AMPP CIP Level 2 Cheat Sheet

Surface Preparation and Inspection

18% of exam
Blast Levels WJ Levels ISO Grades Concrete Prep Prep Picker

Coating Inspection

16% of exam
DFT Methods Adhesion Tests Holiday Detection Failure Modes NDE Methods

Inspection Process

15% of exam
Roles ITP Hold Points Escalation

Coatings and Coating Application

13% of exam
Specialty Systems Cure Types WFT/DFT Math Application Methods

Documentation

10% of exam
Galvanizing Standards Reports NCRs Daily Logs

Corrosion

9% of exam
Corrosion Forms Cathodic Protection CD Testing Corrosion Mitigation

Environmental Conditions and Inspection

7% of exam
Dew Point Rule RH Threshold Instruments Flash Rust

Safety

4% of exam
Stop-Work Hazards Intrinsically Safe Confined Space PPE

Communications and Teamwork

4% of exam
Owner vs Contractor Level 3 Escalation Conflict Resolution Stakeholder Communication

Ethics

4% of exam
Pressure Points Reporting Duty Conflicts of Interest Inspector Limits

Quick Facts

Exam CIP Level 2
Body AMPP
Items 120 (100 scored)
Time 3 hrs seat time
Practical 8 stations, in-person
Pass score Not published
Prereq CIP-1 + 2 yrs exp
Validity 3 years

Blast Level Order SU

SP7 < SP6 < SP10 < SP5 cleanliness
SP7: brush-off, lightest level SP6: commercial, 33% stain SP10: near-white, 5% stain SP5: white metal, zero stain

SP6 vs SP10 SU

SP6 / NACE No.3

Commercial blast
Sa 2 equivalent
≤33% staining allowed

SP10 / NACE No.2

Near-white blast
Sa 2½ equivalent
≤5% staining allowed
Moderate vs high-performance service

Surface Prep Standard Picker SU

Immersion, TSA, or IOZ service → SP5 / NACE No.1 ( Sa 3, zero stain )
Moderate atmospheric maintenance coating → SP10 / NACE No.2 ( Sa 2½, ≤5% stain )
General industrial maintenance work → SP6 / NACE No.3 ( Sa 2, ≤33% stain )
Shop primer or temp protection → SP7 / NACE No.4 ( Sa 1, lightest blast )
Blasting is impractical onsite → SP11 power tool ( Bare metal, min profile )
Galvanized or non-ferrous metal → SP16 brush-off blast ( Keep substrate layer intact )
Need soluble-salt removal → Waterjetting WJ series ( No new profile created )
Confined space or elevated access → Remote/portable prep equipment ( Keeps crew out of hazard )

SSPC/NACE Blast Levels SU

SP1 Solvent cleaning, removes oil/grease
SP2 Hand tool cleaning, loose material
SP3 Power tool cleaning, loose material
SP5 / NACE No.1 White metal blast, zero staining Sa 3
SP6 / NACE No.3 Commercial blast, ≤33% staining Sa 2
SP7 / NACE No.4 Brush-off blast, lightest level Sa 1
SP10 / NACE No.2 Near-white blast, ≤5% staining Sa 2½
SP11 Power tool cleaning to bare metal

WJ Cleanliness Ladder SU

WJ-1 cleanest, WJ-4 lightest cleaning level
WJ-1: bare substrate WJ-2: 95% clean matte WJ-3: two-thirds clean WJ-4: light, adherent stays

Waterjetting WJ Levels SU

WJ-1 Clean to bare substrate ≈SP5
WJ-2 Very thorough, ≥95% residue-free ≈SP10
WJ-3 Thorough, ≥2/3 residue-free ≈SP6
WJ-4 Light cleaning, adherent matter stays ≈SP7

ISO 8501-1 Grades SU

Sa 1 Light blast cleaning
Sa 2 Thorough blast cleaning
Sa 2½ Very thorough blast, slight stains
Sa 3 Blast to visually clean steel
St 2 Thorough hand tool cleaning
St 3 Very thorough power tool cleaning

Abrasive & Concrete Prep SU

SSPC-AB 1 Mineral and slag abrasive quality
SSPC-AB 2 Recycled ferrous abrasive work mix
SSPC-AB 3 New unused ferrous metallic abrasive
SP16 Brush-off blast, galvanized/non-ferrous metals
ASTM D4259 Concrete abrasion prep, removes laitance
ICRI 310.2R Concrete profile scale, CSP 1-9

