NACE Physics Practice Exam With Answers (337 Solved Questions)

Name: NACE Physics Practice Exam With Answers (337 Solved Questions)
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NACE CIP Level 1& 2 Study Guide With Satisfied Solutions
What are the most important characteristics of a good report? - Objective, Accurate, and
Detailed.
What is the inspector's primary responsibility and what should the inspector not do as it
pertains to the specification. - The Inspector's primary responsibility as the inspector is to
"enforce" specification. The inspector is NOT to make changes to the specification for any
reason.
What type of information could you expect to find on a Product Data Sheet? - Surface
preparation and application information such as recommended level of surface cleanliness,
recommended application methods and equipment such as tip sizes. Also, environmental
parameters for application such as max and min temperatures, curing times, recoat
windows.
What type of information could you expect to find on a Safety Data Sheet? - Health, safety
and environmental. The PPE required. Physical characteristics. Emergency responder
information.
Define Corrosion - The deterioration of a substance, usually a metal from a reaction with its
environment
What is passivation? - A layer of oxides formed on the surface of a metal that provides
corrosion protection.
What is an example of passivation? - Stainless Steel
What are the elements of a corrosion cell? - Anode, Cathode, Metallic Pathway, Electrolyte
Describe what happens at the anode. - The metal dissolves into the electrolyte

What is the function of the electrolyte? - Allows the passage of ions to connect the corrosion
cell
What is the function of the metallic pathway? - Allows the flow of electrons to connect the
corrosion cell
What is the galvanic series? - A listing of metals in order of reactivity (more or less noble)
in seawater at 25 C
The general rules of galvanic corrosion are: - The less noble (or more reactive) metal when
connected to a more noble (or less reactive metal) will corrode preferentially
Name the five most important factors that affect the rate of corrosion. - Humidity, oxygen,
chemical salts, pollutants, temperature
General corrosion is: - Results in a relatively uniform loss of material over the entire
surface, Results in a general thinning of the affected surface, Relatively easy to inspect,
Does not casue catastrophic failures
Localized corrosion is: - Typically pitting and crevice corrosion. It is typically of the most
concern as damage is concentrated and loss of integrity or structural failure can result.
List some of the common tools/methods used for corrosion control. - Design, Inhibitors,
Material Selection, Cathodic Protection, Protective Coatings, Splash Zone Systems,
Alteration of the Environment
How does NACE define the inspector's role? - The inspector's role is that of a quality control
technician responsible for observing and reporting conformance or deviation from the
project specification.
What is the inspector's responsibility when it comes to safety on the project? - Safety
enforcement is not the responsibility of the inspector; however, it is his/her responsibility
to report any issues that may affect the project.

Name some tests that may need to be conducted during surface preparation and coating
operations. - Temperature, Relative Humidity, Dew Point, Anchor Profile, Surface Cleanliness
Name some of the documentation/reports that may be required to be maintained on a
coatings project. - Daily/weekly summary, material usage reports, manpower and
equipment, non conformance, and conformance
Explain the difference between Quality Assurance (QA) and Quality Control (QC). - Quality
Assurance - Any systematic process of checking to see whether a product or service being
developed is meeting specs.
Quality Control - A procedure or set of procedures intended to ensure that a manufactured
product or performed service adheres to a defined set of quality criteria or meets the
requirements of the client or customer
Identify some of the defects that can be caused by incorrect application temperatures. -
Failure to cure, too rapid solvent evaporation, poor film formation
Describe relative humidity. - The amount of moisture in the air compared to saturation level
What is the dew point temperature? - The temperature at which moisture will begin to form
on a steel surface.
Name some of the effects wind may have on a coatings project. - blowing abrasives, causing
excessive drift or overspray, accelerating solvent evaporation, contributing to the formation
of dry spray
What are some of the common errors when using an electronic hygrometer? - Failure to
acclimate the instrument to the environment with adequate time.
Explain the process for use of the sling psychrometer. - Make sure the wick is wet and clean,
continue to "sling" until 3 consecutive readings are achieved

