ML20138M892
| ML20138M892 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak, 05000000 |
| Issue date: | 10/24/1983 |
| From: | TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC) |
| To: | |
| Shared Package | |
| ML20138M609 | List:
|
| References | |
| FOIA-85-59 QI-QP-11.4-5, NUDOCS 8511040471 | |
| Download: ML20138M892 (86) | |
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INSTRUCTION REVISION PAGE ES GENERATING CO.
NUMBER - E
-l TEXAS UTILIT]CPSES ' A~ '
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26 l *f 27 I OCT 2 4 ;953 FOR IXFORMATl0h Oh _Y i The surface temperature shall be a minimum of 5' above the dew point.
b) Verify abrasive acceptablility (if used) by obtaining a sample of the abrasive to be used. The abrasive shall be verified to be dry by feel with no grease, oil or deleterious materials. Particle size must be sufficient to achieve a minimum of 1 mil surface profile, c) Veri fy acceptability of blast cleaning equipment (if used) prior to use by:
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- 1. Verifying that water separators are installed in the air supply system anti that separators have l been drained of accumulated water and drains left
! partially open.
- 2. Air supply contamination shall be checked at the l nozzle prior to use by exposing a sheet of white paper or cloth to the blast of air (no sand) for l 1
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approximately 30 seconds. The paper or cloth shall '
be examined for evidence of contamination (oil, !
i water, foreign matter, ete ). No evidence of l
! contamination is acceptable.
d) Veri fy that the blasted or power tooled surface has .
been brushed or vacuumed to the extent requi red for l final surface inspection. The adjacent areas shall be I cleaned to the extent necessary to avoid contamination !
during subsequent coating applications. l l e) Veri fy acceptability of the blast cleaned or power
, tooled surfaces by perfoming the following inspections: '
- 1. Absence of Foreign Matter -- A visual inspection shall be performed to determine that all oil and grease, dirt, millscale, rust, corrosion products, ,
oxides, paint or other foreign matter have been ,
i completely removed from the surface except for light shadows, very slight streaks or slight ,
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' discolorations caused by rust stains, mill scale, oxides, or slight, tight residues of paint or coating that may remain. At least 95 percent of !
each square inch of surface area shall be free of ;
all residues, and the remainder shall be limited to light discolorations as mentioned above. !
. NOTE: In addition to the 5 percent of tight residue l of paint or coating which is pemissible 8511040471 851016 (above), shadows or ti htly wihering residues PDR FOIA of CZ-11 may remain CARDE85-59 PDR without limit) in the profile of the previously prepared substrate. ,
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INSTRUCTION ISSUE REVISION PAGE BER DATE TEXAS UTILITIES GENERATING CO.
CPSES l QI-QP-ll.4-5 25 7 f 27 OCT 17 1983 201 N:0RN A~ 0; 0 \ _Y The surface te.nperature shall be a minimum of 5' above the dew point.
b) Verify abrasive acceptablility (if used) by obtaining a sample of the abrasive to be used. The abrasive shall be verified to be dry by feel with no grease, oil er deleterious materials. Particle size must be sufficient to achieve a minimum of 1 mil surface profile, c) Veri fy acceptability of blast cleaning equipment (if used) prior to use by:
- 1. Verifying that water separators are installed 'in the air supply system and that separators have been drained of accumulated water and drains left partially open.
- 2. Air supply contamination shall be checked at the nozzle prior to use by exposing a sheet of white paper or cloth to the blast of air (no sand) for approximately 30 seconds. The paper or cloth shall l-I be examined for evidence of contamination (oil, water, foreign matter, etc.). No evidence of contamination is acceptabl'e.
'f d) Verify that the blasted or power tooled surface has been brushed or vacuumed to the extent requi red for final surface inspection. The adjacent areas shall be cleaned to the extent necessary to avoid contamination during subsequent coating applications, e) Veri fy acceptability of the blast cleaned or power tooled surfaces by perfoming the following inspections: ;
f 1. Absence of Foreign liatter -- A visual inspection shall be performed to detemine that all oil and grease, dirt, millscale, rust, corrosion products, oxides, paint or otner foreign matter have been completely removed fran the surface except for light shadows, very slight streaks or slight discolorations caused by rust stains, mill scale, f l oxides, or slight, tight residues of paint or
, coating that may remain. At least 95 percent of i each square inch of surface area shall be free of ,
all residues, and the remainder shall be limited l to light distalorations as mentioned above. ,
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4 INSTRUCTION ISSUE NUMBER REVISION PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES 01-0P-11.4-5 25 8 of 27
- 2. Removal of Sharp Projections -- A reinspection for sharp projections that were not blended (rounded) .
during blast cleaning or power tooling shall be pe rfomed.
Weld splatter on structural steel shall be removed by either grinding or sand blasting. However, if the weld splatter should remain after the above operation, the weld splatter will be acceptable.
Sharp projections are not acceptable.
Protrusions and peaks shall be ground to a rounded Contour.
NOTE: Any mechanical surface preparation other than sandblasting or hand or power tooling of sharp edges or weld spatter will require a visual welding inspector's acceptance of the work perfonned.
- 3. Anchor Pattern Depth -- The anchor pattern depth of the blasted surface shall be inspected at random i i locations using a Keane-Tator Surface Profile !
Comparator (model 373) or equivalent. l The anchor pattern depth for a blasted surface f shall be a minimum of 1.0 mils.
- Surfaces that have been power tooled wi th "3M Clean-N-Strip", 80 grit or coarser " flapper wheels",
sanding discs, " roto peans" or equivalent provide acceptable surface profile.
No maximum profile will be specifled, providing that correct millage and su rf ace uni fomi ty requirements can be obtained after primer application, j f) Veri fy applicator quali fications per Section 3.3.1.
g) Verify air supply acceptabili ty per Section 3.3.4.
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t INSTRUCTION ISSUE NUM8ER SiOA PAGE TEXAS UTILITIES GENERATING CO. DATE l QI-QP-11.4-5 24 to of 27
, OCT 101983 l i
l 03 TORT!ATON OLV
- 4. When coating materials are mixed / thinned in locations other than the fi eld , the inspector verifying the mixing operation shall fill out the Paint Mi xing Slip, Attachment 5. The inspector perfoming the pre-application inspection shall !
record the infomation from the Paint Mixing Slip !
on the Inspection Report, Attachment 3. The Paint 3 Mixing Slip need not be retained.
- 1) Veri fy that primer is applied and pot li fe is not exceeded in accordance with Reference 1-8 and 1-C. If a brush technique is used, the inspector shall verify that a short bristle brush is used and rebrushing is -
avoided.
NOTE: Coating interface shall be in acconfance with i paragraph 4.4.3.0 of Reference 1-B. Dry film -
thickness in the area of interface shall be in accordance wi th' Reference 1-8 and associated speci al coatings procedures as -
applicable, i
( j) Verify that hose length is less than 75 feet. .
3.2.3 Primer Touch-up Repair (primer Damage boes Not Extend to Steel Surface The coating inspector shall conduct the following inspections for primer touch-up repair operations when the damage is j within the primer coat and sandblasting to the steel -
substrate is not required.
a) Verify surface is abraded lightly then wiped clean per .
Reference 1-B and 1-C.
b) Perfom inspections (e) through (j) in paragraph 3.2.2.
3.2.4 Repair of Primer by Recoating -
The coating inspector shall conduct the following ;
inspections for primer recoating repair. Only two (2) .
overcoats shall be applied.
j a) Verify that the surface has been solvent cleaned or ;
cleansed in accordance with Reference 1-B and 1-C. A !
clean white cloth shall be used to check primed surface cleanliness. Contamination, other than rust (red) and zine oxide (white) stains, is unacceptable and require further cleaning, b) Perfom inspections (e) through (j) in Section 3.2.2.
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I INSTRUCTION ,
ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO. !
QI-QP-11.4-5 22 lSEP 2 31983 3 of 27
- 0R l\lFORN A~ ION ON_Y L b) For all areas of itner plate which do not have adequate '
documentation, the Inspector shall perfom an Adhesion (patch) test. A calibrated Elcometer 106 Adhesion l Tester shall be used to veri fy that the minimtsn acceptable tensile of adhesion to the steel substrate '
has been attained. Each test shall consist of three !
individual dollies tested to failure. I Criteri a : The minimum acceptable strength per dolly
, shall be 200 psi. If any one of the three dollies should test below the minimum l acceptable strength, the prime coat shall be removed to the steel substrate over the l entire item. 4 c) Verify the primer has cured required amount of time per Reference 1-B or 1-C. as applicable. ,
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' d) Perfonn a visual inspection of the primed surface in
( accordance with the following: ,
- 1. Runs / sags - A 0FT measurement shall be made with '
the Elcometer DFT gage. Runs / sags 7.0 mils for CZ-II and 8.5 mils for Cartoline 191 or less thick j
' (OFT) which show no evidence of mudcracking (See NOTE) are acceptable. Refer to References 1-B and 1-C for repair of unacceptable runs / sags.
I NOTE: Mudcracking is defined as irregula r -
cracking as in a dri ed mud puddle. ,
l 2. Dry Spray - Must be removed by screening or i
f abrading before overcoating. '
- 3. Over Spray - Must be removed before overcoating.
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( 4. Contamination l Oil and grease - unacceptable Embedded foretan materials - unacceptable i Stains - rust (red) and zinc oxide (white) stains ,
are acceptable provided loose particles are i j remoyed prior to application of finish coat.
! 5. Skips / damaged areas / gross discontinuities such as l holidays or voids - unacceptable. '
e) The inspector shall perfom a 0FT inspection of the l cured primer film. A calibrated 0-25 Elcometer +
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' l INSTRUCTION ISSUE REVISION PAGE i TEXAS UTILITIES GENERATING CO. I
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CPSES i 01 -Q P-11.4-5 22 i SEP 2 3 1983 4 of 27 i !
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l Inspector DFT gage Model III/IE, or equivalent, shall be used. Separate spot measurements (See Note 1) spaced evenly over the structure (See Note 2) shall be taken. Since the magnetic gage is sensitive to ;
geometric discontinuities in the steel, measurements :
less than 1 inch from the edge or a hole shall be ,
avoided where possible. (See Note 3)
Ory Film Thickness shall be as follows (See Note 4); i Min. (mils) Max. (mils) ,
Carboline 191 spot test 1.6 8.5 i CZ-II spot test 1.5 7.0 06 spot test 1.5 5.5 06 average OFT 2.0 5.0 CZ-II average DFT 2.0 6.0 Cartoling 191 average DFT 2.0 7.0 NOTE 1: A spot measurement is a series of three
' ( measurements in the same general area. The I probe should be moved a snort distance for ,
each gage reading. Discard any unusually high or low gage reading that cannot be repeated !
consi stently. Take an average of these three gage readings as one spot measurement.
NOTE 2: Five spot tests shall be taken for every l 100 square feet of coated surface. For areas l less than 100 square feet , the following I shall apply: .
Area Sq. Ft. No. Spots l
100-80 5 !
80-50 4 I 50-10 3 !
10-3 2 i l
3-0 1 l
NOTE 3: Items with appreciable surface curvature and other geometrical di scontinuiti es, such as handrails, gratings, stairs, sway struts, etc., shall be exempt from dry film thickness l
! measurement per Reference 1-B and 1-C. '
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" REVISION ^ PAGE t
. TEXAS UTILITIES GENERATING CO. I QI-QP-11.4-5 22 5 of 27 23 E i
NOTE 4: In the event that any spot is found to be '
outside of the acceptable thickness range, three addi tional spots shall be taken at i approximately 6 inches from the failing spot ;
and spaced radially at approvimately 120 degree intervals to determine the extent of the unacceptable area. Dimensions and locations .
of unacceptable areas and results of additional testing shall be documented on the IR. .
i In the event that the average of the area is unacceptable due to unacceptable spot i readings, the unacceptable spots shall be ;
isolated as described above. Additional spot i readings shall be taken equal to the number '
of unacceptable spot readings and the average recalculated. Results of these additional readings shall be documented in the " Remarks" ,
area of the IR. If the recalculated average l 15 acceptable, the IR shall be so marked with an explanation in " Remarks" stating that *
" average recalculated - now acceptable", or '
- wording to that ef fect. If the recalculated i I average is unacceptable, the unacceptable spots shall be isolated (as described above) and the above re-averaging process repeated. ,
3.2 PRIMER REPAIRS l 3.2.1 Saqs and Runs 3 Sags and runs over 7.0 mils DFT for CZ-II and over 8.5 mils DFT for Carboline 191 may be abraded by sanding or aluminum screening . If surface is acceptable pe r Section 3.1, document such on Attachment 3. If surface is unacceptable >
refer to Section 3.2.2 or 3.2.3 as applicable.
3.2.2 Primer Touch-up Repair (Primer Damaged to Steel Surface)
The coating inspector shall conduct the fol lowing inspections to document primer touch-up repair operations when the damage is to the steel surface and spot sandblasting or power tool abrading is required for surface preparation.
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INSTRUCTION ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO.