Holiday Voltage Crossover CO

Under 20 mils wet, over dry-spark
Under 20 mil: low voltage Over 20 mil: high voltage Formula: V equals M root DFT

Verification vs Calibration CO

Verification

Field check
Every shift
No adjustment made

Calibration

Lab or tech performed
Periodic interval
Adjusts the instrument
Confirm vs correct

Thickness & Adhesion Test Picker CO

DFT on steel substrate → Magnetic/eddy-current gauge ( Per SSPC-PA 2 )
DFT on concrete, FRP, wood → Ultrasonic gauge ( ASTM D6132 )
Need pass/fail adhesion class → D3359 tape test ( Qualitative rating only )
Need numeric adhesion value → D4541 pull-off ( Force/area plus failure mode )
Cure check on rigid FRP → Barcol hardness (D2583) ( Shore D saturates near 100 )
Cure check on flexible lining → Shore D durometer (D2240) ( Stays sensitive to cure )
Coating under 20 mils DFT → Low-voltage wet sponge ( Holiday test method )
Coating over 20 mils DFT → High-voltage spark tester ( V = M√DFT )

Profile & DFT Methods CO

D4417 Method A Visual comparator, profile range
D4417 Method B Depth micrometer, max reading recorded
D4417 Method C Replica tape, peak-to-valley depth
D6132 Ultrasonic DFT, non-metallic substrates
Magnetic/eddy-current gauge DFT on steel substrates

Failure Mode Clues CO

Salts blister, thick film mud-cracks, humidity blushes
Osmotic blister: soluble salts Mud-cracking: over-thick film Amine blush: humid cure

WFT vs DFT CO

WFT

Measured wet
Before cure
Predicts final DFT

DFT

Measured cured
Spec compliance value
Pass/fail basis
Wet predicts, dry decides

Adhesion & Hardness Tests CO

D4541 Pull-off adhesion, force plus mode
D3359 Tape test, qualitative classification
D2583 Barcol hardness, rigid FRP
D2240 Shore D hardness, flexible linings
Tooke gauge Cross-section reveals coat thicknesses

Low- vs High-Voltage Holiday CO

Low voltage

Wet sponge
Under 20 mils
Water completes circuit

High voltage

Spark/brush probe
Over 20 mils
V = M√DFT
Thin film vs thick film

Holiday Detection CO

Low voltage Wet sponge, under 20 mils
High voltage Spark tester, over 20 mils
D5162 Holiday testing, metal substrates
D4787 Holiday testing, concrete substrates
V = M√DFT Voltage formula, AMPP SP0188

D3359 vs D4541 CO

D3359 tape test

Qualitative rating
Cross-cut classification
Pass/fail only

D4541 pull-off

Quantitative force value
Failure mode noted
PSI or MPa
Classify vs quantify

Cure & Finish Checks CO

D5402 Solvent rub resistance, cure check
D523 Gloss measured at 60 degrees
Calibration Lab adjusts against reference standard
Verification Field check, no adjustment made

Coating Failure Modes CO

Osmotic blistering Soluble salts draw in moisture
Cathodic disbondment CP current lifts coating edge
Mud-cracking Over-thick film shrinks, cracks
Alligatoring Hard topcoat over soft undercoat
Amine blush Humidity during epoxy cure
Filiform corrosion Thread-like rust under film

NDE Methods CO

VT Visual testing, needs adequate light
PT Dye penetrant, surface-breaking defects
MT Magnetic particle, ferromagnetic only
UT Ultrasonic, volumetric defects
RT Radiographic, volumetric defects

Escalation & Authority Picker IN

Widespread or recurring failure → Escalate to CIP Level 3 ( Root-cause determination )
Verbal request conflicts with spec → Written spec still governs ( Get change in writing )
Contractor pressures skipping a test → Hold to spec, report facts ( Escalate if pressure continues )
Spec interpretation is ambiguous → Route to owner or engineer ( Not resolved onsite alone )

Inspection Process & Roles IN

ITP Inspection and test plan, pre-work
Hold point Work stops for required sign-off
Owner/engineer Sets criteria, final disposition call
Contractor Chooses means and methods
Inspector Verifies work meets specification
De facto standard Common practice, no formal body

Convertible vs Non-Convertible Cure CO

Convertible

Chemical cure reaction
Irreversible once cured
Epoxy, polyurethane

Non-convertible

Solvent/water evaporation only
Re-softens in solvent
Vinyl, chlorinated rubber
React vs evaporate

