ML20107C368

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Rev 6 to Procedure QI-QP-2.1-4, Qualification of Protective Coating Insp Personnel
ML20107C368
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 07/27/1983
From: Manning
TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
ML20106F959 List:
References
QI-QP-2.1-4, NUDOCS 8502210289
Download: ML20107C368 (13)
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Text

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'" REVISICN PAGE TEXAS UT1UTIES GENERATING CO. gq

, CPSES .

j l QI.QP.2.1 4 6 R28 M 1 Of 7 l PREPARED BY: m -_ _ /h APPROVED BY:  ; /

N RS NNEL APPROVED BY: /~

/ Nh i j 2 ATE I

1.0 REFERENCES

l l 1.A CP.QP.2.3, "Docunentation Within QA/QC Personnel t

Qualification File" l i

l 18 CP.QP.2.1, " Training of Inspection Personnel" l 2.0 N AL FOR IMFORMATIDil 0l0  !

The purpose of this instruction is to define specific inspection functions and capabilities for protective coatings inspection personnel . TUGC0 Quality Engineering .

will assure that .the required training is accomplished. I The requirements contained herein are not applicable to j material, parts or components under the jurisdiction of the i ASME Code,Section III, Division I.

3 3.0 INSTRUCTION l 3.1 PROTECTIVE C0ATING QC TECHNICIAN INSPECTION FUNCTION Inspection functions may include, but are not linited to, ,

I the following:

a. Perfoming surface preparation inspections
b. Perfom surveillance of storage and handling of protective coating materials.
c. Perfoming protective coating mixing inspections ,
d. Perfoming in. process inspections of protective coating applications '

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, e. Preparing reports that give the results of the above ,

tests l

8502210289 850213 ',

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l INSTRUCTION ISSUE REVISION PAGE NUMBER DATE TEXAS UTILITIES GENERATING CO.

CPSES QI.QP.2.1 4 6 JUL 2 8 123 2 of 7 l

l 3.1.1 Training and Examination Protective Coating QC Technicians shall have knowledge and

. skill to adequately perfonn their assigned task. The following shall be used as a guide for training and examina.

tion of Protective Coating QC Technicians:

a. Construction specdffcations and procedures
b. Ba' sic inspection plans and procedures
c. Specific instructions, checklist and reports used in performance and documentation of inspections and tests
d. " Hands on" experience using inspection and test equipment
e. Familiarization with required measuring and test equipment-
f. Minimum on the job (0JT) requirements are defined on the Protective Coating Technical Cutline (Figure 1) 3.2 PROTECTIVE C0ATING QC INSPECTOR Inspection functions may include, but are not limited to, the following:
a. May perform duties as a Protective Coating QC Technician in the activities for which qualified' .rtified
b. Prepares and interprets reports '
c. Provides technical direction to Protective Coating QC Technician (s) *

. 3.2.1 Training and Examig tfon Protective Coating Qt. Inspectors shall have sufficient knowledge and skill to adequately perfonn their assigned tasks. The following shall Ni used 's a guide for training and examination of Protective Cating QC Inspectors:

a. Construction specifications' and procedures
b. Basic-inspection plans and procedures
c. Specific instructions, check. list and reports used in -

perfonnance and documentation of inspection and test pen m i " 0^

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t INSTRUCTION REVISION ISSUE NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.

CPSES i QI.QP.2.14 6 El 2 8 1087l 3 of 7

d. " Hands on" experience using inspection and test instructions

.i l e. Familiarization wi th required measuring and test equipment

f. Preparation and interpretation of test results.

3.3 TRAINING AND DOCUMENTATION Qualification of Protective Coating inspection personnel shall be documented in accordance with Reference 1 B.

Protective Coating inspection personnel shall complete the 4 General Training Outline (required by Reference 18) and the Protective Coating General Technical Outline (Figure I).

,', On completion of the General Training Outline , the QC Supervisor or his designee shall interview the trainee and sign and date the Outline. In addition to the Protect'ive Coatir.g General Technical Outline, specific Quality Instructions have been developed by Quality Engineering, for each Protective Coating inspection activity. These form the basis of information required for a particular

- inspection function.

Protective Coating personnel are certified in a given inspection function / activity. A Technical Training Outline (Figure I) docunenting qualification requirements for a given inspection function / activity will be completed and verified by the cognizant QA/QC Supervisor.

3.4 QUALIFICATION MATRIX (WORD PROCESSOR PRINT 0llT)

A matrix shall be maintained by the Protective Coating QC Supervisor to identify the specific inspections an individual is qualified to pe rfonn. The specified

inspections shall be indexed by the Quality Procedure or *

,- Instruction.

3.5 TRAINING CERTIFICATION Inspection Certification per Reference 1.B certifying satisfactory completion of training in accordance with this Instruction will be placed in an individual file for each QC employee, signed by the Site QA Supervisor and Quality control Supervisor or their designees.

