compressed

air with abrasives
For
removing vapor & oil Vapor traps is used

between the compressor & blasting pot
Equipments
Hose
convey the compressed air & abrasive

mixture as well as compressed air also
Nozzle
is the outlet of total unit from where

abrasive blasted on w/p
For
safety every unit should have a dead mans

handle.
Nozzle types
STRAIGHT
BORE : Which can generate the

speed of abrasive at up to 220 m.p.h and is used
for small or repair areas and softer metals.
VENTURI
: Which can generate the speed of

abrasive at up to 450 m.p.h and which gives an
even blast pattern over a relatively large area.
The
pressure at which the abrasive is delivered to

the blast nozzle can be measured by using a
hypodermic needle gauge.
Nozzle types
Air blasting
Air blasting
This
Blasting is called a manual blasting
blaster
moves & points nozzle to the direction of

w/p. So in this blasting more safety should be
provided.
Generally
This
this blasting is done for final painting.
blasting is suitable or any kind of w/p
Air blasting
In
this blasting, both type of abrasives recyclable

and non recyclable, are used
This
blasting is done in generally Heavy

engineering industry.
This
blasting is very much effective in job

production.
Does
Wear
proper P.P.E. for the blasting process for

safety purpose.
Always
use carbon impregnated hoses for

compressed air & abrasive mixture.
Blasting
area should be permanently or

temporarily covered while blasting.
Does
Keep
standard distance from the work piece
Proper
ventilation should be available when

blasting
Proper
dust collection system should be available.
Don'ts
Dont
do blasting in open or crowdy area.
Dont
start blasting without checking the safety

equipment.
Dont
work without fixed dead mans handle with

blasting nozzle
Dont
use wet abrasives for blasting.
Abrasive
Natural abrasive
Garnet,
Silica send
By product
Coal slag
Nickle slag
Copper slag
Specialty abrasive
Plastic shot
Glass bead
Abrasive
Agriculture
Coconut shell
Black walnut
Manufactured
Al.oxide
Silicon carbide
Steel grit/shot
Selection
Cost
Application
method
Availability
selection
of Abrasives
Quality
required
Material
of W/P.
BLASTING REQUIREMENTS
Blasting Report with Temp. Log
Contamination Level check
Blasting Shot Size / Recycling requirements
Blasting Process Controls
Humidity
< 85 %
Ambient Temp. < 60 C
Surface Temp. < 50 C
Surface temp 3C above Dew Point
It may very for the different customer or

application
Blasting grades
In
blasting system different grades are

given below
BS 7079 PtA
SSPC
NACE
Sa3
Sp5
Grade1
Sa2.5
Sp10
Grade2
Sa2
Sp6
Grade3
Sa1
Sp7
Grade4
Quality of blasting
Quality of blasting measured by two parameters
1)Degree of cleaning ness
2)Surface Profile
For measuring Degree of cleaning ness w/p is
compared with standard photographs.degree of
cleaning ness is depends on the surface rust grade
before blasting
For measuring profile following instrument used
-Profile needle gauge
- Micrometer dial gauge with replica tape
Rust grade
Rust grade designated A,B,C & D respectively, are
specified As per SSPC std.,Described below.
A) steel surface largely covered with adhering mill
scale but little, if any rust.
B) Steel surface which has begun to rust & from
which the mill scale has begun to flake.
Rust grade
C) Steel surface on which the mill scale has rusted
away or from which it can be scraped ,but with
slight pitting visible under normal vision
D) Steel surface on which the mill scale has rusted

away and on which general pitting is visible under
normal vision
Comparison
Standards of blasting
Cleaning
ness is measured with grade

e.g.Sa1,Sa2,Sa2.5,Sa3 As per ISO 8501
Profile
is measured in a micron()
e.g. 50,80 As per ISO 8503.
NOTE : There is no relation between cleaning ness

& profile.
FACTORS AFFECTING BLASTING

Factors
Abrasives
Size of Abrasives
Density of
Abrasives
Human Factors
Hard ness of
abrasives
Shape
of Abrasives
Speed of blasting
Angle from the

surface to Nozzle
Distance from
W/P to Nozzle
Time
TESTING FOR SURFACE

CONTAMINATION
Various
tests exist to determine contamination left

on a surface after blast cleaning. The
contamination usually consist of either
Hygroscopic Salts or Mill scale and the tests are as
follows.
1) HYGROSCOPIC SALTS
Soluble Iron Salts

Soluble Chlorides
2) MILL SCALE
Copper Sulphate test.
-Potassium Ferricyanide Test

- Silver Nitrate Test
CKECK POINT FOR BLASTING

OPERATION
Air
& oil filter shall be provided on compressor &

hopper.
Oil/Grease shall be removed from the surface
before blasting.
Abrasive shall be free from salt.
Slag shall not be recycled, and grit can be recycled
after ascertaining its quality.
Uniform pressure of 6-7 Kg/sq.cm shall be
maintained throughout blasting operation.
CKECK POINT FOR BLASTING

OPERATION
Abrasive
size and shape selection based on

surface roughness I.e. profile requirement.
Blasting
shall be permitted only when relative

humidity is less than 85% & steel temperature is
at least 3 degree more than Dew point
temperature.
Blasted
surface shall be free of dirt, dust and

abrasive material. This can be achieved by blowing
air on blasted surface or vacuum cleaning.
Prepared by : VPP
Wheelabrator
Air blasting unit
White metal blast cleaning