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i CPSES -
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]!-QP-11.4-5 l 22 SEP 2 3 -19g3 6 of 27 l
a) Ambient Condi tions -
The inspector shall detennine air temperature, surface temperature, relative humidity and dew point of substrate structures. A calibrated non-mercury filled dry bulb ,
thermometer or calibrated temperature recorder (Bristol ,
4069TH or equivalent) shall be used for air temperature dete mination. A calibrated non-mercury wet bulb p; thennometer or a calibrated humidity recorder (Bristol ;
4069TH or equivalent) shall be used to determine .
relative humidity. The dew point shall be detennined l' by tfie difference in dry and wet bulb temperatures using the U.S. Department of Commerce Weather Bureau l psychometric Tables WB No. 235. When dry bulb readings l are greater than 100*F, the dew point should be detennined using the 100*F dry bulb reading, and relative humidity shall be determined by subtracting wet bulb from the surface temperature or ambient temperature, whichever is greater. If the dry bulb
( thermometer exceeds 100*F. the instrument shall be :
returned to the calibration lab for recalibration. .
The surface temperature shall be determined by placing ,
a calibrated surface temperature thennometer (Omega-Anprobe fast tema, range of 10*-250*F) in contact with the substrate surface until the temperature reading stabilizes.
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Final surface preparation shall not begin unless the !
temperature of the surface is a minimum of 5* above the dew point. -
' Nonnal condi tions of ambi ent and surface temperature for application of primer shall be as follows:
knbient Temp. (*F) Surface Temp. (*F) t Dimetcote 6 40-120 40-130 Cartozinc 11 40-95 40-110 Carboline 191 50-120 50-120 Coating material (if thinned) shall be thinned in :
accordance with Reference 1-B or 1-C. '
Humidity values may va ry from 10% to 95t; howeve r, primer shall not be applied to a wet or damp surface. :
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t i INSTRUCTION l' ' ISSUE N SER OATE PAGE I
TEXAS UTIUTIES GENERATING CO. l REVISION g CPSES .
QI-QP-11 4-5 22 f 27 EP 2 31C0 l 9 i i l * ,
h) 1. Coating Materials Identification !
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The inspector shall inspect the coating material :
) containers prior to mixing contents for product !
identification and verify that all materials are
! correct for coating application. '
l Approved materials are:
CZ-11 Caroo Zinc base (gray or green) .
Carto Zinc filler i Carboline #21 or 33 Thinner '
l Oimetcote Dimetcote 6 base l '
Dimetcote filler Amercoat #65 or 101 thinner l l ,
' Carboline 191 i
! Carooline 191 primer i
( . Cartoline 191 catalyst -
Carboline #15 thi'nner ,
He shall also verify that.each comoonent container
! is identified by batch number and that the shelf l li fe has not expi red . Carto Zinc 11 base and l Carboline 191 has a shelf li fe of 12 months. 1 Carto Zinc filler and Dimetcote 6 base and filler have a shelf life of 24 months.
, f 2. Mixing Operations An inspector shall witness each mi xing/ thinning '
operation. The inspector shall verify that mixing !
operations are pe rfomed in accordance wi th f Reference 1-A and 1-8. ;
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- 3. Thinning Operation An inspector shall veri fy that primer thinning complies with thinning requirements established '
in References 1-A and 1-B. .
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INSTRUCTION ISO REVISION PAGE ,
TEXAS UTILITIES GENERATING CO. I I SES 22 lSEP 2 31983 13 f 27 i lQI-Q P-11.4-5 1 I .
Contamination is unacceptable. All contamination must be !
removed per Reference 1-8 or 1-C prior to finish coating.
Rust (red) and zinc oxide (white) stains are acceptable i provided all loose particles have been removed (as evidenced I
' by existence of no stain on cloth) from the coated surface by approved cleaning operations. Phenoline Thinner or Xylol . j I
are approved cleaners for seal coat. Thinner wiping is not 5 recommended for Dimetcoat primer. Use Carboline #33 cleaner f for CZ11 Primer and #15 thinner for Carboline 191 primer.
g 3.3.4 Air Supply Acceptability
- The Inspector shall inspect the air supply system (pressure l pots and spray guns) for the existence of suitable filters / !
traps /sepa rators.
The effectiveness of these items shall be verified by placing a clean piece of cheesecloth (or white fabric) over the exit :
of the air lines and allowing air to flow for 30 seconds '
( minimum. The cloth shall show no evidence of moisture, oil or foreign matter when examined. .
3.3.5 Finish Coat Mixing Operations i .
3.3.5.1 Prior to mi xi ng , the inspector shall veri fy that each !
component is identi fied by batch numbers and that the 1 24 month shelf life has not been exceeded.
3.3.5.2 The inspector shall verify that ., mixing / thinner operations i i . are perfonned in accordance with References 1-8 and 1-C. i j Thinning may be done up to two quarts of Phenoline Thinner j per gallon of Phenoline 305.
3.3.5.3 The inspector shall verify that the pot life has not expired per References 1-8 and 1-C.
3.3.5.4. When coating materials are mixed / thinned in locations other !
than the field, the inspector verifying the mixing operation I shall fill out the Paint Mixing Slip, Attachment 5. The !
inspector perfonning the pre-application inspection shall record the infonnation from the Paint Mixing Slip on the Inspection Report, Attachment 1. The Paint Mixing Slip need .
not be retained. .
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I INSTRUCTION ISSUE REVISION PAGE NUMBER DATE TEXAS UTluTIES GENERATING CO. I !
CPSES QI-Q P-11. 4-5 22 15 of 27 EP 2 31983 j i
i 3.6.2 Visual Defects Inspection The Inspector shall perfonn a visual inspection of the cured finish coated substrate su rface in accordance with the following :
a) Runs / sags - Runs or sags in which the DFT of the total coating system is 15.0 mils or less thick, which show no evidence of mudcracki ng , are acceptable. Those greater than 15.0 mils shall be repaired in accordance with Reference 1-B or 1-C.
b) Skips / damaged areas / dry spray / over spray / gross di scontinuities such as holidays, voids, and bubbles are not acceptable.
c) Pinholes - acceptable to the extent allowed by Attachment 2. ;
d) Contamination - Embedded foreign materials unacceptable.
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3.6.3 Dry Film Thickness (DFT) 4 The Inspector shall pt mn a DFT of the cured coating
! system (See NcLE A A calibrated 0-25 Elcometer Inspector DFT Gy ha . III/1E, or equivaient, shall be used. Separate spot measurements (See Note 1) spaced evenly ;
over the structure (See Note 2) shall be taken. Since the '
magnetic gage is sensitive to geometric discontinuities in the steel, measurements less than 1 inch from an edge or a hole shall be avoided where possible.
The average DFT of the total coatino system shall be a minimum of 6.0 mils and a maximum of 13.0 mils. The spot test OFT of the total coating system shall be a minimum of 6.0 mils and a maximum of 15.0 mils (See Nota 4).
The finish coated system shall exhibi t full " hiding" properties of the primecoat.
NOTE 1: A spot measurement is a series of three measure-ments in the same general area. The probe should be moved a short distance for each gage reading.
Di scard any unusually high or low gage reading that cannot be repeated consistently. Take an average of these three gage readings as one spot measu rement. ,
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! INSTRUCTIONREVISION ISSUE PAGE TEXAS UTILITIES GENERATING CO.
QI-QP-11.4-5 22 16 of 27
! SEP 2 31983 I
NOTE 2: Five spot tests s'hal l be taken for every 100 square feet of coated su rface . For areas less '
than 100 square feet, the following shall apply: '
Area Sq. Ft. No. Spots 100-80 5 80-50 4 50-10 3 10-3 2 3-0 1 Items with appreciable surface curvature and other NOTE 3:
geometrical di scontinui ties such as handrails, gratings, stairs, sway struts, etc. shall be exempt from DFT measurement (See DCA 11421).
In the event that any spot is found to be outside NOTE 4:
of the acceptable thickness range, three additional spots shall be taken at approximately 6 inches
(- from the failing spot and spaced radially at approvimately 120 degree intervals to - determine the extent of the unacceptable area. Dimensions i and locations of unacceptable areas and results of I additional testing shall be documented on the IR.
In the event that the average of the area is unacceptable due to unacceptable spot readings, the unacceptable spots shall be i solated as described above. Additional spot readings shall be taken equal to the number of unacceptable spot readings and the average recalcula ted . Results of these additional readings shall be documented in the " Remarks" area .of the IR. If the recalculated average is acceptable, the IR shall be so marked with an explanation in "Rema rk s"
' stating that " average recalculated -
now acceptable", or wording to that effect. If the recalculated average is unacceptable, the unacceptable spots shall be i solated (as described above) and the above re-averaging process repeated.
NOTE 5: PCR's from previous OFT inspections that are satisfactory per current requirements of DCA 12145 R.3, do not requi re addi tional DFT inspections provided no additional coatings have been applied to the area.
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,1 INSTRUCTION RWISION ISSUE
^ PAGE TEXAS UTILITIES GENERATING CO. !
CPSES QI-QP-ll.4-5 22 SEP 2 31983 20 of 27 :
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b) Dimensions i n' relationship to azimuths, -
column lines, reactor centerline or other. j components of known location.
c) Quadrant, compartment, cavi ty or room in which inspection is located.
d) Unit number.
l e) Relation of surface to cardinal di rections j _ (i .e. , North, South, etc. ) .
3.9 NONCONFORMANCES .
Nonconfaming conditions shall be reported on an IR in accordance with CP-QP-18.0.
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INSTRUCTION ISSUE NUMBER RNSION PAGE $
TEXA5 UTI'_ITIES GENERATING CO. DATE CPSES l QI-QP-11.4-5 21 3 of 24 08/25/83
. FOR NFORMATION ONLY b) For all areas of liner plate which do not have adequate documentation, the Inspector shall perfom an Adhesion (pa tch) test. A calibrated Elcometer 106 Adhesion Tester shall be used to verify that the minimum acceptable tensile of adhesion to the steel substrate i has been attained. Each test shall consist of three I individual dollies tested to failure.
Criteria: The minimum acceptable strength per dolly ;
shall be 200 psi. If any one of the three dollies should test below the minimum ;
acceptable strength, the prirge coat shall be removed to the steel substrate over the !
entire item. l l c) l Verify the primer has cured required amount of time per '
Reference 1-8 or 1-C, as applicable. j d) Perfoim a visual inspection of the primed surface in j accordance with the following:
- 1. Runs / sags - A - 0FT measurement shall be made wi th
( the Elcometer DFT gage. Runs / sags 7.0 mils or '
! less thick (DFT) which show no evidence of mudcracking (See NOTE) are acceptable. Refer to i
References 1-B and 1-C for repair of runs / sags
, exceeding 7.0 mils.
NOTE: Nudcracking is defined as irregular cracking as in a dried mud puddle.
- 2. Dry Spray - Must be removed by screening or abrading. before overcoating.
- 3. Over Spray - Must be removed before overcoating.
4 Contamination I, l Oil and grease - unacceptable 1
Emoedded foreton materials - unacceptable Stains are
- rust (red) and zinc oxide (white) stains acceptable i
provided loose particles are i
removed prior to application of finish coat.
l S. Skips / damaged areas / gross discontinuities such as 3 holidays or voids - unacceptable.
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( e) The inspector shall perfom a 0FT inspection of the i cured primer film. A calibrated 0-25 E1cometer i
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INSTRUCTION ISSUE NUMBER RNSION PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES QI-QP-11.4-5 21 08/25/83 13 of 24 shall be perfomed immediately prior to turnover of each area within the containment building and should be coordinated wi th Area Management. In addi tion , finish coated containment liner surfaces shall be visually reinspected in accordance with Paragrapn 3.6.2 immediately prior to turnover of each containment area.
3.6.1 Finish Coat Cure The QC Inspector may perfom a final' acceptance inspection after a minimum topcoat cure of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> or minimum cure for recoat as stated in Reference 1-B or 1-C, Section 4.4.21 Paragraph 4, which ever is greater. A calibrated non-mercu ry filled dry bulb thermometer, a calibrated temperature recorder, or local weather station may be used.
3.6.2 Visual Defects Inspection The Inspector shall perfom a visual inspection of the cured !
! finish coated substrate surface in accordance with the !
following:
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\ 1 a) Runs / sags - Runs or sags in which the DFT of the total l coating system is 15.0 mils or 16ss thick, which show I no evidence of mudcracking, are acceptable. Those ;
greater than 15.0 mils shall be repaired in accordance :
wi th Reference 1-B or 1-C. '
b) Skips / damaged areas / dry spray / over spray / gross discontinuities such as holidays, voids, and bubbles are not acceptable.
c) Pinholes -
acceptable to the extent allowed by Attachment 2. {
d) Contamination - Embedded foreign materials unacceptable.
3.6.3 Dry Film Thickness (DFT) i i
The Inspector shall perfom a DFT of the cured coating I system. A calibrated 0-25 E1cometer Inspector DFT Gage I, Model III/1E, or equivalent, shall be used. A minimum of I five separate spot measurements (See flote 1) spaced evenly ;
over the structure (See flate 2) shall be taken. Since the magnetic gage is sensitive to geometric discontinuities in l
'- the steel, measurements less than 1 incn from an edge or a ;
hole shall be avoided where possible.