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1 INSTRUCTION REVISION ISSUE NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.

'CPSES QI.QP.2.1 4 6 JUL 2 8198? ; 4 of 7 Certification in a particular inspection function will be for a period of 1 year.

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INSTRUCTION REVISICN ISSUE PAGE NUM8ER DATE TEXAS UT11.ITIES Gi1NERATING CO.

QI-QP-2,1-4 6

l JOL 2 81983 5 of 7 FIGURE 1

  • CP5ES QUALITY CONTROL DEeanNE'ef PROTECTIVE COATING GENERAL TECHNICAL OUTLINE NAME: 0 ATE COMME'tCED:

A. Read and discuss the following documents with designated Lead Inspectors:

1. G1H Specification A$.31. " Protective Coatings" Trainee Oate Lead Inspector Oate
2. CP.QP.2.0. " Implementation of CPSES Program
  • Trainee Date Lead Inspector Cate

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3. CP.QP.3.0."CPSf3SiteCA/CCOrganization" Trainee Date Leaa Inspector Date 4 CP.CP.11,4. " Inspection of Protective Coatings
  • Trainee Oate Leac Ins;ector Oate
5. QI.QP.11.41. " Inspection of Steel Substrate Surface Preparation and Primer Application
  • Trainee Oate Less Ins;ector Oate
6. QI.cP-11.4 5. ' Inspection of Steel Substrate Prfmer Pepair and Seal and Finish Coat Appliestion and Repatr*

Trainee Date Lead Inspector Date

7. QI.CPoll.4 8. " Inspection of Special Coating Operations" Trainee Date Lead Inspector Date
8. QI.QPoll.4 9. ' Inspection of Shop Primed Equipment" Trainee Oate Lead Inspector Oate j
9. QI.CP.!!.410. *!nspection of Concrete Substrate Surface Preparation 4  !

Ccatings Application t Re; air * .

l Trainee - Date Lead Inspector Date TUGCC CA -

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INSTRUCT 10N REVISION ISSUE pggg NUMBER DATE TEXAS UYILITIES GENERATING CO.

CPSES l

QI-QP-2.1-4 6 g JiL 2 8123 6 of'7 FIGURE 1 (Cont. )

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^ ' 19 P90TECTIVE COATINGS GENERAL TECHNICAL OUTLINE PAGE 2 CF 3 4

10. Q1-0P-!!.4-17, " Surveillance of Storage and Handling of Protective CoatimJs*

Trainee Date Lead Ins;ector Cate

!!. QI-CP-11.4 20,

  • Final Inspection of Steel suostrate Finish Coats
  • Trainee Gate Leac Ins;ect:r Jate
12. QI QP-11.4-21, " Final Inspection of Concrete Substrate Finish Coats"

, Trainee ~ Gate Lead Inspector Gate

13. O!-QP-ll.4-22, *QC Verification of Protective Coatings Unique !centification Nuncer Transfer" l

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t Trainee Cate Leaa Inspector Cate l 6

14 QI CP-11.4 23, " Reins;ection of Coatings A; plied on Steel Suostrates* '

erainee Da te Leae Inspector

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15. 01-QP-II.4-24, " Reinspection of Protective Coatings on Concrete Substrates L for whica Occumentation is Missing or Discrepant
  • l Trainee Date Lead Inspector Date
16. CCP-30,
  • Coating Steel Substrates Inside Reactor Building & Radiation Areas" i

Trainse Date . Lead Inspector Date

17. CCP-30A,
  • Coating Steel Substrates inside Reactor Butiding f. Radiation Areas *

. Trainee Date Leas Inspector .Date

18. CCP-40,
  • Protective Coating of Concrete Surfaces *  !

I Trainee Date Lead Inspector Date l

19. CP-CP-13.0, " Control of M&TE" I i

( Trainee Gate Leae Inspector Date l Tuoco c4 .

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INSTRUCTION REVISICN ISSUE PAGE NUMBER ** DATE TEXAS UTIUTIES GENERATING CO.

CPSES ,

i AVL 2 81963 ' Of 7 QI-QP-2.1-4 6 i FIGURE 1 (Cont.)

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PROTECTIVE CCATINGS GENERAL TECHINICAL QUTLINE

{ AGE 30F3 IO. CP-CP-15.0, " Tagging S.wstem" wesc ins;ector

  • Trainee Cate i.a te II. CP-07-16.3 "Nonconfomances and Oeficiencies" i Trainee cate Leaa :nscector Oate
22. CP-OP-;3.3 " Ins:ection Re:crt" g Trainee Date Leac inspector Date
8. Perfor= a minimum of 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> *on-tne-jen" training in tnis activity.

i QC Supervisor i Deeenstrate proficiency in redei-' ring inspection.