This
blasting called as a Sa3 or SSPC SP5 blasting
When
without magnifying glass surface should be

viewed clean & free from mill scale, rust, foreign
matter, oil, grease & dirt
It
should have a uniform metallic colour
Very through blast cleaning

This
type of blasting called as a Sa2.5 or SSPC

SP10 blasting
Some
remaining traces of contamination shall

show only as slight stains in the form of spots &
strips but visible grease, mill scale, rusting, oil,
foreign matter should be not visible on surface.
This
blasting is known as a near white metal

blasting
Commercial blasting
This
type of blasting called as a Sa2 or SSPC SP6

blasting.
In
this type of blasting without glasses oil,

grease,& dirt fully removed. most of the mill scale
,rusting, paint coating should be removed.
This
blasting known as a through blast cleaning
Brush of blasting
This
blasting called as a Sa1 or SSPC SP7 blasting
When
viewed without magnification surface shall

be free from visible oil, grease,& dirtbut poorly
adhering mill scale, rust, paint coating & foreign
matter.
This
blasting known as a light blast cleaning
This
grade blasting is not used for rust grade-1
Rust grade
Dead mans handle
LARSEN & TOUBRO LIMITED

HAZIRA WORKS
SURFACE PREPARATION & COATING REPORT
REPORT DETAILS
L&T PROJECT
NO.
EQUIPMENT NO: MV-RDZ311-C05

EQUIPMENT NAME: CRUDE COLUMN
DATE
45366
COATING CONTRACTOR(NAM E) : BLAST O PAINT
05-Oct-07
NO.
5
CONDITION IN WORK AREA

ITEM
NO.
1
ITEM PREPARED OR COATED
Externel surfaces of shell,

nozzles & appartances from
4th stiffner ring to bottom
tanline
20:00
DRY
BULB
0
C
33
62
DEW
POINT
0
C
25
23:00
31
26
67
24
31
1:00
30
25
67
23
29
3:00
29
25
72
23
29
6:00
29
26
79
26
30
8:00
31
25
67
26
31
10:00
33
26
60
23
34
10:00
32
24
52
21
33
12:00
34
26
53
23
35
14:00
35
26
49
23
36
COND.
REFS.
DATE
TIM E
HRS
25-Sep
SURFACE PREPARATION M ETHOD

Abrasive Blasting
01-Oct
PREP.
REF.
COND.
REFS.
A-E
PREP. STD.
SPECD.
ACT.
SP-10
SP-10
ABRASIVE M ANFG.: Hindalco Industries
INTERZINC-12
INTERTHERM-181
HD 4905
HE 5312
HE 5071
HE 5520
HA
HA
HA
HA
RH
%
SURFACE
PROFILE M ICR.
70
TYPE: Copper Slag
COATING M ANUFACTURER: Ak zo-Nobe l pvt.ltd.(INDIA)

PRODUCT DETAIL
ITEM
COAT
COND
NO.
NO.
REF
NAM E
BATCH NO.
1
WET
BULB
0
C
27
PREP
REF
F-G
H-J
STEEL
TEM P
0
C
34
TIM E
START
END
20:00
6:00
GRADE: N.A.
M ETHOD
TIM E
WFT
DFT
OF
ENDED M ICRON M ICRON
APPL.
Airless
10:30
--85
spray
Airless
14:00
180
spray
PREV.
COAT
DATE
--25-Sep
1) Salt contamination test: Test carried out using SCM 400 meter and f ound contamination 3.5 gm/sq.cm.
L & T
INSPECTION AGENCY

What Is Surface Preparation?

Uploaded by

Copyright:

Available Formats

What Is Surface Preparation?

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

What Is Surface Preparation?

Uploaded by

Copyright:

Available Formats

Surface preparation

Types of surface preparation

Water jet cleaning

Hand & power

Blasting is a process in which abrasives are blasted

Blasting is most common & applicable method in

are centrifugal blasts units Which is

is maintained by conveyer in fixed m/c. In

recycled type abrasive used in this

a shot speed of 220mile/hour by rotor

effective in a batch or mass production

types of process is most commonly used in

( blasting storage ):To store the abrasive

this types of blasting is better result on

m/c should be proper sealed

bypass any safety limit switch while entering

blasting. Abrasive is blasted with compressed air

- If Blasting done on 100 psi (7kg/sq.cm) it gives

is used for giving the high

pot store abrasive & mix compressed

removing vapor & oil Vapor traps is used

convey the compressed air & abrasive

is the outlet of total unit from where

safety every unit should have a dead mans

BORE : Which can generate the

: Which can generate the speed of

pressure at which the abrasive is delivered to

Blasting is called a manual blasting

moves & points nozzle to the direction of

this blasting is done for final painting.

blasting is suitable or any kind of w/p

this blasting, both type of abrasives recyclable

blasting is done in generally Heavy

blasting is very much effective in job

proper P.P.E. for the blasting process for

use carbon impregnated hoses for

area should be permanently or

standard distance from the work piece

ventilation should be available when

dust collection system should be available.

do blasting in open or crowdy area.

start blasting without checking the safety

work without fixed dead mans handle with

use wet abrasives for blasting.

It may very for the different customer or

blasting system different grades are

D) Steel surface on which the mill scale has rusted

ness is measured with grade

NOTE : There is no relation between cleaning ness

FACTORS AFFECTING BLASTING

Angle from the

TESTING FOR SURFACE

tests exist to determine contamination left

Soluble Iron Salts

-Potassium Ferricyanide Test

CKECK POINT FOR BLASTING

& oil filter shall be provided on compressor &

CKECK POINT FOR BLASTING

size and shape selection based on