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I ' INSTRUCTCN ISSUE
~ T#~AS UT1JTIES GENERATING CO. NUMBER REVISICN CATE PAGE CPSES I i QI-QP-11.4-5 18 AUG 10 1983 1 f 24 PREPARED BY:/ fy[ d ',,,., c4 / /J INSPECTION OF STEEL SUBSTRATE PRIMER j f /
Op TE
/J g, oA.-/ 57d.5 REPAIR AND SEAL AND lAPPROVEDBY:
FINISH C0AT APPLICATION ' I
- AND REPAIR ~
APPROVED BY: / -
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DATE V-(' )
1.0 REFERENCES
i 1-A QI-QP-11.4-1, " Inspection of Steel Subs tra te Su rf ace
! Preparation and Primer Application ano Repair" -
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, 1-B CCP-30, " Coating Steel Subs tra tes Inside Reactor Buildings and Radiation Areas" I I i l l-C CCP-30A, " Coating Steel Subs trates Inside Reactor Buildings l and Radiation Areas" -
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1-0 CP-QP-18.0, " Ins pection Reports" l l l 1-E QI-QP-11.4-22 "QC Verification of Protective Coating -
- Unique Identification Number Verificat;on" g (us k#
- 1-F CP-QP-lS.0, " Tagging Sys tem" g.
[&t Y'h b5!
t l 2.0 s 'o '
i GENERAL Dg.,?,
g 5 %.if'<V'.
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,i"y l
- 2.1 PURPOSE AND SCOPE
{6W "
The purpos e of this ins traction is to outline me tnocs utilized by Quali ty Control personnel in inspection of l primer repair and seal and finish ccat application ano .,
repair.
3.0 INSTRUCTION
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l Visual inspection of painted surf aces as addressed by this ,
instruction shall be made at approximately an arms length '
from the surface being ins pected. The area of inspection '
shall be adequately lighted during the inspection activity. :
Adequate lighting is defined as the minimum light produced '
by a two (2) cell battery flashlight. ,
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INSTRUCTION IS UE REVISION PAGE TE.7 AS UTILITIES GENERATING CO.
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CPSES ' !
QI-QP-11.4-5 l 18 AUG 10 100 ' 2 of 24 I I i
3.1 INSPECTION OF PRIMER -
i 3.1.1 Primer Inspections Prior to Application of Seal or Finish Coat l a) QC shall verify that construction has identified each piece with a unique number in accordance with References 1-A, 1-8 and 1-C. The QC Inspector shall maintain a Protective Coating Unique Identification Numbe r Log, Attachment 1 for all protective coatings application on all s teel designated for use in the Reactor Building.
Subsequent subdivision of coating steel in the field or shop shall be witnessed by QC in accordance with ,
Reference 1-E.
l!
NOTE-A. Unique rumber may be assigned to a lot of .. . L.
material to be prime coated at the same time. l For example, six pieces steel :o be coated !
at same time may all have same unique number. l B. Liner plate is excluded from QP numbers .
s . 3, Equipment which is identified with permanent plant identification number need not be identified wi th a Pro'tective Coatings unioue identification n umber. i,
- b) For all areas of liner plate wnich do not have adequate i
documentation, the Inspector shall perfonn an Adhesion 1 (pa tch) tes t. A calibrated E1cometer 106 Adhes ion Tes ter shall be used to verify that the minimum i accep table tensile of aches fon to the steel substrate j has been attained. Eacn test shall consist of three individual dollies tes ted to failure. ;
f Criteria: The minimum acceptable s trength per dolly shall be 200 ps i . If any one of the three ,
dollies should tes t below the minimum (
acceptable strength, the prime coat shall be i removed to the s teel subs trate over the. !
entire item, i c) Verify the primer has cured required amount of time per Reference 1-B or 1-C, as applicable. l d) Perfonn a visual inspection of the primed surface in accordance with the following:
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INSTRUCTION ISSUE
' REVISION l PAGE TEXAS UTILITIES GENERATING CO.
CPSES l
QI-QP-11.4-5 i 18 1.nJ910 1997 3 of 24 a !
l 1. Runs / sags - A DFT measurement sna i l be made wi th the Elcometer DFT gage. Runs / sags 5.5 mils or
, less thick (DFT) whicn show no evidence of
' mudcracking (See NOTE) are acceptable. Refer to References 1-B and 1-C for repair of runs / sags exceeding 5.5 mils.
l l NOTE: Muderacking is
- defined as irregula r cracking as in a dried mud puddle.
- 2. Dry Spray - Mus t be removed by screening or .
abrading before overcoating. I i
! 3. Over Spray - Mus t be removed before overcoating.
l 4. Contamination
' Oil and crease - unacceptable ' " ~ ~
1mbedded foreign materials - unacceptable Stains are
- rust (red) and zinc oxide (white) stains acceptable
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provicea loose particles are l removed prior to application of finish coat.
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,. p 5. Skips / damaged areas / gross discontinuities such as
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holidays or voids - unacceptable. l I
N"A e) The inspector shall perfonn a 0FT inspection of the l cured primer film. A calibrated 0-25 Elcometer !
l Inspector DFT gage Model III/IE, or equivalent, shall i
be used. A minimum of five. separate spot measurements (See Note 1) s paced evenly over the structure (See Note 2) shall be taken. Since the magnetic gage is sensitive to geometric discontinuities in the steel, measurements less than 1 inch from the edge or a hole shall be avoided where possible. (See Note 3) l
- a. i Dry Film Thickness shall be as follows : i Min. (mils) Max. (mils)
CZ-II spot tes t 1.5 5.5 06 s pot tes t 1.5 5.5 06 average DFT 2.0 5.0 CZ-II average DFT 2.0 4.5 NOTE 1: A spo t measurement is a series of three measurements in the same general area. The probe should be moved a short distance for i each gage reading. Discard any unusually high !
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i i INSTRUCTION i '
ISSUG REVISION PAGE i - TEXAS UTILITIES GENERATING CO.
QI-QP-11.4-5 20 l
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l14of24
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! 20R NFORMATI0h ONLY The average DFT of the total coa ting system shall be a minimum of 6.0 mils and a maximum of 13.0 mils. The spot
! test OFT of the total coating system shall be a minimum of 6.0 mils and a maximum of 15.0 mils.
The finish coated sys tem shall exhibi t full " hiding" properties of the primecoat.
j NOTE 1: A spot measurement is a series of three measure-ments in the same general area. The probe should be moved a short cistance for eacn gage reading.
Discard any unusually nigh or low gage reading that cannot be repeated consistently. Take an average of these three gage readings as og spot nea su rement.
NOTE 2: For small areas of coa ting , 5 sepa ra te spo t i
measurements shall be taken. For larger areas, 5 spot measurements shall :e taken for every 100 square feet of coating.
NOTE 3: Items with appreciable surface curvature ano otner geometrical di scontinui ties, such as handrails, gratings, stairs, sway struts, etc. shall be exempt from 0FT measurement (See OCA 11421). )
NOTE 4: PCR's from previous OFT inspections tnat a re satisfactory per current requirements 01 DCA 12145 R.3, do not requi re additional 0FT ins pections provided no additional coatings have been applied to the area.
3.6.4 Centinuity inspection The Inspector shall test the continuity of the cured finish coat using a Tinker and Rasor Model M1 (67.5 volt) noliday
' de tector. 100% of the finish coated surface area shall be tested.
The applied film should contain only a minor number of points of di sconti nui ty. No more than two points of
' discontinuity should occur within an area having a radius of 6
inches as measured from a point of di scontinui ty (pinholes). No more than 40% of the total numbe r of allowable points of discontinuity should occur witnin any one area equal to 25t of the total area being coated. The I' total number of pinhole discontinuities allowed is defined l in Attachment 2. No gross discontinuities are allowed.
l 3.6.5 Documentation of Finish Coat / Seal Coat Acceptance inspections
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Results of inspections described in Sections 3.6 shall be ,-
documented on an Inspection Report (IR). Attacnment 4, in ,-
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t INSTRUCTION ISSUE '
NUMBER RESION GE -
TEXAS UTILITIES GENERATING CO. DATE ,
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i 20 Ql-QP-11.4-5 l j l ,
! AUG 18 i983l / of 24 l
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f accordance with this instruction, shadows l
or tight residues of primer wnich may remain in the profile of the previously f prepared substrate is acceptable.
- 2. Removal of Sharp Projections -- A reinspection for i sharp projections that were not blended (rounded)- l t
during blast cleaning or power tooling shall be !
, pe rfomed. j i Weld splatter on structural steel shall be removed !
by either grinding or sand blasting. However, if the weld splatter should remain after the above '
operation, the weld splatter will be acceptable.
Sharp projections are not acceptable.
j Protrusions and peaks shall be ground to a rounded
- contour. .
g NOTE: Any mechanical surface preparation other i
( than sandblasting or hand or power l tooling of sharp edges or neld spatter I will require a vis'ual welcing inspector's l acceptance of the work perfomed.
l
- 3. Anchor Pattern Depth -- The anchor pattern depth of the blasted surface shall be inspected at random locations using a Keane-Tator Surface Profile Comparator (model 373) or equivalent.
The anchor pattern depth for a blasted su rf ace shall be a minirmm of 1.0 mils. -
Surfaces that have been power tooled with "3M
- Clean-N-Strip", 80 grit or coarser " flapper wheels",
j sanding discs, " roto peans" or equivalent provide i
acceptable surface profile.
l' No maximum profile will be specified, providing that correct millage and su rf ace uni fo mi ty
! requirements can be obtained after primer application.
, f) Ve ri fy applicator quali fica tions pe r Section 3.3.1. l l
g) Verify air supply acceptabili ty per Section 3.3.4 I
h) 1. Coating Materials identification The inspector shall inspect the coating material ..
containers prior to mixing contents for product coen reo e TUGCO CA
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I INSTRUCTION ISSUE NUMBER SiON AGE TEXAS UTIUTIES GENERATING CO. DATE QI-QP-11.4-5 20 ggg 7 g igg 3 3 of 24 b) For all areas of liner plate wnich do not have adequate documentation, the inspector shall perfom an Adnesion (pa tch) test. A calibrated Elcome ter 106 Adhesion Tester shall be used to veri fy tha t the minimum acceptable tensile of adhesion to the steel substrate has been attained. Each test shall consist of three individual dollies tested to failure.
Criteria: The minimum acceptable strength per dolly r I shall be 200 psi, if any one of the three l dollies should test below the minimum j acceptaole strength, the prime coat shall be .
removed to the steel substrate over the z l entire item.
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' c) Verify the primer has cured required amount of time per Reference 1-B or 1-C, as applicible.
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?d
~f27 d) Perfom a visual inspection of the primed surface in l accordance with the following: N
- 5
- 1. Runs / sags - A 0FT measurement shall be rade wi th .
I the Elcometer DFT gage. Runs / sags 6.0 mils or .,
less thick (DFT) which 'show no evidence of w ruderacking (See NOTE) are acceptable. Refer to f.
References 1-8 and 1-C fo r repair of runs / sags ;
- exceeding 6.0 mils. -
NOTE: Mudcracking is de fined as irregula r
- cracking as in a dried mud puddle.
- 2. Dry Spray - Must be. removed by screening or i
abrading before overcoating.
- 3. Over Spray - Must be removed before overcoating.
I
- 4. Contamination I 3
Oil and arease - unacceptable !
Embedded foreign materials - unacceptable l
i Stains - rust (red) and zinc oxide (white) stains are acceptable provided loose particles are removed prior to application of finish coat.
- 5. Skips / damaged areas / gross discontinuities such as ,
l holidays or voids - unacceptable. '
I e) The inspector shall perfom a OFT inspection of the cured primer film. A calibrated 0-25 Elcometer l
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TEXAS UBUDES GENERADNG CO. SER . REVISION O PAGE CPSES
.QI.0P.11.4 5 17 h 4, 3 aca , 1 of 24 PREPARED SY: 4 / f/f3 P N fN FINISH C0AT APPLICATION '
APPROVED BY: I E
i i
AND REPAIR APPROVED BY: -
g 4 // 'f J ;
'/ z' _ .. m DATE 1.0 REFERENC ES _h '5
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' C . ' ' ',< .. u C aus 2mm 1.A QI.QP.11.4 1, 489pection - bf' Ste61,~ i Substrate Su rface Preparation and Primer Application and Repair" 18 CCP.30, " Coating Steel Substrates Inside Reactor Buildings and Radiation Areas" l l
1.C CCP.30A, " Coating Steel Substrates Inside Reactor Buildings j and Radiation Areas" .
10 CP.QP.18.0, " Inspection Reports" i
1.E QI.QP.11.4 22, "QC Verification of Protective Coatings Unique Identification Number Verification" 1.F CP.QP.15.0, " Tagging System" i
l 2.0 GE NERAL -
l 2.1 PURPOSE AND SCOPE The purpose of this instruction is to outline me tnods utilized by Quali ty Control personnel in inspecti on of
, primer repair and seal and finier coat application and repair.
3.0 INSTRUCTION I
3.1 INSPECTION OF PRIMER 3.1.1 Primer Inspections Prior to Application of Seal or Finish Coat !
l a) QC shall verify that construction has identified each piece with a unique number in accordance with References i 1.A. 1.B and 1.C. The QC Inspector shall mainta'in a ;
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' l INSTRUCTION l lSSUE REVISION PAGE
- TEXAS UTilJTIES GENERATING CO. " ' ^ !
