Archive for August, 2008
Wireless measurement technology optimizing quality and safety inspections of large steel constructions.
Wireless measuring technologies have proven to be advantageous wherever corrosion coating can only checked while climbing such as the quality and safety inspections of large steel constructions like pylons and antennae. Modern measuring gauges enable the user to check the coating thickness on the object completely and effectively. The use of small measuring probes such as the wireless miniaturized QNix® 8500 sat and the QNix® Keyless enable the user to work particularly fast and conveniently in each situation. Even under such difficult conditions as they occur on pylons, the work will be done in compliance with all safety regulations and without any cables hindering the work.
Coating material protects against corrosion
To ensure passive corrosion protection organic coating materials are used. Inorganic coatings are mostly manufactured in a galvanizing process. It is the impermeability against affecting media of such coating materials that is the most important aspect of their various protective features.
Existing pores allow subsurface corrosion to spread and destroy the coating from underneath. Therefore, steel structures are layered with several coatings to protect the structure for a longer period of time. Careful selection of adequate coating materials and the quality of the coating process are of the utmost importance to the durability of the coated layers. To ensure the quality of a Duplex system for instance, the coating thickness of the galvanized layer and the organic coating on the steel underground have both to be measured in a controlled manner.
Combined measuring mode for convenient coating thickness measurements
The combined measuring mode of the QNix® 8500 measuring system from AUTOMATION Dr. Nix, Cologne offers a particularly convenient way of measure multiple layers in a controlled manner. The zinc layer and the upper organic layer are being measured in one single measuring process and then recorded. The coating thickness of both layers can then be analyzed simultaneously.
Providing safety - standards for the inspection of coating thickness.
As the protection and safety of large steel constructions are of such importance, the DIN EN ISO 12944 Part 7 “Corrosion protection of steel structures by protective paint systems” regulates the execution and monitoring of coating work. The standard explicitly requires dry coating thickness to be checked with measuring procedures and methods that are in compliance with the EN ISO 2808:2007(D) as stated under item 6.3. The standard includes: magnetic measurement methods based on the measurement of changes in the magnetic field as implemented by AUTOMATION Dr. Nix (item 5.5.6) and measurements with Hall sensors as well as eddy current measurement methods (item 5.5.8).
Measuring gauges for everyday use are sought-after
The ease-of-use and ease-of-calibration are of particular advantage for gauges measuring corrosion protection and coating thickness. Easy operation, a rugged construction and a design that is ideally suited for everyday use are only a few of the important requirements for a reasonable application of these gauges in the quality management of major projects.
Application report: wireless radio probes for measuring work at pylons.
„How using wireless measuring probes for coating thickness measurements increases the safety of renovating steel constructions”.
Wireless measuring technology for corrosion protection in quality management and the restoration and monitoring of pylons and large steel constructions.
Wireless measuring technologies have proven to be advantageous wherever corrosion coating can only checked while climbing such as the quality and safety inspections of large steel constructions like pylons and antennae. Here, praxis- oriented QNix® Keyless-gauges and the new modular QNix® 8500 measuring system are particularly valuable. Their very small measuring probes are equipped with a hand strap and allow free climbing with both hands. The wireless measuring gauges enable the user to check the coating thickness on the object completely and effectively. The use of small measuring probes such as the wireless miniaturized QNix® 8500 sat and the QNix® Keyless enable the user to work particularly fast and conveniently in each situation. Even under such difficult conditions as they occur on pylons, the work will be done in compliance with all safety regulations and without any cables hindering the work. Determining coating thickness accurately and fast using the only thumb-sized and 30 grams light QNix® radio probe, is an advance in the field of coating thickness measurement, which both facilitates work and improves quality control and operational safety considerably.
Steel corrodes – coating protects.
About 15 billion tons of crude steel have been manufactured word wide in the last 140 years. Its excellent physical characteristics make steel the most versatile material. All these advantages however are opposed by one undeniable disadvantage: steel corrodes!