List three desirable properties of a coating? - Chemical Resistance, water resistance, ease
of application, cohesive strength, impact resistance, dielectric strength
Two broad classifications of a coating are: - Organic/Inorganic, Convertible/non-
convertible, thermosetting/thermoplastic
What are the two primary components of a liquid applied coating? - Pigment, Vehicle (Resin
or Binder)
What are the three methods by which a coating provides corrosion control? - barrier,
inhibitive, sacrificial
What are the three different ways a coating can adhere to the surface? - Chemical,
Mechanical, Polar, or combo of all three
The two broad classifications for curing mechanisms are: - Convertible and Non-Convertible
List two Non-convertible coating types: - Chlorinated rubber, vinyl
List three convertible coating curing mechanisms - oxidation, co-reaction (polmerization),
hydration, fusion
List two characteristics of oxidation cure coatings - Not suitable for immersion service, not
suitable for use over alkaline substrates, limited dry film thickness per coat
List three coating types that cure by polymerization - epoxies, polyurethanes, polyureas,
polyaspartics, polysiloxanies
Induction time is: - the time required by the product data sheet (coatings manufacturer)
between mixing the coating and the start of application
What is the main requirement for a hydrolysis coating cure? - Moisture
Industrial and marine coatings are commonly referred to by - generic resin type

Oil based coatings applied over alkaline surfaces may result in - saponification
List five of the formal sections usually contained in a good specification - scope of work,
terms and definitions, pre-job conference, application, sampling coatings, inspection
What are two of the inspector's responsibilities as it relates to the specification? - Enforce
the specification, NOT to make changes to the specification
During the surface preparation, surface cleanliness should be inspected (as a minimum) the
following three times: - Before any surface preparation activities, after surface preparation
- before coating begins, between each application of coating in a multi-coat system
Factors during surface preparation that may effect service life include: - residues of oil,
grease, and soil. rust on the surface. loose or broken mill scale. rust scale. anchor pattern.
surface condensation.
Common design defects include: - Hard to reach or inaccessible areas. rivets, bolts, or other
connectors. welds. gaps. overlapping surfaces. threaded areas. dissimilar metals.
construction aids
Common fabrication defects include: - weld spatter, skip welds, sharp corners & Edges
Four typical SSPC SP1 pre-cleaning methods include: - Solvent wipe with cloth or rag,
immersion of the substrate in solvent, solvent spray, vapor degreasing, emulsion cleaining,
chemical paint stripping, use of alkaline cleaners
One standare for use with Power Tool Cleaning is: - ISO St2. ISO St3. SSPC SP-3. SSPC SP-11
Four examples of tools used for Power Tool Cleaning are: - rotary wire brushes, impact
tools, needle scaler, disc sanders, piston scalers
Two Abrasive Blasting methods include: - Centrifugal blasting, sand-injected water blast,
slurry blast, wet abrasive blast, dry grit blasting

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Visual Standards for abrasive blasting include - SSPC-Vis 1, ISO 8501-1
SSPC SP 10/NACE 2 limits staining to ___ per each unit area - 5%
SSPC SP 5/NACE 1 limits staining to ___ per each unit area - 0%
SSPC SP 6/NACE 3 limits staining to ___ per each unit area - 33%
The two types of abrasive blasting nozzles include: - Straight, Venturi
The specified level of surface cleanliness must be achieved and maintained - immediately
prior to coatings application
Advantages of centrifugal blast equipment include: - Dust and fines are contained, abrasives
are easily recycled, blasting and priming can be an inline operation, general overall economy
compared to air blasting, no compressors, piping, or air handling equipment needed for
wheel blasting
The Inspector's checklist for surface preparation should include: - ambient conditions,
conditions of substrate, pre-blast surface cleanliness, shot/grit size selection, shot/grit
cleanliness, abrasive blasting equipment, surface profile, surface cleanliness after abrasive
blasting, operator qualifications, safety
Abrasive media types include: - shot & grit (metallic), crushed slag, ceramic grit, silica sand,
garnet, agricultural abrasives, specialty abrasives
Abrasive media typically used for recycling include: - steel shot, steel grit
List the pressure ranges that categorize - low pressure water cleaning: <34 MPa (5,000
psi), high-pressure water cleaning: 34 to 70 MPa (5,000 to 10,000 psi), High-Pressure water
jetting: 70 to 210 MPa (10,000 to 30,000 psi), Ultrahigh=Pressure water jetting: >210 MPa
(30,000 psi)