CPSES j
QI-Q P-i l .4-5 l 17 .JUL
'4 9 l9fs3 2 of 24 i l
I 1
l Protective Coating Unique [dentification Number Log, l Attachment 1 for all protective coatings application on
- all steel designated for use in the Reactor Building.
l Subsequent subdivision of coating steel in the field l
,j or shop shall be wi tnessed by QC in accordance with
- l. Reference 1-E. l i
- 10TE
- I A. Unique number may be assigned to a lot of material to be prime coated at the same time.
For example, six pieces steel to be coated [
at same time may all have same unique number. '
B. Liner plate is excluded from QP numbe rs .
Equipment which is identified with permanent plant '
identification number need not be identified wi th a Protective Coa tings unique identification number. ,
i b) for all prime coated items which do not exhibi t a Protective Coatings Unique Identification Number (QP Number) the Inspector shall perform an Adhesion (Patch) l Tes t. If adequate documentation exists the above is not l applicable. A calibrated E1cometer 106 Adhesion Tester
- l shall be used to verify that the minimum acceptable ,
i tensile of adhesion to the steel substrate has been '
! attained. Each test shall consist of three individual
,1 collies tes ted to failure. (See Notes 1 and 2 below.)
Cri teria : The minimum acceptable strength per dolly shall be 200 ps i . If any one of the three dollies should tes t below the minimum acceptable strength, the prime coat shall be V0ID removed to the s teel subs trate over the entire item. ,
l Prime coated items which are acceptable shall be stamped with a "QP" number by Construction. The QC j Inspector shall maintain a protective coatings unique identification number log for all protective coatings applications per this section. .
Primer repai rs , if required, shall be performed in accordance with Section 3.2.
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l INSTRUCTION I pAGE REVISION NUMBER TEXAS UM ?'ES GENERATING CO.
CPSES Ql.QP.11.4 5 17 !.JUL49 3 of 24 I
I NOTE 1: Any item, 'which due to their size or configuration will not accomodate test ng i with an E1cometer 106 Adhesion Tester, snall not be subject to adhesion testing. f NOTE 2: For items with total exposed surface area of i 10 square feet or less . each adhesion test :
shall consist of only one dolly tested to failure.
c) Verify the primer has cured required amount of time per Reference 18 or 1.C as applicable.
d) Perfom a visual inspection of the primed surface in accordance with the following:
- 1. Runs / sags . A 0FT measurement shall be made with the Elcometer DFT gage. Runs / sags 5.5 mils or
- less thick (DFT) dich show no evidence of mudcracking (See NOTE) are acceptable. Refer to References 1.B and 1.C for repair of runs / sags A exceeding 5.5 mils.
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01% 2.
NOTE:
Dry Spray .
Mudcracking is defined as irregula r cracking as in a dried mud puddle.
Must be removed by screening or abrading before overcoat ng.i
- 3. Over Spray . Must be removed before overcoating.
4 Contamination f
011 and grease . unacceptable '
EmDedded foreign materials . unacceptable Stains . rust ( red) and zinc oxide (white) stains are acceptable provided loose particles are removed prior to application of finish coat.
l 5. Skips / damaged areas / gross discontinuities such as i holidays or voids . unacceptable.
l e) The inspector shall perfom a DFT inspection of the i cured primer film. A calibrated 0 25 E1cometer l Inspector 0FT gage Model !!!/1E, or equivalent, shall j be used. A minimum of five separate spot measurements i (See Note 1) spaced evenly over the structure (See Note 2) shall be taken. Since the magnetic gage is sensitive to geometric discontinuities in the steel,
%%, TUGCO OA
(.
--XAS UtutES GENERAUNG CC. U E.q m:SICN fh- ? AGE CP5ES j QI-QP-11.4-5 13 MAR 01 1963 1 uf Ca
- ' PRE?tRED BY
- huudbj6N'.,.s t/t 1/,cv INSPECTION OF STEEL
, / ;; g SUBSTRATE PRIMER /.
REPAIR AND SEAL AND FINISH COAT APPLICATION 4FD"CVED 3Y:
'd
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M WE 1 '/ 7 l '
ff AND REPAIR
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1.0 REFERENCES
I-A QI-QP-11.4-1, " Inspection of Steel Subs tra te Surface Preparation and Primer Application and Repair" 1-8 CCP-30, " Coating Steel Substrates Inside Reactor Buildings and Radiation Areas" 1-C CCP-30A, " Coating Steel Substrates Inside Reactor Buildings and Radiation Areas" 1-0 CP-QP-18.0, " Inspection Reports" 1-E QI-QP-11.4-22 "QC Verification of Protective Coatings Unique Identification Number Verification" 2.0 GENERAL $ f f FJ7 t
- ' I* ,s.
E OF.f " h g *
(: D.
2.1 PURPOSE AND SCOPE f, l !. 's. L 't.. ' i d VI D N, S The purpose of this instruction is to outline metneds utilized by Quality Control personnel in inspection of primer repair and seal and finish cca t application and repair.
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l 3.0 INSTRUCTION +
l L.
l 3.1 INSPECTION OF PRIMER 3.1.1 Primer Inspections Prior to Application of Seal or Finish Coat a) QC shall verify that construction has identified each piece with a unique number in accordance with References 1-A, 1-B and 1-C. The QC Inspector shall maintain a Protective Coating Unique Identification Number Log, Attach. cent 1 for all protective coatings application on all steel designated for use in the Reactor Building.
Subsequent subdivision of coating steel in the field or shop shall be witnessed by QC in accordance with Reference 1-E.
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' , INSTRUCTION i ISSUE I ' PAGE NUMBER l REVISION OATE l
- TEXAS UTILITIES GENERATING CO. ! !
' 8 jQI-QP-11.4-5 11 2 of 24 i i i iMAR 01 1983 [ l i
I NOTE:
t i
A. Unique number may be assigneo to a lot of l material to be prime coated at the same time.
For example, six pieces steel to be coated
- at same time may all have same unique number.
- 8. Liner plate is excluded from QP numbers.
Equipment which is identified with pemanent plant identification number need not be identified witn a Protective Coatings unique identification number. The j
\\ tem " Equipment" is not to include pipe hangers, cable tray hangers, conduit supports, or structural steel.
They will all have Protective Coating unique identification numbers assigned.
l i
b) For all prime coated items which do not exhibit a Protective Coatings Unique Identification Number (QP
(
l Number) the Inspector shall pertom an Adhesion (Patch)
Test. If adequate documentation exists the above is not applicable. A calibrated Elcometer 106 Adhesion Tester shall be used to verify that the minimum acceptable I tensile of adhesion to the steel substrate has been !
a ttained. Each test shall consist of three individual j
, dollies tested to failure. (See Notes 1 and 2 below.) I Cri teria : The minimum acceptable strength per dolly '
shall be 200 psi. If any one of the three dollies shcsid , test below the minimum i acceptable strength, the prime coat shall be removed to the steel substrate over the t
entire item.
Prime coated items which are acceptable shall be l stamped with a "QP" number by Construction. The QC Inspector shall maintain a protective coatings unique i
l identification number log for all protective coatings !
applications per this section.
I Primer repairs, if required, shall be perfomed in accordance with Section 3.2.
NOTE 1: Any item, which due to their size or configuration will not accomodate testing with an Elcometer 106 Adhesion Tester, shali not be subject to adhesion testing.
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INSTRUCTION ' b REVISICN DAGE TEXAS UTILITIES GENEPATING CO ! '
CPSES Ql-0P-11.4-5 .,iAR 01 .E 13 ;y 3 NOTE 2: For items with total exposed surface area of 10 square feet or less - each adhesion test shall consist of only one dolly tested to '
failure, e
c) Verify the primer has cured required amount of t1me oer Reference 1-8 or 1-C, as applicable.
d) Perform a visual inspection of the primed surface in aCCordance with the following:
i
' 1. Runs / sags - A 0FT measurement shall be made with the Elcometer DFT gage. Runs / sags 5.5 mils or less tnick (DFT) which show no evidence of l mudcracking (See NOTE) are acceptable. Refer to References 1-B and 1-C for repair of runs / sags exceeding 5.5 mils. '
I i
NOTE: Muderacking is defined as irregular cracking as in a dried mud puddle.
- 2. Dry Spray - Must be removed by screening or abrading before overcoating.
- 3. Over Spray - Must be removed before overcoating.
l I 4 i
Contamination Oil and arease - unacceptable Embedded foreton materials - unacceptable Stains are
- rust (red) and zinc oxide (white) stains acceptable provided loose particles are removed prior to appi tca tion of finish coat.
- 5. Skips / damaged areas / gross discontinuities such as holidays or voids - unacceptable, e) The inspector shall perfom a DFT inspection of the
! cured primer film. A calibrated 0-25 Elcometer i
i Inspector DFT gage Model !!!/IE, or equivalent, shall be used. A minimum of five separate spot measurements I
(See Note 1) spaced evenly over the structure (See Note 2) shall be taken. Since the magnetic gage is i
sensitive to geometric discontinuities in the steel, j
measurements less than 1 inch from the edge or a hole shall be avoided where possible. (See Note 3) h
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INSTRUCTION ISSUE .
NUMSER REVISION PAGE TEXAS UTluTIES GENERATING CO DATE i
cmES Ql-QP-11.4-5 13 MAR 01 1% ', 4 of 24 :
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i i,
Ory Film Thickness shall be as follows:
Min. (mils) Max.(mils) l CZ-11 spot test 1.5 5.5 i 06 spot test 1.5 5.5 06 average DFT {
2.0 5.0 CZ-II average DFT 2.0 4.5 l NOTE 1: A spot measurement is a series of three measurements in the same general area. The l
probe should be moved a short distance for each gage reading. Olscard any unusually high ,l
'or low gage reading that cannot be repeated '
consistently. Take an average of these three i i
gage readings as one spot measurement.
J l NOTE 2: For small areas of coating, 5 separate spot f measurements shall be taken. For larger . ,
areas, 5 spot measurements shall be taken for i
every 100 square feet of coating.
I NOTE 3: Items with appreciable surface curvature and '
- other geometrical discontinuities, such as
- handrails, gratings, stairs, sway stru ts , ,
etc., shall be exempt from dry film thickness i
measurement per Reference 1-8 and 1-C.
I 3.2 PRIMER REPAIRS 3.2.1 Saos and Runs Over 5.5 Mils DFT !
Sags and runs over 5.5 mils DFT may be abraded by sanding or aluminum screening. If surface is acceptable per Section '
3.1, document such on Attachment 3. If surface is unaccept. '
able refer to Section 3.2.2 or 3.2.3 as applicable, i 3.2.2 Primer Touch-up Repair (Primer Damaged to Steel Surface)
The coating inspector shall conduct the following inspections to document primer touch-up repair operations when the damage is to the steel surface and spot sandblasting or power tool abrading is required for surface .
l preparation.
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h i INSTRUCTION ISSUE i NUM8ER ESION DATE PAGE TEXAS UTILITIES GENERATING CO. -
QI-QP-11.4-5l 13 , MAR 01 !$dj, 5 of 24 t .
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a) Ambient Conditions The inspector shall determine air temperature, surface temperature, relative humidity and dew point of substrate structures. A calibrated non-mercury filled dry bulb thermometer or calibrated temperature recorder (Bristol 4069TH or equivalent) shall be used for air temperature determination. A calibrated non-mercury wet bulb themometer or a calibrated humidity recorder (Bristol 4069TH or equivalent) shall be used to detemine relative humidity. The dew point shall be determined by the difference in dry and wet bulb temperatures using the U.S. Department of Commerce Weather Bureau Psychometric Tables, WB No. 235. When dry bulb readings are greater than 100*F, the dew point and relative humidity should be determined using the 100*F reading.
The surface temperature shall be determined by placing I a calibrated surface temperature thermometer (Omega-Anprobe fast temp. range of 10*-250*F) in contact with l l the substrate surface until the temperature reading i stabilizes.
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Final surface preparation shall not begin unless the t i temperature of the surface is a minimum of 5* above '
! the dew point. .
l t i
Nomal conditions of ambient and surface temperature !
l for application of primer shall be as follows: [
. 6 Ambient Temp. (*F) Surface Temp. (*F) !
. Dimetcote 6 40-120 40-130 Carbozinc 11 40-95 40-110 l In no case shall Carboline and Ameron limits be exceeded '
l (0*-130*F ambient and 0*-200*F surface temperatures). !
- Coating material (if thinned) shall be thinned in !