Specialty Coating Systems CO

Thermal spray AWS C2.23M / SSPC-CS 23.00
Thermal spray guide AWS C2.18, selection guidance
Pipeline FBE 100% holiday tested at mill
3LPE Polyethylene jacket, standard temperature service
3LPP Polypropylene jacket, high-temperature service
Polyurea Plural-component, mixed at spray tip

WFT/DFT Formulas CO

WFT formula WFT = DFT ÷ %VS
Thinner correction Raises WFT needed for target DFT
Spreading rate m2/L = %VS x10 / DFTum
Volume solids Percent resin/pigment left after cure

Galvanizing & Doc Standards DO

ASTM A123 Original hot-dip galvanized coating spec
ASTM A780 Field repair of damaged galvanizing
NCR Non-conformance record, documents deviation
Daily log Records conditions, activities, and results

Corrosion Forms CO

Galvanic corrosion Dissimilar metals, electrolyte contact
Pitting corrosion Localized, chloride-driven attack
Crevice corrosion Stagnant electrolyte, tight gaps
SCC Stress corrosion cracking, tensile plus environment
MIC Microbiologically influenced corrosion

Cathodic Protection CO

ICCP Impressed current, rectifier power source
Galvanic anodes Sacrificial zinc, aluminum, or magnesium
Rectifier Converts AC to DC current
SP0169 Buried/submerged pipeline CP standard
Anode selection Small/isolated favors galvanic anodes

Cathodic Disbondment Lab Tests CO

ASTM G8 Room-temperature immersion CD test
ASTM G42 Elevated-temperature CD test
ASTM G80 Specific cathodic disbonding test
ASTM G95 Attached-cell CD test method

Dew Point Margin EN

Five degrees F, three C, above
Applies during prep, coat, cure SSPC-PA 1 states the rule Below margin risks moisture

Environmental Rules & Instruments EN

Dew point rule Surface 5°F (3°C) above dew point
RH threshold Above 60% RH accelerates flash rust
Psychrometer Measures relative humidity
Surface thermometer Contact probe, steel temperature
D4285 Blotter test, oil/water in air

Intrinsically Safe Equipment SA

Verify ratings before confined space entry
Limits electrical, thermal ignition energy Check before tanks, confined spaces Certified for flammable atmospheres present

Inspector Authority vs Contractor Responsibility CO

Inspector

Verifies the work
Reports facts objectively
No means/methods say

Contractor

Chooses means/methods
Performs the work
Meets spec requirements
Judge vs performer

Common Traps

Wet sponge ≠ spark tester

Low voltage under 20 mils ≠ High voltage over 20 mils

Calibration ≠ verification

Calibration adjusts the instrument ≠ Verification only checks reading

Visual clean ≠ salt-free

Visual grade misses invisible salts ≠ Salts need a separate test

Tape test ≠ pull-off

Tape gives a class rating ≠ Pull-off gives a force value

Waterjetting ≠ new profile

Waterjetting only cleans the surface ≠ It creates no new profile

Sa 2½ ≠ Sa 3

Sa 2½ allows slight staining ≠ Sa 3 allows zero staining

Verbal request ≠ spec change

Verbal input is context only ≠ Written spec still governs plans

Bulging hose ≠ minor issue

Bulge signals lining/reinforcement failure ≠ Treat as immediate stop-work hazard

Schedule pressure ≠ valid reason

Compression tempts skipping hold points ≠ Spec requirements still fully apply

Last Minute

1. Prep 18%, Inspection 16%, Process 15%
2. 120 items: 100 scored, 20 unscored
3. 3-hour seat time, no passing score
4. SP5/NACE1 = white metal, zero stain
5. SP10/NACE2 = near-white, 5% stain max
6. SP6/NACE3 = commercial, 33% stain max
7. WJ-1 cleanest, WJ-4 lightest waterjet level
8. Dew point: 5°F/3°C above surface
9. Holiday test: wet sponge under 20mil
10. Holiday test: spark tester over 20mil
11. D4541 = numeric pull-off force value
12. D3359 = qualitative tape classification only
13. Calibration adjusts; verification only confirms reading
14. Barcol (D2583) rigid FRP; Shore flexible
15. Written spec governs over verbal requests

AMPP CIP Level 2 Coating Inspector

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