Fortunately, corrosion damage can be avoided by either alloying steel with various other elements (chromium, nickel and others) or by covering it in an organic or inorganic protective coating (paint, galvanizing, powder lacquer). Such coatings are used in over 90 per cent of all cases.
Corrosion protection is becoming more important.
The cost of corrosion protection is usually quite low. Especially when compared to the expected obsolescence of equipment or constructions and the cost of an operation shut down.
In Germany, such costs amount to billions. 20 years ago, the cost of corrosion damage has already been estimated at 70 billion Deutsche Mark (the former German currency); 4.5% of Germany’s gross national product of that time. Today, the cost is considerably higher. At 4% of Germany’s current gross domestic product, the amount now reaches 70 billion Euros. (Source: Flyer Corrosion Protection of the Fachhochschule Ostwestfalen, Iserlohn).
Therefore, the issue of corrosion protection is becoming more important to the industry. Numerous rules and regulations, such as DIN EN ISO 12944, support the constant effort to avoid and reduce corrosion damage.
Modern coating materials protect against corrosion.
To ensure passive corrosion protection, organic coating materials are used. Inorganic coatings are mostly manufactured in a galvanizing process. It is the impermeability against affecting media of such coating materials that is the most important aspect of their various protective features.
Existing pores allow subsurface corrosion to spread and destroy the coating from underneath. Therefore, steel structures are layered with several coatings to protect the structure for a longer period of time. Careful selection of adequate coating materials and the quality of the coating process are of the utmost importance to the durability of the coated layers. To ensure the quality of a Duplex system for instance, the coating thickness of the galvanized layer and the organic coating on the steel underground have both to be measured in a controlled manner.
Here, the combined measuring mode of the QNix® 8500 measuring system from AUTOMATION Dr. Nix, Cologne offers a particularly convenient way of measurement. The zinc layer and the upper organic layer are being measured in one single measuring process and then recorded. The coating thickness of both layers can then be analyzed simultaneously.
Providing safety - standards for checking coating thickness
As the protection and safety of large steel constructions are of such importance, the DIN EN ISO 12944 Part 7 “Corrosion protection of steel structures by protective paint systems” regulates the execution and monitoring of coating work. The standard explicitly requires dry coating thickness to be checked with measuring procedures and methods that are in compliance with the EN ISO 2808:2007(D) as stated under item 6.3. The standard includes: magnetic measurement methods based on the measurement of changes in the magnetic field as implemented by AUTOMATION Dr. Nix (item 5.5.6) and measurements with Hall sensors as well as eddy current measurement methods (item 5.5.8).
Measurement gauges suited for everyday use are sought-after.
In praxis, ease-of-use and ease-of-calibration are of particular advantages to gauges measuring corrosion protection and coating thickness. Easy operation, a rugged construction and a design that is ideally suited for everyday use are only a few of the important requirements for a reasonable application of such gauges in the quality management of major projects.
CarCheck System
A world novel menu driven measuring system for checking and documenting the lacquer coating thickness of cars. The CarCheck system optimizes the cost, quality and damage management.
As a specialist for innovative user oriented solutions, AUTOMATION Dr. Nix created a milestone of non-destructive lacquer coating measurement technology: the world novel CarCheck measuring system. A menu driven quality system working in accordance with future rules and regulations of the automobile industry regarding the recording, analysis and documentation of measurements.
Based on the proven technology of the QNix® 1500, user-friendly advantages and features have been developed even further. Thus, a rugged, easy-to-use and reliable measuring system of future generations has been created, providing a large range of measurement and an innovative software solution.
Increasing demands on the management of cost and quality require new integral measuring systems.
The CarCheck measuring system offers a completely new way of managing cost, quality and damage in the automobile industry. Structured design of the measuring task, systematic and verifiable documentation of measurements as well as analysis of measuring values combined with intuitive menu navigation provide considerable advantages.