! accordance with Reference 1-8 or 1-C.
i l Humidity values may vary from lot to 95t; however, primer shall not be applied to a wet or damp surface.
l t The surface temperature shall be a minimum of 5' above l l the dew point. ,
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I INSTRUCTION
- I NUMBER O PAGE TEXAS UTILITIES GENERATING CO. l REVISION s CPSES 13 MAR 01 1983 6 of 24 lQI-QP-11.4-5 t
} Verify abrasive acceptablility (if used) by obtaining a sample of the abrasive to be used. The abrasive shall be verified to be dry by feel with ,no grease, oil or ;
deleterious materials. Particle size must be sufficient to achieve a minimum of 1 mil surface profile.
c) Verify acceptability of blast cleaning equipment (if used) prior to use by: ,
- 1. Verifying that water separators are installed in i the air supply system and that separators have .!
been drained of accumulated water and drains lef t !
partially open.
lt
- 2. Air supply centamination shall be checked at the nozzle prior to use by exposing a sheet of white paper or cloth to the blast of air (no sand) for approximately 30 seconds. The paper or cloth shall .
be examined for evidence of contamination (oil, j water, foreign matter, etc.). No evidence ,of a <
contamination is acceptable. '
l d) Verify tha t the blasted or power tooled surface has been brushed or vacuumed to the extent required for i
final surface inspection. The adjacent areas shall be
, cleaned to the extent necessary to avoid contamination
- ; during subsequent coating applications. l e) Verify acceptability of the blast cleaned or power tooled surfaces by performing the following inspections
- 1. Absence of Foreign Matter -- A vi:ual inspection shall be performed to determine that all oil and grease, dirt, millscale, rust, corrosion products, !
oxides, paint or other foreign matter have been !
completely removed from the surface except for !
light shadows, very slight streaks or slight .
discolorations caused by rust stains, mill scale, '
oxides, or slight, tight residues of paint or i coating that may remain. At least 35 percent of !
each square inch of surface area shall be free of !
all residues, and the remainder shall be limited '
to light discolorations as mentioned above. !
NOTE: If coating removal is required from an !
area or item which has been coated in accordance with this instruction, shadows
' or tight residues of primer which may remain in ene profile of the previously prepared substrata is acceptable.
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TEXAS UTluTIES GENERATING CO. '
CPSES l
al-QP-11.4-5 13 7 Of 24 l MAR 01 1983 6 l f
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- 2. Removal of Sharp Projections -- A reinspection for sharp projections that were not blended (rounded) during blast cleaning or power tooling shall be performed. i I
Weld splatter on structural steel shall be removed '
by either grinding or sand blasting. However, if !'
the weld splatter should remain after the above operation, the weld splatter will be acceptable. {
Sharp projections are not acceptable. i Protrusion * :nd peaks shall be ground to a rounded con *:,o r, i
NOTE: Any mechanical surface preparation other than sandblasting or hand or power tooling of sharp edges or weld spatter will require a visual welding inspector's I acceptance of the work perfomed.
- 3. Anchor Pattern Oepth -- The anchor pattern depth l of the blasted surface shall be inspected at random l locations using a Keane-Tator Surface Profile ;
, Camparator (model 373) or equivalent. A power i i
tooled surface shall be inspected with use of I either a roughness gage and/or equivalent. l The anchor pattern depth for a blasted or power '
tooled surface shal1 ~ be a minimum of 1.0 mils.
No maximum profile will be specified, providing ;
that correct millage and surface unifomity '
requirements can be obtained a f ter primer appitcation.
f) Verify applicator qualifications per Section 3.3.1.
- 9) Verify air supply acceptability per Section 3.3.4 h) 1. Coating Materials Identification The inspector shall inspect the coating material containers prior to mixing contents for product identification and verify that all materials are correct for coating application.
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- INS ON REVISION PAOI O
) TaxAS UTiuTIES GENERATING CO. ! l
{ QI-QP-11.4-5 13 MAR 01 !% 8 of 24 !
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Approved materials are:
CZ-11 Dimetcote
! Carbo Zine base (gray or green) Dimetcote 6 base Carbo Zinc filler Dimetcote filler Carboline #21 or 33 Thinner Anercoat 165 or 101 Thinner He shall also verify that each component container i is identified by batch number and that the shelf life has not expired. Carbo Zinc 11 base has a shelf life of 12 months. Carbo Zinc filler and -
Dimetcote 6 base and filler have a shelf life of 24 months.
- 2. Mixing Operations An inspector shall witness each mixing / thinning operation. The inspector shall verify that mixing operations are perfonned in accordance with
\ Reference 1-A and 1-B.
l
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- 3. Thinning Operation l An inspector shall verify that primer thinning complies with thinning requirements established l l in References 1-A and 1-B. I
- 4. When coating materials are mixed / thinned in locations other than the field, the inspector l verifying the mixing operation shall fill out the '
g Paint Mixing Slip, Attachment 5. The inspector
- perfonning the pre-application inspection shall .
record the infonnation from the Paint Mixing Slip on the Inspection Report. Attachment 3. The Paint Mixing Slip need not be retained. '
- 1) Verify that primer is applied and pot life 'is not exceeded in accordance with Reference 1-8 and 1-C. If a brush technique is used, the inspector shall verify
' that a short bristle brush is used and rebrushing is avoided.
j) Verify that hose length is less than 75 feet.
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} INS C ON REVISION PAGE i TEXA8 UTILITIES GENEMA"'NG CO.
l CPSES
]!-QP-11.4-5 13 l MAR 01igdh,11 of 24 l
20R IFORVATOY O EY The pennicsible range of surface and ambient temperature for j application of finish coat shall be 50-120*F.
l Maximum values of relative humidity shall be 85t.
The surface temperature shall be a minimum of 5'F above the dew point.
3.3.3 Coated Surface Acceptability The Inspector shall visually reinspect the previously coated surface just prior to finish coat application for evidence of contamination (oil, grease, foreign matter) and stains.
Contamination is unacceptable. All contamination must be removed per Reference 18 or 1.C prior to finish coating.
l Rust (red) and Zinc oxide (white) stains are acceptable
- provided all loose particles have been removed (as evidenced l by existence of no stain on cloth) fram the coated surface I
by approved cleaning operations. phenoline Thinner or Xylol l
l are approved cleaners for seal coat. Thinner wiping is not
- recommended for Dimetcoat primer. Use Carboline #33 cleaner for CZ11 Primer. i i 3.3.4 Air Supply Acceptability I
f The Inspector shall inspect the air supply system (pressure t l
pots and spray guns) for the existence of suitable filters / !
l , traps / separators. '
t The effectiveness of these items shall be verified by placing a Clean piece of cheesecloth (or white fabric) over the exit of the air lines and allowing air to flow for 30 seconds
, minimum. The cloth shall show no evidence of moisture, oil l or foreign matter when examined. '
l 3.3.5 Finish Coat Mixina Operations 3.3.5.1 prior to mixing, the inspector shall veri fy that each component is identified by batch numbers and tha t the 24 month shelf life has not been exceeded.
3.3.5.2 The inspector shall verify that mixing / thinner operations are perfonned in accordance with References 1-B and 1-C.
Thinning may be done up to two quarts of Phenoline Thinner per gallon of Phenoline 305.
%, tuoco on l
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ON REVISICN INS]U PAGE ,
TEXA8 UTILITIES GENERATING CO. i QI-QP-11.4-5 13 12 of 24 MAR 01 @
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3.3.5.3 The inspector shall verify that the pot life has not expired !
per References 1-B and 1-C. I 3.3.5.4. When coating materials are mixed / thinned in locations other than the field, the inspector verifying the mixing operation shall fill out the Paint Mixing Slip Attachment 5. The l inspector perfoming the pre-application inspection shall I record the information from the Paint Mixing Slip on the Inspection Report, Attachment 1. The Paint Mixing Slip neeo not be retained. ,
3.4 SURVE!LLANCE OF SEAL OR FINISH. COAT APPLICATION -
The Inspector shall verify that hose length is less than 75 feet. If a brush technique is used, the inspector shall verify that a short bristle brush is used and rebrushing is avoided.
The inspector shall also verify that the seal coat (if present) is solvent wiped with Phenoline 305 thinner or 8
\ Xylol prior to finish coat application. ,
! 3.5 00CUMENTATIONOFPRIMERINSPECTIONAb0FINISHC0AT '
j PRE-APPLICATION / APPLICATION INSPECTIONS Results of inspections described in Sections 3.1, 3.3, and 3.4 shall be documented on an Inspection Report (IR), i Attachment 1. In accordance with Reference 1-C. The completed IR shall be forwarded to the PPRV for retention.
NOTE 1: All items within the scope of each inspection which are determined by the Inspector to be
. satisfactory may be documented on a single ;
IR.
3.6 FINISH COAT FINAL ACCEPTANCE INSPECTION ,
The inspector shall perfonn a final acceptance inspection of each finish coated item in accordance with Paragraphs 3.6.1 through 3.6.5. For finish coated containment liner i
i i
pem sem i N CA
(
71xAs urtuttES caNERAriNo Co. WSgegyN N nE'/ISICN hg anoE CP583 QI-QP-11.4-5 12 1 of 22 l Sp g toog INSPECTION OF STEEL 3953aRE SY: w$/d//L
/
j with an E1cometer 106 Adhesion Tester, shall ! I not be subject to adhesion testing. ' ? \' , kw l %, TUCCC CA
- r. ,
wy + / - TEXAS UTILITIES GENERATING CO. lQI-QP-11.4-5 l 12 SEp 3 :982 , 3 of 22 ' i
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NOTE 2: For items with total exposed surface area of ' 10 sqaare feet or less - each adhesion test shall consist of only one dolly tested to i failure. ,, 3 c) Verify the primer has cured required amount of time per C Reference 1-8 or 1-C, as appitcable. l d) Perform a visual inspection of the primed surface in ~ accordance with the following:
- 1. Runs / sags - A 0FT measurement shall be made with the Elcometer 0FT gage. Runs / sags 5.5 mils or l
i . less thick (DFT) which show no evidence of ! mudcracking (See NOTE) are acceptable. ' Refer to , i ' References 1-B and 1-C for repair of runs / sags . exceeding S.5 mils. ' j NOTE: Mudcracking is defined as irregular ,, cracking as in a dried mud puddle.
- 2. Dry Spray - Must be removed by screening or
, abrading before overcoating. '
- 3. Over Spray - Must be removed before overcoating.
4 Contamination 'J, Oil and crease - unacceptable Emoedded foreign materials - unacceptable Stains - rust (red) and zine oxide (white) stains acceptable are provided loose particles are ! removed prior to application of finish coat.
- 5. Skips / damaged areas / gross discontinuities such as l holidays or voids - unacceptable. '
e) The inspector shall perfonn a 0FT inspection of the cured primer film. A calibrated 0-25 E1cometer Inspector DFT gage Model !!!/1E, or equivalent, shall ! be used. A minimum of five separate spot measurements . l (See Note 1) spaced evenly over the structure (See i Note 2) shall be taken. Since the magnetic gage is . sensitive to geometric discontinuities in the steel, measurements less than 1 inch from the edge or a hole i shall be avoided where possible. (SeeNote3) l , fuGCC CA - r ,( l ' i INSTRUCTION ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO. m Es I n;,q,,11,4,3 11 3 f 22 IJUL 2 31992 l FOR 1FORMATOb ON Y l l NOTE 2: For items with total exposed surface area of 10 square' feet or less - each adhesion test shall consist of only one dolly tested to failure. c) Verify the primer has cured required amount of time per ! Reference 1-B or 1-C, as appitcable. d) Perform a visual inspection of the primed surface in accordance with the following- l 4
- 1. Runs / sags - A 0FT measurement shall be made with the Elcor'eter DFT gage. Runs / sags 5.5 mils or less thick (DFT) which show no evidence of mudcracking (See NOTE) are acceptable. Refer to References 1-B and 1-C for repair of runs / sags exceeding 5.5 mils. I NOTE: Muderacking is defined as irregular !
cracking as in a dried mud puddle. ,
- 2. Dr y Spray - Must be removed by screening or I
abrading before overcoating. . ! 3. Over Spray - Must be removed before overcoating. -
- 4. Contamination '
011 and crease - unacceptable i Embedded foreion materiels - unacceptable Stains are - rust (red) and zinc oxide (white) stains acceptable provided loose particles are removed prior to application of finish coat. S. Skips / damaged areas / gross discontinuities such as holidays or voids - unacceptable, e) The inspector shall perfonn a DFT inspection of the cured primer film. A calibra ted 0-25 E1cometer l-Inspector DFT gage Model III/IE, or equivalent, shall I be used. A minimum of five separate spot measurements ! (See Note 1) spaced evenly over the structure (See ! Note 2) shall be taken. Since the magnetic gage is sensitive to geometric discontinuities in the steel. measurements less than 1 inch from the edge or a hole shall be avoided where possible. (SeeNote3) , , i I , TUCCO oA \ l ( / TEXAS UT!UTIES GENE.9ATING CO. CPSES N h" REVISICN g PAGE lQI-QP-11.4-5 10 JUN 11 1982 1 of 21
- PREPARED SY
- vI[(/ m g(/p INSPECTION OF STEEL EE SUBSTRATE PRIMER REPAIR AND SEAL AND,-
i APPROVED BY: 4[9/ L l FINISH C0AT APPLICATION AND REPAIR APPROVED SY: A [ e 7 h I! i /M RC f CA7E
1.0 REFERENCES
1-A QI-QP-11.4-1, " Inspection of Steel Substrate Surface Preparation and Primer Application and Repair" 1-B CCP-30. " Coating Steel Substrates Inside Reactor Buildings !
and Radiation Areas" '
1-C CCP-30A, " Coating Steel Substrates Inside Reactor Buildings
, and Radiation Areas" ~
1-D CP-QP-18.0, " Inspection Reports" l
. 2.0 GENERAL
- 2.1 PURPOSE AND SCOPE El '
The purpose of this instruction is to outline methods .
utilized by Quality Control personnel in inspection of primer repair and seal and finish coat application and repair.
n & '.