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Three types of Water-Blasting include: - Comparator and coupons, replica tape, digital
surface profile gauge
Types of soluble salt contamination include: - chlorides, sulfates, nitrates
If inspection is to be effective with regards to soluble salts, the specification should very
clearly state: - limits to be accepted, specific salts to be limited, test method to be used,
frequency of testing, locations in which tests should be administered
Test for soluble salts include: - bresle patch, sleeve test, soluble salt meters, conductivity
meters
Depth of surface profile can be evaluated by several methods: - ISO Comparator, replica
tape, digital profile gauge
The ISO Comparator grades may be recorded: - Finer-than-fine grade, fine grade, medium
grade, coarse grade, coarser than coarse grade
The two types of replica tape are commonly used: - Coarse - for 20 to 64um (0.8 to 2.5
mils), X Coarse - for 38 to 115 um (1.5 to 4.5 mils)
List the standards for using the Replica tape: - ASTM D 4417 Method C, NACE SP 0287-2202
When using Replica tape common errors include: - variation in point-to-point profile over the
surface being tested, the presence of particles of dirt on either the replica tape or gauge,
gauge accuracy, the rubbing or burnishing technique
Goals of a pre job conference include: - discuss health, safety and environment (HES)
Requirements, address / clarify emergency procedures, review and discuss scope of work
(SOW), review logistical support, discuss line communications between parties, review
known critical hazards, establish list of critical point of contacts (POCS), discuss and clarify
inspector (s) responsibilities and authority, clarify the chain of command (reporting
system), discuss and clarify areas of concern in the project specification, agree on critical

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hold points for inspections, conflict resolution between the inspector and applicator, change
orders
People may be required to attend a pre-job conference include: - owner, owner contract
manager, engineer, specifying engineer, operations personnel, specifier, purchasing agents,
coatings manufacturer, coatings inspector, project safety personnel, coatings applicator
Before the start of the Pre Job Conference the inspector should obtain a copy of, read, and
understand the: - specification, any standard / procedure referenced in the project
specifications, manufacturer's product data sheets, safety requirements of the MSDS
Documentation may include: - Detailed written daily reports, inspection logs, routine reports,
reports for weekly progress meetings, daily entries in a project log book, a daily inspection
report using standardized forms, routine reports, monthly or quarterly reports
Inspection records show: - environmental conditions, pretreatment details, cleaning details,
materials details, coating applications details, results of work and all tests
Good records allow management to: - detect and tag design defects for future work,
evaluate coating performance, determine annual cost data on each coating system, develop
ongoing maintenance program
Project inspection documentation provides: - inspection (QC) records, management
information, verification of work by the contractor, details of non-conforming work
One guide for enclosures for coatings projects is: - SSPC Technology Guide No. 12, SSPC
Technology Update No. 6 Guide for Containing Surface Preparation Debris Generated During
Paint Removal Operations
Low Temperature concerns during coatings application include: - Slow the curing of
chemically curing coatings, will increase the viscosity of material, some coatings may use
special cure