Increasing quality standards in industry, craft and service providers, such as experts, insurance companies, lessors and car manufacturers resulted in the need for complete, detailed and verifiable documentation of measurements. Acting on this, the new CarCheck measuring system now, meets these high and individual demands in an impressive manner. Even concerning speed and reliability of measurement recording, processing, and documentation.
The CarCheck system: a lacquer coating measuring system setting new standards.
A modern car is fitted with five qualitative coatings during the production process. Each of these layers – electrophoretically deposited bond coat, anti-chip layer, primer, base coat and clear coat – serve to protect the car body against corrosion and affecting weather. With 100µm these layers are together not thicker than a hair. They also provide the foundation of a car’s visual appearance, which plays such an important causal part of the purchase decision process. Single measurements of coating thickness on different parts of the car body, taken during production process and final inspection ensure the quality of the vehicles surface.
Innovation: easy, fast, reliable and menu driven – recording, processing and documenting measurements of all coating layers.
The new CarCheck® system from AUTOMATION Dr. Nix is the first measuring system utilizing a pre-defined network of coordinates for statistical quality control purposes. Measurement spots of a car body are systematically created, recorded and documented in a menu driven environment. An innovation that is not only of considerable use to the automobile production but which also facilitates work in all areas of damage management, service and automobile trade.
In addition to the usual individual measurements, it is now possible during production to select specifically between two different measurement programs depending on the application.
After selecting the type of vehicle (e.g. Cabriolet or Van), at least three measurements on pre-defined spots on the measurement object (fender, hood, side part, etc.) are necessary for “base measurement”. Whereas the “intensive measurement” requires at least six measurements per measurement object, which can then be documented. To avoid errors and to facilitate measurements easy but clear instructions appear on the display and guide the user through the measuring process. After recording each individual measurement, the menu navigates to the next measuring spot on the “raster of coordinates” until all measurements and results are finally saved and completely documented within the system.
The “network” of saved analyzable data also facilitates the quality management of users by providing reproducibility of measurements.
The provided USB-dongle ensures interference free radio communication between measuring device and PC. The measurements are saved in the gauge until the user deletes them with the supplied system software.
The gauge’s menu is as easy to understand as modern cell phones guaranteeing a save and intuitive operation of the measuring system and meeting the requirements of today’s generation. The gauge’s handling is facilitated even more by the included software for administrative and analysis purposes, which is quite similar to MS-Office applications.
IMO Standards
International standards focus on the inspection of ship’s coating thicknesses.
As protective coatings reduce corrosion and are thereby increasing a ship’s stability, the quality of coatings in ship construction are increasingly becoming subject of international regulations [1], [2], [3]. Particularly the ship’s ballast water tanks are of importance here. They are prone to corrode and therefore a danger to the ship’s structure; especially as corrosion damage is so difficult to detect.
In this regard, the “Safety of Life at Sea” (SOLAS) regulation II-1/3-2 for ballast water tanks and double hulls is the first international convention concerned with corrosion prevention that has been established.
It results in the latest, very extensive IMO resolution MSC215(82): the “Performance Standard for Protective Coating” PSPC. Goal of this standard is to ensure that the quality of coating lasts at least during the 15 years of a ship’s average service life. This standard applies to all ships over 500 gross registered tons regarding their ballast water tanks and to double hull ships with an overall length of 150 meters and building contracts placed after July 1 2008. In coordination with the new IMO resolution, the IACS (International Association of Classification Societies) has issued procedural requirements (IACS PR 23) demanding the continuous documentation of work in a so-called “Coating Technical File” (CTF). This CTF is to be kept on board during the whole lifetime of ship. The file includes specifications of the coating system, and records of the shipyard and the shipping company or the ship owner considering inspection, maintenance and repair work.
This results in new challenges for shipyards, shipping companies and classification societies, as, according to sections 6.1.1-3 of the new IMO resolution, all measurements have to be documented within the CTF by an accredited inspector.