, 3.0 INSTRUCTION Ei! -
3.1 3.1.1 INSPECTION OF PRIMER Y* f Primer Inspections Prior to Application of Seal or Finish Coat ,'
a) After blasting power tool and prior to prime coat i application, QC shall verify that construction has '
identified each piece with a unique number in accordance !
with References 1-A and 1-B. The QC Inspector shall !
maintain a Protective Coatings Unique Identification Number Log, Attatchment I for all protective coatings i
,,,,,, . rucco c4 -
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l INSTRUCTION ISSUE N BER DN PAGE TEXAS UTILITIES GENERATING CO. ! g DATE CPSES QI-QP-11.4-5 10 JUN 11 iSSE 2 of 21 application on all steel designated for use in the Reactor Building. Subsequent subdivision of coating steel in the field or shop shall be witnessed by QC in accordance ,
with Reference 1-C.
I NOTE:
A. Unique number may be assigned to a lot of material to be prime coated at the same time.
For example, six pieces steel to be coated at same time may all have same unique number.
- 8. Linear plate is excluded from QP numbers.
Equipment which is identified with permanent plant identification number need not be identified with a p Protective Coatings unique Idnetification Number. The term " Equipment" is not to include pipe hangers, cable
% M w% tray hangers, conduit supports, or structural steel.
They will all have Protective Coating unique Identification g $;
t Numbers assigned..
I b
b) Verify the primer has cured required amount of time per Reference 1-8 or 1-C, as applicable.
I c) Perfonn a visual inspection of the primed surface in accordance with the following: ,
- 1. Runs / sags - A DFT measurement shall be made with the Elcometer DFT gage. Runs / sags 5.5 mils or i less thick (DFT) which show no evidence of ,
mudcracking (See NOTE) are acceptable. Refer to ;
References 1-B and 1-C for repair of runs / sags ,
exceeding 5.5 mils. j NOTE: Mudcracking is defined as irregular l cracking as in a dried mud puddle. ,
- 2. Dry Spray - Must be removed by screening or -
abrading before overcoating.
- 3. Over Spray - Must be removed before overcoating.
- 4. Contamination .
Oil and arease - unacceptable Embedded foreion materials - unacceptable Stains - rust (red) and zinc oxide (white) stains .
i
,,,,,,,, TUGCC CA '
l INSTRUCT ON I
REVISION '
- PAGE
' TEXAS UTILITIES GENERATING CO.
CPSES i
' < 1
! QI-QP-11.4-5 10 JUN I 1 i932; 3 of 21 1
l I l i
{
' are acceptable provided loose particles are l removed prior to application of finish coat. i 1
I
- 5. Skips / damaged areas / gross discontinuities such as holidays or voids - unacceptable.
c) The inspector shall perfom a DFT inspection of the cured primer film. A calibrated 0-25 Elcometer ;
., Inspector DFT gage Model III/1E, or equivalent, shall ;
' be used. A minimum of five separate spot measurements '
(See Note 1) spaced evenly over the structure (See Note 2) shall be taken. Since the magnetic gage is i
sensitive to geometric discontinuities in the steel, measurements less than 1 inch from the edge or a hole shall be avoided where possible. (SeeNote3)
Ory Film Thickness shall be as follows:
A 7 Min. (mils) Max.(mils) t, CZ-II spot test 1.5 e
,g y; D ,.
hM, 06 spot test 5.5
" 1.5 5.5 D6 average DFT
~ 2.0
- 5.0
] CZ-II average DFT 2.0 4.5 NOTE 1: A spot measurement is a series of three measurements in the same general area. The L
probe should be moved a short distance for i each gage reading. Discard any unusually high or low gage readi.ng that cannot be repeated
- consistently. Take an average of these three ,
gage readings as one spot measurement.
NOTE 2: For small areas of coating, 5 separate spot j
measurements shall be taken. For larger areas, 5 spot measurer. .ats shall be taken for every 100 square feet sf coating.
NOTE 3: Items with appreciable' surface curvature and other geometrical discontinuities, such as handrails, gratings, stairs, sway stru ts ,
etc., shall be exenpt from dry film thickness measurement. (See OCA 11421) d) For all prime coated items which do not exhibit a
( Protective Coatings Unique Identification Number (QP Number) the Inspector shall perfonn an Adhesion (Patch)
Test. If adequate documentation exists the above is not i applicable. A calibrated Elcometer 106 A;:hesion Tester l
, Tuoco cA
- i INSTRUCTION ' REVISION I
TEXAS UTILITIES GENERATING CO.
NUMBER ,
E l PAGE ,
I :
l CPSES , ;
l lQI-QP-11.4-5 10 JUN 11 982 , 4 of 21 I ,
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t shall be used to verify that the minimum acceptable l l tensile of adhesion to the steel substrate has been attained. Each test shall consist of three individual dollies tested to failure. (See Notes 1 and 2 be6.)
l Cri teria: The minimum acceptable strength per dolly j shall be 200 psi. If any one of the three ,
dollies should test below the minimum '
j acceptable strength, the prime coat shall be !
removed to the steel substrate over the l entire item. l Primer repairs, if required, shall be performed in m .gg n -
accordance with Section 3.2.
U- L item,
- , NOTE 1: Any which due to their. size or configuration will not accomodate testing V'
with an Elcometer 106 Adhesion Tester, shall not be subject to adhesion testing. ;
( l j NOTE 2: For items with total . exposed surface area of 10 square feet or less - each adhesion test l l :
shall consist of only one dolly tested to l i failure.
i 3.2 PRIMER REPAIRS I l 3.2.1 Sags and Runs Over 5.5 Mils OFT I
Sags and runs over 5.5 mils DFT may be abraded by sanding or aluminum screening. If surface is acceptable per Section
! 3.1, document such on Attachment 3. If surface is unaccept-l s
able refer to Section 3.2.2 or 3.2.3 as applicable.
I 3.2.2 Primer Touch-up Repair (Primer Damaged to Steel Surface) !
'f The coating inspector shall conduct the following inspections to document primer touch-up repair operations l when the damage is to the steel surface and spot l sandblasting or power tool abrading is required for surface i
preparation. I a) Verify abrasive acceptablility (if used) by obtaining a I sample o'f the abrasive to be used. The abrasive shall !
be verified to be dry by feel, Particle size must be
- sufficient to achieve a minimum of 1 mil surface profile.
All contamination is unacceptable.
I a.,=,, aco o4
h INSTRUCTION ISSUE ER SiON PAGE TEXAS UTILITIES GENERATING CO. I l DATE CPSES l !
,QI-QP-11.4-5 l 10 JUN I 1 1982 l 5 of 21 l i
~0R INFORMATI0l\ 0\lY !
I b) Verify acceptability of blast cleaning equipment (if used) prior to use by:
- 1. Verifying that water separators are installed in the air supply system and that separators have been drained of accumulated water and drains left partially open.
- 2. Air supply contamination shall be checked at the nozzle prior to use by exposing a sheet of white paper or cloth to the blast of air (no sand) for approximately 30 seconds. The paper or cloth shall be examined for evidence of contamination (oil, water, foreign matter, etc.). No evidence of contamination is acceptable.
c) Verify that the blasted or power tooled surface has been brushed or vacuumed to the extent required for final surface inspection. The adjacent areas shall be i cleaned to the extent necessary to avoid contamination during subsequent coating applications.
d) Verify acceptability of the blast cleaned or power tooled surfaces by performing the following inspections: ;
- 1. Absence of Foreign Matter -- A visual inspection
- shall be perfomed to determine that all oil and grease, dirt, millscale, rust, corrosion products, oxides, paint or othqtr foreign matter have been completely removed from the surface except for light shadows, very slight streaks or slight j discolorations caused by rust stains, mill scale, i oxides, or slight, tight residues of paint or coating that may remain. At least 95 percent of each square inch of surface area shall be free of all residues, and the remainder shall be limited i to light discolorations as mentioned above.
NOTE: If coating removal is required from an area or item which has been coated in accordance with this instruction, shadows or tight residues of primer which may remain in the profile of the previously prepared substrate is acceptable.
- 2. Removal of Sharp Projections -- A reinspection for sharp projections that were not blended (rounded) during blast cleaning or power tooling shall be perfomed.
%,, TUGCO OA
INSTRUCTION ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO. I DATE i CPSES _
i .
{QI-QP-11.4-5l 10 iJUN I1 $82i 6 of 21 l Weld splatter on structural steel shall be removed l by either grinding or sand blasting. However, if I the weld splatter should remain after the above operation, the weld splatter will be acceptable.
Sharp projections are not acceptable.
Protrusions and peaks shall be ground to a rounded contour.
NOTE: Any mechanical surface preparation other than sandblasting or hand or power j tooling of sharp edges or weld spatter will require a visual welding inspector's acceptance of the work performed.
- 3. Anchor Pattern Depth -- The anchor pattern depth of the blasted surface shall be inspected at random I locations using a Keane-Tator Surface Profile
( Comparator (model 373) or equivalent. A power tooled surface shall be . inspected with use of either a roughness gage and/or equivalent.
I
,! The anchor pattern depth for a blasted or power !
tooled surface shall be a minimum of 1.0 mils.
No maximum profile will be specified, providing that correct millage and surface uniformity requirements can be obtained after primer
, application.
l
- e) Verify applicator qualifications per Section 3.3.1.
f) Verify ambient conditions per Section 3.3.2.
g) Verify air supply acceptability per Section 3.3.4.
l h). Verify that mixing operations are per Reference 1-B or 1-C. The inspector shall record batch number of materials used. Additionally, the inspector shall verify that the shelf life has not been exceeded.
i) Verify that primer is applied in accordance with ,
Reference 1-B and 1-C and pot life is not exceeded. If ;
a brush technique is used, the inspector shall verify that a short bristle brush is used and rebrushing is l avoided.
%, Tuoco CA
INSTRUCTION ISSUE
' REVISION PAGE TEXAS UTILITIES GENERATING CO.
CPSES QI-QP-11.4-5 9 RB 2 5 1982 14 of 20 FOR INFORMAT0h Oh _Y 3.7.5 Repair of Pinholes and Discontinuities, and/or Overcoating a) Verify all loose particles are removed and area is solvent wiped.
b) Perfonn inspections described in 3.7.2 (c).
3.7.6 Documentation of Repairs All repairs shall be documented on an Inspection Report, Attachment 1. Repairs involving application of primer will be documented on Attachment 3.
3.8 MAPPING OF LARGE AREAS For large arecs (such as reactor containment liner plate) which have received coatings prior to 10/23/81 (Issuance date of Rev. 5 of this procedure), a unique number shall be assigned to the origiral inspection checklist. This number will be transferred to the area on a map drawing to provide traceability to the original checklist. For any coatings applied after 10/23/81, the IR number shall be transferred to the area on the map drawing.
The map drawing shall be maintained by the QC Supervisor, or his designee, until the entire surface has been coated, at which time, the completed map shall be transmitted to the Permanent Plant Records Vault.
NOTE 1: Separate maps shall be maintained for the prime, seal and finish coats.
NOTE 2: If the coated area applicable to a given IR is ;
irregular in shape, a sketch should be attached to the IR to indicate the extent of the area inspected.
l l
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i l TUGCO OA d
INSTRUCTION ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO. ^
CPSES QI-QP-11.4-5 9 FEB 9 5 182 3 of 20 NOTE 1: A spot measurement is a series of three measurements in the same general area. The probe should be moved a short distance for each gage reading. Discard any unusually high or low gage reading that cannot be repeated consistently. Take an average of these three gage readings as one spot measurement.
NOTE 2: For small areas of coating, 5 separate spot measurements shall be taken. For larger areas, 5 spot measurements shall be taken for every 100 square feet of coating.
NOTE 3: Items with appreciable surface curvature and other geometrical discontinuities, such as handrails, gratings, stairs, sway stru ts ,
etc., shall be exempt from dry film thickness measurement. (See DCA 11421)
( d) For all prime coated items which do not exhibit a Protective Coatings Ur.ique Identification Number (QP Number) the Inspector shall perfonn an Adhesion (Patch)
Test. A calibrated Elcometer 106 Adhesion Tester shall be used to verify that the minimum acceptable tensile strength of adhesic.i to the steel substrate has been attained. Each test shall consist of three individual dollies tested to failure. (See Notes 1 and 2 below.)
Criteria: The minimum acceptable strength per dolly shall be 200 psi. If any one of the three dollies should test below the minimum acceptable strength, the prime coat shall be removed to the steel substrate over the entire item.
Primer repairs, if required, shall be performed in accordance with Section 3.2.
I NOTE 1: Any iten, which due to their size or configuration will not accomodate testing with an E1cometer 106 Adhesion Tester, shall not be subject to adhesion testing.