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1 OC Supervisor D. Demonstrate proficiency in ecmoletina the inspection checklist (s).

Oc Sweervisor E. Attend femal training session for this activity.

OC Supervisor .

i F. Examination comoleted.

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. Score: Concrete Steel 3  ; Sackfit .

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komnents:

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. Training Completed:

ac suoervisor .Nte_ 4 I

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/' TIX-4249 August 10, 1984 j

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QUESTIONS RELATIVE TO ALLEGATION No. 21 A. Adhesion Tests At the July 11, 1984 site meeting, CPSES briefed the NRC Coating Allegation Team members on the overall secpe of the Coating Backfit Program. R. Tolson (TUGCO) informed the team of a discrepancy in calibrating Elcometers used for the coating adhesion test that was discovered after most of the Backfit Program adhesion tests were completed. This discrepancy would allow in-plant test results to be in error by 200 psi in the non-conservative direction.

CPSES should revise and correct the original adhesion test data based on dead weight calibration records for each Eleometer used to provide the original test data. The corrected data should then be statistically re-evaluated to establish the fraction (%) of total coated area that passes the 200 psi acceptance level with the stated confidence level. This re-evaluated data should be separately reported for: concrete, containment liner and miscellaneous steel. Describe the method and basis for re-constituting the original test data and establishing the confidence level. Also, describe how the area fraction was established.

In providing the above requested information, the following specific information should be supp. lied.

a. For each adhesion test sample area in which at least one test reading is below 400 psi, provide:
1. All test readings for the sample area. If sample area is reworked, give test readings before and after repair.

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TXX-4249 August 10, 1984 QUESTIONS RELATIVE TO ALLEGATION NO. 21

2. PCR numbers for all adhesion tests, the area sampled (e.g. ,100 f t ), date and E1cometer number.
3. Calibration readings for that E1cometer at nearest calibration dates before and after testing the sample area.

4 Corrected readings for.the sample area (Field reading - largest positive deviation during calibration period).

b. For each Elcometer used in the Backfit program, provide a table or curve showing calibration deviations (at the 200 psi point value) as a function of date for the complete Backfit period. In case the instrument zero required adjustment show deviations before and af ter adjustment.
c. For each of the three surface types, containment liner surface, concrete surfaces and miscellaneous steel surfaces, provide:
1. Total area and total area tested for adhesion.
2. Total area which failed the pull test before repair. (Sum of sample areas represented by at least one failed pull test before repair).
3. Fraction of total area tested which failed the pull test before repair.

4 Number of sample areas tested and average number of tests per sample area.

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TII-4249 August 10, 1984 QUESTIONS RELATIVE TO ALLEGATION NO. 21

5. Using the pull test data after correcting for instrument bias

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(calibration), provide a statistical evaluation of the fraction of the painted area failing the adhesion test, not including the exempted area. Where calibration data are not available, assume an instrument bias of 200 psia. Provide the standard deviation associated with the estimate of the fraction of the total painted area which failed the pull test, based on the corrected data.

Construct a 95: upper confidence limit for the proportion of the area which would fail the pull test.

6. Describe how the sample areas (.e.g., grids) were selected.

Indicate the degree to'which the spots actually tested were representative of each sample area.

7. For each item on the Coating Exemption Log involving an area of 1000 ft.2 or more, describe in detail the method of estimating the area. Provide the total exempted area for each of the three main types of surface.

B. Drv Film Thickness Tests For each of the three surface types, provide:

1. Total area tested for DFT (a) of primer, and (b) of complete coating systems. ,

TXI-4249 August 10, 1984 QUESTIONS RELATIVE TO ALLEGATION NO. 21

2. Total area which failed the DFT test before repair (a) of primer and (b)'for complete coating system.
3. Fraction of total area tested which failed to meet DFT specifications before repair (a) for primer and (b) for total coat.
4. Number of sample areas tested and average number of DFT tests per sample area (a) for primer and (b) for the complete coating system.

Response

We will respond to this question at a later date.

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TXX-4249 August 10, 1984 QUESTIONS RELATIVE TO ALLEGATION NO. 22 Provide information requested for allegation #19 above.

Response

See our response to question 19.

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m IXX-4249 .

August 10, 1984 l l

QUESTIONS RELATIVE TO ALLEGATION NO. 26 a) Describe the system and the requirements to revise the coating specifications to incorporate DCA's. ,

b) Describe the system utilized to control DCA's used by personnel applying or inspecting coatings, as described in the first paragraph of your 06/22/80

response.

Response

a) When engineering determines that the specification requires revision, outstanding generic DCA's are incorporated. A copy of procedure CP-EP-4.6

- is attached.

b) Design documents used by construction and QC personnel are controlled by 1.

i Document Control. A copy of DCP-3 is attached.

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