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High temperatures concerns during coatings application include: - Can cause the solvent to
evaporate too fast, will reduce the pot life, decrease the viscosity of many two-component
materials
High humidity during coating application: - Slows the evaporation of the solvent, can leave
moisture on the surface of the coating, may effect the gloss or color, may cause amine
blush (must be removed prior to top coating)
Coatings may be applied by the following methods: - Roller, brush, airless spray (including
plural component), conventional spray, high volume low pressure (HVLP), air assisted airless
Coatings Product Data Sheets (Paint Specs) provide users with the following: - surface
preparation, storage, mixing and thinning, application procedure, DFT requirements
SDS contains the following: - Provides workers and emergency personnel with critical
information on composition, handling or working with the substance. Includes information
such as melting point, boiling point, flash point, toxicity, health effects, first aid, reactivity,
storage, disposal, protective equipment, and spill handling procedures. Provides info
regarding the safety issues associated with any hazardous (or potentially hazardous)
material. Provides instructions for the correct action to take in the event of a spill,
explosion, fire or hazardous exposure.
Failure of coatings to cure may be caused by: - not adding curing agent, wrong curing agent
or incorrect amount of it. problem with material from the manufacturer. environmental
issues (too cold, hot, or humid). wrong or contaminated thinner (solvent)
Some of the problems that can be caused by amine blush are: - surface tackiness or
greasiness, incomplete curing, poor adhesion, coating discoloration, poor gloss retention
Runs, Sags, and wrinkles may be caused by: - applying the coating too thick, too much or the
wrong thinner used, surface too hot to apply the coating, application of coating at the end of
its pot life, wrong thixotrope used in manufacturing

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____ is a powdery, friable layer on the surface of a coating that is most common with epoxy
coatings. - Chalking
Cratering may be caused by: - air trapped in the coating and forming a bubble which then
bursts, air trapped in the coating during mixing if the proper procedures are not followed
Vacules or voids are typically caused by: - running the mixer too fast
Pinholes are: - Very small holes in a coating typically caused by air or solvent trapped in
porous film and escaping.
A common cause of blistering is: - Surface Contamination under the applied coating
Cracking of coating is noted: - When the crack extends to the substrate
Checking can be described as: - fine cracks in the surface of a coating that don't extend
through to the substrate
Adhesion failures may be caused by: - contamination on the surface, wrong surface
preparation specified, failure to inspect surface preparation, insufficient surface profile,
exceeding the topcoat window, application of incompatible coatings
General types of holiday detectors include: - Low-voltage DC, High-voltage DC, High-voltage
AC
Low-voltage (wet sponge) holiday detectors are powered by batteries with output voltages
ranging from ______. - 5 to 120 V DC
Describe Low-voltage (wet-sponge) holiday dectectors: - ground cable is attached directly
to substrate, sponge saturate with a solution of tap water/wetting agent, maximum rate of
30 cm/s (1 linear ft/s) double stroke, used on coatings up to 500 uM (20 mils), may be used
on concrete
High Voltage DC Holiday detector types include: - DC - Pulsed, DC - Constant Current

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Describe High Voltage DC Holiday Detectors: - Ground conection must be made direct to
metal substrate (preferred) or indirectly when necessary (e.g., to soil for pipeline
measurement). Rule of thumb: 100V/mil (4V/um). Electrode rate of 0.3 m/s (1 ft/s) in a
single pass (according to NACE Standard SPO 188). Voltage output range from 800 to
60,000 V
The type of High Voltage Holiday dectector used for concrete is a: - High Voltage DC Constant
Current
What is a Standard? - An established norm or requirement that is written by industry
professionals. A formal document that establishes uniform engineering or technical criteria,
methods, processes and practices
What percentage of NACE Standards relate to coatings? - 50%
NACE CIP Level 2 Study Guide
WJ-1 (visual cleanliness) is comparable to which abrasive blast cleaning standard? - ISO SA
3
Robotic water jetting includes - *attaches using vacuum, cables or magnets
*Vertical, Horizontal or overhead surface
*Controlled by single operator
*Collects in excess of 95% of the water, removed coatings and rust (waste generated)
A typical waterjetting team consists of? - *Nozzle operator