TUGCO CA
(
TUQ-1274 TEXAS UTILITIES GENERATING CO.ilP. ..Y OFFICE MEMOR ANDUM T,, _ History File QI-QP-11.4-5, Rev. 9 _ __ _ _ , _ . ca,n %,, 7,x , _ May 2h.1982 siay ce __ Intent of_QI-QP-11.._4-5,. para. 3.1.1 3 )_ _ _
The intent of subject paragraph was to require an adhesion test only for surfaces which do not have acceptable documentation to substantiate the acceptability of the existing primer coat. It is not, nor never was, the intent to require that an adhesion test be performed on areas with acceptable primer just because a QP number was not present. It was never the intent to stamp-QP numbers on the containment liner, for example.
The misleading statement will be corrected in Revision 10.
/ f
.- ' i f '/ s i .. ,I '
s -/
. T. Brandt u Mechanical / Civil QA/QC Supv.
CTB/1s cc: R. G. Tolson N. Britton w ^ven FOR i\ F0N A" ON 0LY R. Wallace B. Lockamy .
.I e
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L.
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INSTRUCTION ISSUE j TEXAS UTluT1ES GENERATING CO., AUMBER ; REVISICN OATE PAGE i
! CPSES g [ ,,:2
- . - ~ ' ,1 .b ';. Jgh0P-11.4-5 8 1 f 20
- e. e., . f . <- .:
j - -
!/M I S 1982 ,
U ,fa; h2D INSPECTION OF STEEL PREPARED BY: / /!/f 4b SUBSTRATE PRIMER REPAIR AND SEAL AND l
- APPROVED B'. >
[ ,
nAT y
- i FINISH C0AT APPLICATION ; /_ # '
[A.
f APPROVED BY- /
l
- v ~
, DATE I
j
1.0 REFERENCES
i 1-A QI-QP-11.4-1, " Inspection of Steel Substrate Surface i Preparation and Primer Application and Repair"
! 1-B CCP-30, " Coating Steel Subs trates Inside Reactor Buildings !
j and Radiation Areas" ,
- 1-C CCP-30A, " Coating Steel Substrates Inside Reactor Buildings '
, and Radiation Areas" 1
1-0 CP-QP-18.0, " Inspection Reports"
( f .
2.0 GENERAL -
2.1 -
PURPOSE AND SCOPE I I
{' The purpose of this ins truc tion is to outline methods
, utilized by Quality Control personnel in inspection of j l primer repair and seal and finish coat application and '
i repair.
3.0 INSTRUCTION i 3.1 INSPECTION OF PRIMER 3.1.1 Primer Inspections Prior to Aoplication of Seal or Finish Coat a) Verify the primer has cured required amount of time per '
Reference 1-B or 1-C, as applicable.
I b) Perfonn a visual inspection of the primed surface in accordance with the followir:g:
i
, TUGCC oA
INSTRUCTION ISSUE BER REVISION PAGE
- TEXAS UTILITIES GENERATING CO. OATE <
CPSES QI-QP-11.4-5 8 19 1N2 2 of 20 l l
- 1. Runs / sags - A DFT measurement shall be made with the Elcometer DFT gage. Runs / sags 5.5 mils or less thick (DFT) which show no evidence of mudcracking (See NOTE) are acceptable. Refer to References 1-B and 1-C for repair of runs / sags exceeding 5.5 mils.
NOTE: Mudcracking is defined as irregular cracking as in a dried mud puddle.
- 2. Dry Spray - Must be removed by screening or abrading before overcoating.
- 3. Overspray - Must be removed before overcoating.
- 4. Contamination Oil and arease - unacceptable Embedded foreign materials - unacceptable e Stains - rust (red) and zinc oxide (white) stains i are acceptable provided , loose particles are removed prior to application of finish coat.
'5. Skips / holidays - unacceptable. !
c) The inspector shall perform a DFT inspection of the cured primer film. A calibrated 0-25 Elcometer Inspector DFT gage Model III/1E, or equivalent, shall be used. A minimum of five separate spot measurements (See Note 1) spaced evenly over the structure (See '
Note 2) shall be taken. Since the magnetic gage is i sensitive to geometric discontinuities in the steel, j measurements less than 1 inch from the edge or a hole i shall be avoided where possible. (See Note 3)
Dry Film Thickness shall be as follows:
Min. (mils) Max. (mils) j CZ-II spot test 1.5 5.5 I D6 spot test 1.5 5.5 i D6 average DFT 2.0 5.0 :
CZ-II average DFT 2.0 4.5 j I
l 4
l l
%g, TUGCO CA J
-s.
I ; 1 i INSTRUCTION ISSUE 1 REVISION PAGE
- TEXAS UTIUTIES GENERATING CO. I
^
( CPSES i ;
QI-QP-11.4-5 8 (18191982 l 3 of 20 NOTE 1: A spot measurement is a series of three measurements in the same general area. The probe should be moved a short distance for each gage reading. Discard any unusually high or low gage reading that cannot be repeated consistently. Taxe an aierage of these three gage readings as one spet measurement.
NOTE 2: For small areas of coating, 5 separate spot measurements shall be taken. For larger areas, 5 spot measurements shall be taken for every 100 square feet of coating.
NOTE 3: Items with appreciable surface curvature and other geometrical discontinuities, such as )
handrails, gratings, stairs, sway struts, etc., shall be exempt from dry film thickness I measurement. (See DCA 11421)
- (,~ d) For all prime coated items which do not exhibit a Protective Coating: Unique Identification Ni.mber (QP Number) the Inspector shall perfonn an Adhesion (Patch)
Test. A calibrated E1cometer 106 Adhesion Testtr shall be used to measure the tensile strength of adhesion to the steel substrate. Each test shall consist of three individual dollies tested to failure.
Criteria : The minimum acceptable strength per dolly shall be 200 psi. If any one of the three dollies should test below the minimum acceptable strength, the prime coat shall be removed to the steel substrate over the entire item.
Primer repairs, if required l shall be performed in accordance with Section 3.2.
3.2 PRIMER REPAIRS 3.2.1 Sans and Runs Over 5.5 Mils OFT Sags and runs over 5.5 mils DFT may be abraded by sanding or aluminum screening. If surface is acceptable per Section 3.1, document such on Attachment 3. If surface is unaccept- ,
able refer to Section 3.2.2 or 3.2.3 as applicable.
6 menn mu6
t INSTRUCTION ISSUE NUM8ER MSG DATE PAGE TEXAS UTILITIES GENERATING CO.
CPSES g gQI-QP-11.4-5 8 AN1g g 10 of 20 The inspector shall also verify that the seal coat (if present) is solvent wiped with Phenoline 305 thinner or Xylol prior to finish coat application.
3.5 DOCUMENTATION OF PRIMER INSPECTION AND FINISH C0AT PRE-APPLICATION / APPLICATION INSPECTIONS Results of inspections described in Sections 3.1, 3.3, and 3.4 shall be documented on an Inspection Report (IR),
Attachment 1, in accordance with Reference 1-0. The completed IR shall be. forwarded to the PPRV for retention.
NOTE 1: All items within the scope of each inspection which are detennined by the Inspector to be sa tisfactory may. be documented on a single IR.
3.6 FINISH C0AT FINAL ACCEPTANCE INSPECTION j The inspector shall perfom a final acceptance inspection of each finish coated item in acco,rdance with Paragraphs 3.6.1 through 3.6.5. For- finish coated containment liner plate su rfaces , the final acceptance inspection shall be perfomed at the completion of the curing period. For all other finish coated items, the final acceptance inspection shall be perfomed imediately prior to turnover of -each area within the containment building and should be coordinated with Area Management. In addition, finish coated containment liner surfaces shall be visually reinspected in accordance with Paragraph 3.6.2 immediately prior to turnover of each containment area.
3.6.1 Finish Coat Cure Prior to perfoming finish coat final ac'ceptance inspections, the Inspector shall verify that the finish coat has fully cured in accordance with the required final curing time /
temperature relationships indicated in References 1-B or 1-C. A calibrated non-mercury filled dry bulb themameter, a calibrated temperature recorder, or local weather station data may be used.
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I L i lNSTRUCTION ISSUE REVISION PAGE TEXAS UTILmES GENERATING CO.
^
C*JES
) QI-QP-11.4-5 8 JAN is 582 11 of 20 3.6.2 Visual Defects Inspection The Inspector shall perform a visual inspection of the cured finish coated substrate surface in accordance with the following:
a) Runs / sags - Runs or sags in which the DFT of the total coating system is 11.5 mils or less thick, which show no evidence of mudcracking, are acceptable. Those greater than 11.5 mils shall be repaired in accordance wi th Reference 1-B or 1-C.
b) Skips / damaged areas / gross discontinuities such as holidays, voids, and bubbles are not acceptable.
c) Pinholes - acceptable to the extent allowed by Attachment 2.
d) Contamination - Embedded foreign materials unacceptable. ,
3.6.3 Ory Film Thickness (DFT)
The Inspector shall perfonn a DFT of the cured coating system. A calibrated 0-25 Elcometer Inspector DFT Gage Model III/IE, or equivalent, shall be used. A minimum of five separate spot measurements (See Note 1) spaced evenly over the structure (See Note 2) shall be taken. Since the magnetic gage is sensitive to geometric discontinuities in the steel, measurements less than 1 inch from the edge or a hole shall be avoided where possible.
The average DFT of the total coating system shall be a minimurn of 7.0 mils and a maximum of 11.0 mils. The spot test OFT of the total coating system shall be a minimum of 7.0 mils and a maximum of 11.5 mils.
NOTE 1: A spot measurement is a series of three measure-ments in the same general area. The probe should be moved a short distance for each gage reading.
Discard any unusually high or low gage reading that cannot be repeated consistently. Take an average of these three gage readings as one spot measu rement.
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l lNSTRUCTION ! ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO. !
CPSES I QI-QP-11.4-5 l 8 JAN 19 1!B2 12 of 20 NOTE 2: For small areas of coating, 5 separate spot measurements shall be taken. For larger areas, 5 spot measurements shall be taken for every 100 square feet of coating.
NOTE 3: Items with appreciable surface curvature and other geometrical discontinuities such as handrails, gratings, stairs, sway struts, etc. shall be exempt from DFT measurement (See OCA 11421).
3.6.4 Continuity Inspection The Inspector shall test the continuity of the cured finish coat using a Tinker and Rasor Model M1 (67.5 volt) holiday de tec tor. 100% of the finish coated surface area shall be tested.
The applied film should contain only a minor number of f
points of discontinuity. No more than two points of discontinuity should occur within an area having a radius of' 6 inches as measured from a point of discontinuity (pinholes). No more than 40% of the total number of allowable points of discontinuity should occur within any one area equal to 25% of the total area being coated. The total number of pinhole discontinuities allowed is defined in Attachment 2. No gross discontinuities are allowed.
3.6.5 Documentation of Finish Coat / Seal Coat Acceptance Inspections Results of inspections described in Sections 3.6 shall be l documented on an inspection report (IR), Attachment 4 in accordance with Reference 1-0. The completed IR shall be forwarded to the PPRV for retention.
NOTE 1: All items wi thin the scope of each inspection per Paragraph 3.6 which are determined by the i Inspector to be satisfactory may be documented I on a single IR.
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INSTRUCTION ISSUE I -
NUMBER REVISION PAGE TEXAS UTILITIES GENERATING CO. DATE I
CPSES '
i QI-QP-11.4-5 8 ! JAN I 9 gp 15 of 20 i
I FOR INFORMATi0h ONLY 3
Attachment 1 c wANcat SUN STEAM E'.!CTmC $?AUCN sve- r INSECTION REPCRT ,e
" d d E I53E CCAT!NGS y [" '
mm m ,,
AS-31 Jw Q1-QP-11.4-5.
a; ;;c. a eso aRev. :w.c.s ,o. pus a :m u a ;cu c
.)
C @ #E d F*1,NEW* CD$cT C D neme. DMrec=
asp. answrs ..
C masterton consures , au. ecasts stess sar:sracrew C inspec rom ce, unsi- . scrow : artw watto seure ac insacrea m ;
INSPECT:CM ATTRl8UTES garg A';i g gy,g I SEAL COAT FIN!SW CCAT l I' ! '
l ORINGINAL ' '
REPAIR l i
- l. 4 Verify Primer Care per para. 3.1.1.a. l I 1
- 2. I Perfom Visual Inspection of Primed Sur#sce eer ears. I I I
( l 3.1.1.b. i ' 3
- 3. t Perform 0FT of Prime r Coat per cara. 3.1.1.c (For. '
I t 4 I multiple items ind14ateMin. Soot, Man. Soot and Averagh ! l i 1 l CCT for each item in 'Remarts"). I I l I I RECJ10: Minimum Soot Test: 1 i ' (
l Maximum Seet Test: I I I (
l Averece OFT; l i ! I
- a. Perform Adhesion Test per para. 3.1.1.d if primed I i l l i item does not eihibit OP No. I i i 3 l RECCRD: Adhesion Test strength in PS! l I I 8 i Colly el Colly #2 , Dolly #3 1 I .
I i l (For multiple itens in *1 gate in "%emarts" with I i
- I corresponding 0FT readint s from it;* #3 aeove. ) i i ! ! -
1
! I i :
6.
I Ameient conditiens emecked e** cara. 3.3.2 erier to I i i coating apolication and record,below: I l ' 8
- I CATE: TIME: WET BUL8_ TEMP- 1 i '
l ORY BUL8 TEMP: RELATIVE NtNIO! Tit I t ! i 8 I DEW PO!NT: ' $URFACE TEwP! l I l 8 !
