AMPP CIP Level 2 cheat sheet

An inspection plan defines hold points, witness points, and surveillance frequency before production work begins.

A hold point prevents further work until the inspector verifies the required characteristic and records acceptance.

A witness point is a notified inspection stage that work may pass if the inspector is absent, unless the contract states otherwise.

Inspector authority is normally limited to verifying conformance and reporting; approving specification deviations requires contract authority.

Stop-work authority exists only when granted by the contract or specification; otherwise the inspector documents and escalates the nonconformance.

Destructive tests require written approval and a repair procedure because they damage the applied coating system.

Instrument calibration status is verified and recorded before readings are accepted as inspection evidence.

Incoming coating materials are checked for batch number, shelf life, storage temperature, mixing ratio, and specification compliance.

A nonconformance report identifies the condition, location, requirement, objective evidence, disposition, and corrective action.

Epoxy coatings are two-component amine-cured systems with good chemical resistance; their recoat window is critical for intercoat adhesion.

Polyurethane topcoats are UV-stable and moisture-sensitive during cure; they are commonly applied over epoxy primers.

Zinc-rich primers protect steel cathodically; zinc dust content and binder type must match the specified product standard.

Coal tar epoxy is not UV-stable and is normally covered by a topcoat when exposed to sunlight.

Dry-film thickness equals wet-film thickness multiplied by the volume solids fraction of the coating.

Theoretical coverage in square metres per litre equals 1000 times volume solids divided by target dry-film thickness in micrometres.

Mixing ratio by volume must be followed; adding thinner beyond the product data sheet alters viscosity, VOC content, and cure.

Coating selection considers service environment, substrate, operating temperature, expected service life, and application constraints.

Exceeding the recoat window usually requires abrasion of the previous coat before applying the next coat.

Solvent cleaning per SSPC-SP 1 removes oil, grease, dirt, and similar contaminants before abrasive blasting or power tool cleaning.

SSPC-SP 10 or ISO Sa 2½ is near-white blast cleaning; staining is limited to a small percentage of each unit area.

SSPC-SP 5 or ISO Sa 3 is white metal blast cleaning with no visible oil, grease, rust, mill scale, coating, or foreign matter.

ISO 8501-1 grades progress from Sa 1 light blast through Sa 2 thorough blast, Sa 2½ near-white blast, to Sa 3 white metal blast.

Abrasive blast profile improves mechanical adhesion; profile depth must fall within the coating manufacturer's specified range.

Soluble salts are measured by the Bresle method and reported as chloride concentration in micrograms per square centimetre.

Surface temperature must be at least 3°C or 5°F above dew point to prevent condensation during surface preparation and coating.

Relative humidity is commonly limited to 85% or less for solvent-borne coatings unless the product data sheet states otherwise.

Power tool cleaning per SSPC-SP 3 removes loose material; SSPC-SP 11 removes coatings to bare metal at specified areas.

Airless spray atomizes coating by forcing it through a small tip at high hydraulic pressure.

Tip orifice size and fan angle are selected according to coating viscosity, desired film build, and surface geometry.

Applying a coat too soon after the previous coat can trap solvent; applying too late can cause intercoat adhesion failure.

Plural-component spray equipment meters and mixes base and catalyst at the specified ratio before delivery to the gun.

Stripe coats are applied by brush or roller to edges, welds, corners, and back of angles before full spray application.

Wet-film thickness is checked immediately after application; target wet-film thickness equals dry-film thickness divided by volume solids fraction.

Spray passes commonly overlap about 50% to produce uniform coverage without skips or heavy build.

Compressed air for conventional spray must be clean, dry, and oil-free; traps and filters are checked before use.

Magnetic pull-off dry-film thickness gauges measure coatings on ferrous substrates and are verified with foil shims.

Eddy current dry-film thickness gauges measure coatings on nonferrous substrates and are not suitable for steel.

Holiday detectors locate pinholes, cracks, and thin spots; test voltage depends on coating thickness and the applicable standard.

Pull-off adhesion testing per ASTM D4541 records both the numerical result and the observed failure mode.

Cross-cut adhesion testing per ASTM D3359 uses a classification from 5B, no removal, to 0B, greater than 65% removal.

Surface profile is measured with comparator discs or replica tape; replica tape gives a more objective peak-to-valley reading.

Salt contamination is measured with a Bresle patch and conductivity meter, with chloride reported in micrograms per square centimetre.

Gloss is measured with a glossmeter at a specified angle, commonly 60 degrees or 85 degrees depending on gloss level.

Ambient relative humidity and surface temperature are measured with hygrometers and infrared thermometers before coating application.

Daily inspection records include date, time, location, weather, ambient conditions, surface temperature, dew point, readings, and inspector signature.

Nonconformance reports track description, cause, corrective action, disposition, and closure status.

Calibration records identify the instrument, calibration date, due date, and traceability to a recognized standard.

Test reports state the test method, acceptance criterion, measured result, pass or fail determination, location, date, and instrument used.

As-built coating records include the coating system, batch numbers, final dry-film thickness map, repairs, and acceptance status.

Records retention periods are defined by the contract and may extend beyond project completion.

Chain-of-custody records are required for samples sent to a laboratory for analysis.

Inspection records must be legible, dated, signed, and traceable to the specific area or component inspected.

Confined space entry requires a permit, atmospheric testing for oxygen, flammables, hydrogen sulfide, and carbon monoxide, plus ventilation and an attendant.

Abrasive blasting can generate respirable crystalline silica; controls include respiratory protection, ventilation, and dust suppression.

Solvent vapours and coating mists are flammable; ignition sources are controlled and equipment is bonded and grounded.

VOC content limits are regulated; compliance depends on product data, thinner addition, and application method.

Spill containment uses berms, absorbents, and proper disposal according to the safety data sheet and local hazardous waste rules.

Heat stress controls include monitoring wet-bulb globe temperature, hydration, and work-rest schedules.

Fall protection is required when working at height; harnesses, lanyards, and anchor points are inspected before use.

Used solvents, blast media, and paint containers are segregated and disposed of according to safety data sheets and local regulations.