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*Pump Operator
*Additional operators or workers as required
Considerations with Back Thrust are: - *Causes Fatique
*Should be no more than 1/3 of operators body weight
Safety considerations before waterjetting are - *work area is properly barricaded
*Electrical equipment protected from water
*Electrical connections are not allowed to sit in water
*All fittings and hoses are in good condition / proper pressure rating
*Nozzles are free of obstructions
*System is flushed clean and air removed
*The dump system and all control systems are
operational
*Proper LockOut/ TagOut provisions in place
*Confined entry requirements addressed
Waterjetting advantages include? - *Worker Safety
*Worker air quality
*Less stringent respiratory requirements
*No dust or contamination or clean up
*Environmentally friendly
*Requires less cleanup
Waterjetting disadvantages include: - *Waterjetting does not leave a surface profile
*Equipment is very expensive
*Danger of Ultra High Pressure hose breaking
*Danger of injection into the skin or serious cuts
*Collecting and disposing of the contaminated
Water
*Proficient operators needed
Cause of Blistering on coatings? - Oil, moisture and / or grease

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Saturation point drops as? - Air is compressed, making air wetter
Check compressor for water contamination at? - Moisture traps, inter cooler and
aftercooler
Common Hot Dipped (HD) inspection defects - Cracking, peeling, bare spots, lumps, Blisters,
flux inclusions, ash inclusions and dross inclusions
Describe what a Tooke Gage is and some models - *Destructive test instrument
*Used on non-magnetic or nonferrous
Substrate
*has illuminated 50x microscope
*good from 0-100 mils
*Groove cut through coating
*Models are Mark II and Mark III
Centrifugal blast machine showing low amperage could indicate? - *Abrasive starved wheel
or
*Flooded or choked wheel
How to rectify water contamination: - *ensure cooling water is turned on
*Ensure drains are not plugged
*last resort is to consider installing larger or
Additional moisture traps
Air oxidization enters the coating when? - After solvent evaporates
What is the curing method for alkyds and epoxy ester? - Air drying
What is the NACE / SSPC standard for Surface Prep by Chemical or thermal means for
concrete? - NACE 6 / SSPC-SP13
What are impressed current power sources - *Rectified Commercial Power
*Solar Cells

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*Generators
*Fuel cells
*Wind Powered Cells
*Thermo electric
What is the purpose of dehumidification? - remove moisture to lower dew point
Electronic hygrometers check - *Relative humidity
*Air temperature
*Dew Point temperature
How do you reduce the relative humidity of the boundary layer? - *Increase surface
temperature
*Reduce moisture by dehumidification
Equipment used for dehumidification? - *Refrigeration
*Desiccant
Describe passivation and what it does? - *formation of protective oxide film
* reduces chemical activity
*reduce the ability to corrode
What are the effects of oxygen on corrosion? - Oxygen increases corrosion
What are the effects of temperature on corrosion? - Higer temperature increases corrosion
What are the effects of chemical salts on corrosion? - They increase the electrolyte
efficiency, therefore increasing corrosion
What are the effects of Humidity on corrosion? - A wetter environment means more
corrosion is likely to occur
What are the effects of Pollutants and Acid gases on corrosion? - Acid rain, chemical
byproducts and chlorides all promote corrosion.

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What are the causes for pinholes? - *Coating overspray
*solvent entrapment
*porosity in previously applied coat
*incorrect spray viscosity
*coating on hot surface
What are the limitations of Magnetic Gages? - *only work on magnetic surfaces
*Sensitive to discontinuities in the steel, like
holes, corners and edges
*Affected by nearby magnetic fields like power
lines, welding equipment or other masses of
steel.
*roughness of steel may distort the readings
What type of High Voltage (HV) detector is used for concrete? - Constant current DC
Water entering from compressor is dependent on? - *prevailing ambient temperature
*relative humidity
What are the causes of amine blush on cure epoxies and coal tar epoxies? - *Moisture
condensation from high humidity
Atmosphere
*Fast thinners used in high humidity
*condensation on a cold surface
What is the finish on cured epoxies and coal tar epoxies with amine blush? - Flat and milky
finish
Procedure for testing compressed air supply - *Test air supply downstream from oil &
moisture traps
*Hold as close as possible in airstream for 2 minutes
*No further than 24" from source
*Examine test material for evidence of oil contamination and moisture

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