Precise and effective analysis of coating thickness measurements in practical use.
Regarding the quality control of usually epoxy-based coatings, the IMO standard MSC215(82) requires coating thickness to be evaluated according to the 90/10 rule. This rule specifies that 90% of all measurements have to be equal to or excess the required coating thickness. The remaining 10% of the measurements must not fall below 0.9 times the required coating thickness [5]. Furthermore, shipyards work in accordance with DIN EN ISO 12944-5 [6]. Its controversial part 5 refers, since January 2008, to the ISO 19840 and the ISO 2808 regarding rough surfaces in particular [7], [8]. The qualification of personnel in accordance with certain training standards such as FROSIO or NACE is just as important as fast and reliable measuring gauges to record, for instance, 40.000 measurements a day in rough environment and difficult locations, as shown in figure 1.
Regarding the reliability of coating thickness measurements during several thousand measurements a day, the exchangeable measuring probes (figure 2) of the QNix® 8500 measuring system are equipped with ruby measuring heads. As rubies have a much higher hardness than any metal overlay the probes offer highest wear resistance.
Shipyards organize the construction of a ship in so-called ship sections that are coated and measured separately before assembly. The use of methodical recording allows single sections to be saved in individually named batches, as shown in figure 3. Each single layer of the usually applied multi-layer systems is measured fast and methodically with regard to time and location. This is important, as it provides an effective method of operation and increases the cost-efficiency of the quality management. To achieve a comprehensive analysis and documentation of measurements for the “Coating Technical File” the gauge conveniently allows measurements to be transmitted wirelessly using a personal computer, as shown in figure 4.
The direct transfer of measuring data to Microsoft Excel enables users not only to analyze the measurements statistically according to their personal requirements but also to individually document the data for use in the “Coating Technical File”. Together with Excel, the QNix® 8500 measuring system provides a convenient method to combine the recording, analysis and documentation of measurements in one device. This guarantees institutions responsible for construction, inspection and verification a fast and effective processing and documentation of measurement data. This will be of even more important in future, when the new IMO regulation MSC res. 244(83) documentation will presumably make the maintenance and repair work of ships with at least 500 gross registered tons mandatory [9].
Summarization
The terrible ship disasters of the past that were, among other things, due to extensive corrosion damage [4], are the reason why IMO, classification societies, ship owners and shipyards focus their attention on corrosion protection. Modern coating thickness measuring devices such as the modular QNix® 8500 provide fast and exact coating thickness measurements and an effective and convenient documentation of these measurements using a PC. Especially, since the implementation of the “Coating Thickness File”, which is to be kept as record of a ship’s whole service life, the various organizations have to be able to analyze and individually document the required measurements of coating thickness.
Manufactured exclusively in Germany, measuring gauges from AUTOMATION Dr. Nix provide high quality, fast customer-oriented service and simple and individual data processing capabilities using a PC and Microsoft Excel. This guarantees the highest degree of productivity, flexibility and an increase in the user’s value creation.
Literature
[1] Timothy E. Dunbar, Neil Pegg, Farid Taheri and Lei Jiang
“A computational investigation of the effects of localized corrosion on plates and
stiffened panels”
Marine Structures, Volume 17, Issue 5, September 2004, pages 385-402
[2] J. K. Paik and A. K. Thayamballi
” Ultimate strength of ageing ships”
Proceedings of the Institution of Mechanical Engineers, Part M
Journal of Engineering for the Maritime Environment
Volume 216, Number 1 / 2002; pages 57-77
[ 3] Brian Goldie
“Marine coatings under the regulatory spotlight”
Journal of Protective coatings & linings, Volume 25 , Number 2 ; Feb. 2008, pages 48 - 52
[ 4] Thorsten Lohmann und Daniel Engel
“Aktuelle Entwicklungen im Bereich Korrosionsschutz bei der IMO und IACS”
Tagungsband zur 7. Tagung ” Korrosionsschutz in der maritimen Technik”, pages 15-22
[ 5] Resolution MSC.215(82)
„Performance standard for protective coatings“
IMO Naval Architectural Group - Maritime Safety Committee (MSC)
[ 6] DIN EN ISO 12944
“ Korrosionsschutz von Stahlbauten durch Beschichtungssysteme“
CEN Europäisches Komitee für Normung
International Organization for Standardization (ISO)
[ 7] ISO 19840
“Beschichtungsstoffe - Korrosionsschutz von Stahlbauten durch Beschichtungssysteme
- Messung der Trockenschichtdicke auf rauhen Substraten und Kriterien für deren
Annahme”
CEN Europäisches Komitee für Normung
International Organization for Standardization (ISO)
[ 8] DIN EN ISO 2808
” Paints and varnishes — Determination of film thickness”
CEN Europäisches Komitee für Normung
International Organization for Standardization (ISO) (TC 35/SC 9)
[ 9] RESOLUTION MSC.244(83)
” ADOPTION OF PERFORMANCE STANDARD FOR PROTECTIVE COATINGS
FOR VOID SPACES ON BULK CARRIERS AND OIL TANKERS”
IMO Naval Architectural Group - Maritime Safety Committee (MSC)
New development: A magnet-inductive precision measuring probe for coating thickness measurements of coatings on ferromagnetic steel - expanding the application range of the modular QNix® 8500 system.
QNix® 8500 pen-shaped probe for precision measurements of micro coating thickness on small parts
The innovative magnet-inductive QNix® pen-shaped measuring probe MI Fe 500µm developed by AUTOMATION Dr. Nix, Cologne expands the application of the modular QNix® 8500 measuring system in the area of precision measurements of thin coating even further.
Now, whole new areas of application in quality management of small parts or in measuring around close edges are possible.
In addition to standard probes based on the Hall-sensor principle, AUTOMATION Dr. Nix, the specialist for non-destructive coating thickness measurements, now offers its users a new magnet-inductive pen-shaped probe for a measuring range of 0 – 500 µm. The new interchangeable probes measure most precise within the lower measuring range even on thin non- ferromagnetic coatings of small parts.
Quality control of corrosion protection
In praxis, small steel parts, such as screws or bolts, are protected by an anti-corrosion coating. Only the correct coating thickness – usually within the lower measuring range – guarantees a good cohesion and sufficient corrosion protection.
The new optimized QNix® pen-shaped probe MI Fe 500 µm reduces interfering measuring effects considerably, enabling the user to accurately measure more closely to edges and on smallest parts. This guarantees a reliable quality control of corrosion protection on smallest surfaces or close to edges.
That way, it is possible to precisely measure coating thickness of thin non-ferromagnetic metal coatings including chromium, copper, zinc as well as paint, enamel or synthetic coating on steel substrates. These precision measurements are based on the magnet inductive measuring method as described in the DIN EN ISO 2178, ISO 2808 and ASTM B499 standards.
In addition, the pen-like shape of the probe offers perfect control over manual adjustments on the measurement object. If particular high accuracy is required, the measuring probe can even be mounted on a measuring stand, for which sample holders are available.
Flexibility in the quality management of major projects.
The latest module of the QNix® 8500 measuring system – the new pen-shaped probe – increases flexibility in the use and opens up new areas of application for coating measurements on angle brackets, shims, screws, bolts and nuts as well as frictional connections.
Customized calibrations allow for particularly convenient and easy measurements on thin-coated small parts. This results in a more reliable quality management of large steel works when checking protective coatings on steel bolts and nuts such as the ones used on rotor fastenings, wind energy plants, bridges or window fittings.
Furthermore, the new pen-shaped probe is suited for PVD coatings such as TiN, TiCrN, CrN and TiAIN.
The known user oriented advantages of QNix® measuring devices, their high and rugged quality and their ease of use are trademarks of the new pen-shaped probe.