- 7. I Perdom Visual f asDection of erevien tv ceated I I I i '
I surdece per oara. 3.3.3.
I I l I
- 9. ! Verify surface creearation acte 9 table eer '.9 30 er 3cAI l I - '
- 9. I Verify air sucoly acceptable per para. 3.3.4 ' I I I
- t
- 10. I Verify mining operatiens are per CCP.30 or 30A and I I -
i para. 3.3.5 I 4 '
I '
f Continued on Nant theetl I.'
Pennno.1 TUGCO CA
I INSTRUCTION l ISSUE 8 -
DATE N '
TEXAS UTILITIES GENERATING CO.
CPSES -
QI-QP-11.4-5 l 8 JAN I 9 '982 16 of 20 Attachment 1., Sheet 2
, CDMANCHE PEAM STEAM ELECTRIC STATION INSPECTION REPORT Qt-CP-11.4-5 Rev.
1 (SUPPLEMENTAL)
. $" n -
INSPECTICN ATTRieuTES r *
- Tuu
.a 11 . Coatino material creduct +deati*ici* tea- 1 I RECORD 8ATCH NUM8ERS: 1 PART A:
PART 9:
4 THINN(R: !
l TIME MIXED: I 6 12 1 Verify that shelf life of coating materials nas not i I expired. I
- 13. Verify that Dot Itfe is not esteeded. I i l I
- 14. Verify qualification of apoltcator oer cara. 3.3.1. I 4 l list Applicators: I l i I I 4 l 1 6 1 1 4 1 t
- 15. Verify hose leaq'M is less tman 75 feet, I I i I l l } I i ! 6 I i 4 I i l 1 4 i i I
, I i I 6 6 t 1 I I I i 1 1 I t 1 4 1 1 I e 1 4 1 1 1 1 i i l i (
, RO8ANets: (cues. specs.rTcj l'
4 e
s ? ' oc especron a 1
,,,,,,g, TUGCC CA
I INSTRUCTION ! ISSUE I
NUMBER REVISION ' PAGE TEXAS UTIUTIES GENERATING CO. i i DATE CPSES i 7
QI-QP-ll.4-5 { 7 l0EC 11 W 13 of 17 l t
ATTACht1ENT 1
~0R NFORMATION 0\"Y _ l 1
i CCMANCHE 8GX $7DM E'. ECTRIC S U .*.CN 9.tr. .' er 7 INSPECT lCN RE?CRT
\ .res as:.marca .cLirsc.:.;3 .o
[4 j
- ,s,s:tw,sra.cr.n ;4..s=4r a se0TEC~fVE COATINGS r **
ys;.4 . n .. g v a; :cc. s n , o : w.e4 so . +us a rm c;..a s w .e AS-31 ,1 e O!-CP-11.4-5. Rev. J , ,
C 3"sa7n lI.*o'= CF*d.',5!hy,";" O'.8Isin~"N C ode -.e C EsEE-.e, y map. mesus s
- O certen
- :-uns . u_ i, scuu . tos 34rsuc :., l Cimsaterca cowurts. .asAr:srac?:av tws s to sc.:. 8' '"'"*'" **
,g, .
etta go g '
its37CT:CN t.?"'* t t u N3 8C
- g, sarg i ,,,,y, ,
. . .a sr ... l l SEAL COAT = Ft4ttu COAT R t 8 8 t !
l ORIGINAL _
REPAIR R ! 6 8 .
- 1. ! Perform 0FT of Primer Coat te* Para. 3.1.5 i I ' I !
l RECORD: Minimum Soot *est: l l . i i Maximum Scot Test: 11l . .
l Average CFT: l } j ;
k 2. . Record all Pro teett.e Coatings Unicue ! .D. flo. 's : 1 I i i l l .
I I I I i
- I '
. I i ! l I . I i i ,
i i i i i 3.
f 1 Ambtent eenditions crected :er para. 3.J.2 cet:r to i ! I l coating acoltcation ano record below: l i t i !
I CATE: TIME: WET SUL3 TEMP: i i . '
l CRY BULB TE"P: RELAT!vE Hu?'!0f *V: 1 I .
8 OE'd POINT: :UEFACE TEMP: i t l
, 4. I perform Visual Insoection of oreviousiv coatec I I
- f t I SUr#9ce ?e* D1*1. 3.3.* ! ' I e
- 6. I Yeed 'v 19 e'!ca ? -a c e r. t 4 a a c=Stelo See er2 3rj Se M P .' I .
- 6. I verifv air Surofv seceetie f e ee, sire. 3.3.4 i i ! : ,
- 7. I Verify mining coerstters are er CCP-30 or 30A and i i i I l Paragraon 3.J.5.
. I '
- 8. I Coatino material creduct identiff eation: I 4 l I I
! l RECCR0 BATCH NUtt9ERS:
I I ! I i l* I PART A: l l l 1 l
I PART B: I l l I i THINNER: I l I ' '
l TIME MIXED: i i ! t
- 9. I verify that snel' fife of c:atino materials has not I I '
f l enoired. I
- 8 i !
- 10. I Verify that cot life is not exceeded. I l ! ! i (Continued on Next Sheet...)
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r INSTRUCTION ISSUE NUMBER WSION PAGE j
, ' TEXAS UTILITIES GENERATING CO. DATE
, CPSES !
4 QI-QP-11,4-5 7 M OEC 11 891 l " Of U l ATTACHMEtlT 1 (Continued)
, QI.QP.11,4 5. Aev, Sheet 2 of 2 cc h.: wt sti.x s?tra t'_ n *c sT/.?: N INSPECTICN ME?CET
(%9*.Dcsi:.0 .
l
' in, i i : san m:- ::
w l INSMCTICN Ai?mevits ; g
.. 4. . . t
- 11. '
ver* *v cualif t entien o* aenlicater oea pare. 3.11 6 l t*st aco1+ caters ' ' ' +
4 i i i {
. . i
. . i e a t j
- 12. Vertfy mese tenetM ts less tman 75 feet. * *
- 5 l i i
- I +
) l it 4 oe r'o- vis ual 'asceetton of ceated surface eer - '
+ i t Para. 3.5.1. ' a t i e i ta i verifv euetao is ese Ctp.30 oc cca.30s sad oarn. 1. 5 . ? .- ' -
- I i e e e i , ,
ic ioes - 05' an cented suedice esta'sn cent en6vi es ' i I g
f eer para. 3.5.3. i,' e i a ceattne e v t+.. cee 'no w e-u-- *. > i
. I Coating System Scot Test ran* v : e * + 1 i I Avee*ee CFT C3attaa System a
- 8 1 f.
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- -- , -.-, --- - --.-_,.-_.--,,,,,-n , . , - - . . - - , , . - . . - - , ~ . _ _ . - , - - - . r-,. .
-n--
TEXAS UTILITIES GENERATING CO. NU E AEVISION O PAGE
! CPSES
. QI-QP-II.4-5 6 DEC 2 1981 1 of 17 I
-CREPARED 5!: '
0 /2l2l81 EP M apoeCK D BY. /
REPAIR AND SEAL AND
/
y j CATE FINISH COAT APPLICATION ,
AND REPAIR '
APPRO\ED BY: /^ v
/f[kf/
- l OATE ,
1.0 REFERENCES
1-A QI-QP-ll.4-1 " Inspection of Steel Substrate Surface Preparation and Primer Application and Repair" 1-B CCP-30, " Coating Steel Substrates Inside Reactor Buildings and Radiation Areas" l-C CCP-30A, " Coating Steel Substrates Inside Reactor Buildings and Radiation Areas"
( 1-D CP-QP-18.0, " Inspection Reports" ,, .
gg /.
2.0 - -'
GENERAL -
gg/ ,
2.1 PURPOSE AND SCOPE The purpose of this instruction is to outline methods utilized by Quality Control personnel in inspection of a
primer repair and seal and finish coat application and repair.
. 3.0 INSTRUCTION .
3.1 INSPECTION OF PRIMER Prior to application of a seal or finish coat, the QC Inspector shall perfonn the following inspections:
a) Perfonn a visual inspection of the primed surface in accordance with the following:
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INSTRUCTION ISSUE REVISION PAGE '
TEXAS UTILITIES GENERATING CO. I CPSES j l j QI-QP-11.4-5 t
6 DEC 2 tegt: 2 of 17 i
l . !
- i
- 1. i Runs / sags - A 0FT measurement shall be made witn the E1cometer DFT gage. Runs / sags 5.5 mils or less thick (DFT) which show no evidence of mudcracking (See NOTE) are acceptable. Refer to .
References 1-B and 1-C for repair of runs / sags :
exceeding 5.5 mfis.
NOTE: Mudcracking is defined as irregular ;
cracking as in a dried mud puddle. i
- 2. Dry Spray -
Must be removed by screening or abrading before overcoating.
- 3. Overspray - Must he removed before overcoating, l ,
! 4 Contamination !
l Oil and crease - unacceptable I Enbedded foreign materials - unacceptable
( [ Stains - rust (red) and zinc oxide (white) stains are acceptable provided
< loose particles are removed prior to application of finish coat.
- 5. Skips / holidays - unacceptable.
b) The inspector shall perform a DFT inspection of the '
cured primer film.
{
A calibrated 0-25 E1cometer Inspector DFT gage Model Ill/IE, or equivalent, shall -
be used. A minimum of five separate spot measurements (See Note 1) spaced evenly over the structure (See !
Note 2) shall be taken. Since the magnetic gage is
' sensitive to geometric discontinuities in the steel, measurements less than 1 inch from the edge or a hole '
shall be avoided where possible. (SeeNote3)
Ory Film Thickness shall be as follows: I Min. (mils) Max. (mils)
CZ-!! spot test 1.5 5.5 06 spot test 1.5 5.5 l 06 average OFT 2.0 5.0 t
CZ-!! average OFT , 2.0 4.5 i
Meun Bee.1
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INSTRUCTION ' IS UE REVISION PAGE TEXAS UTILITIES GENERATING CO. ! .
^
CPSES j
/ j QI-QP-11.4-5 6 3 of 17 i
E2 1981}l i
I NOTE 1: A spot measurement is a series of three '
measurements in the same general area. The probe should be moved a short distance for i each gage reading. Discard any unusually high or low gage reading that cannot be repeated ,
consistently. Take an average of these three gage readings as one spot measurement.
NOTE 2: For small ar?as of coatir.g 5 separate spot >
measurements shall be taken. For larger areas, 5 spot measurements snall be taken 'or every 100 square feet of coating.
NOTE 3: Items with appreciable surface curvature and other geometrical discontinuities, such as handrails, gr3 tings, stairs, swy struts, ,
etc., shall be exempt from dry film thickness !
measurement. (See OCA 11421) l t
' Primer repairs, if required, shall be performed in '
( accordance with Section 3.2.
c) Veri fy the primer has cured recuired amount of ti.?e
' per Reference 1-3 or 1-C, as applicable.
3.2 DRIMER REPAIRS 3.2.1 Saqs and Runs Over 5.5 Mils DFT Sags and runs over 5.5 mils DFT may be abraded by sanding or aluminum screening. If surfa'ce is acceptable per Section 3.1, document such on Attachment 3. If surface is unaccept-able refer to Section 3.2.2 or 3.2.3 as applicable.
3.2.2 Primer Touch-up Reoair (Primer Damaced to Steel Surface)
The coating inspector shall conduct the following inspections to document primer touch-up repair operations ,
when the damage is to the steel surface and spot '
sandblasting is required for surface preparation.
a) Verify abrasive acceptablility by obtaining a sample of i
the abrasive to be used. The abrasive shall be verified l
TUGCO CA
r INSTRUCT!CN ISSUE BER . REVISION PAGE
- TEXAS UTIUTIES GENERATING CO. l OATE CPSES j ,
jQI-QP-11.4-5 6 lDEC 2 1081
. j 4 of 17 I to be dry by feel . Particle size must be sufficient to achieve a minimum of 1 mil surface profile. All contamination is unacceptable, b) Verify acceptability of blast cleaning equipment prior to use by:
- 1. Verifying that water separators are installed in l
the air supply system and that separators have been drained of accumulated water and drains lef*
partially open. J l
- 2. Air supply contamination shall be checked at the >
nozzle prior to use by exposing a sheet of white l paper or cloth to the blast of air (no sand) for i approximately 30 seconds. The paper or cloth shall be examined for evidence of contamination (oil, water, foreig,; matter, etc.). No evidence of j contamination is at.ce.otable. i
( I l
c) Veri fy that the blasted surface has been brushed or !
vacuumed to the e'xten t required for final surface inspection. The adjacent areas shall oe cleaned to the extent necessary to avoid contamination during subsequent coating applications, j
d) Verify accepta::: . i ty of the blast cleaned or power l tooled surfaces by perfoming the following inspections: j
- 1. Absence of Foreign Matter -- A visual inspection i i
shall be perfomed to determine removal of foreign matter from the surface. !
l The surface, when viewed without magni fica tio 1, j
shall be free of all oil, grease, visible mill -
scale, rust, corrosion products, oxides, paint, or ;
any foreign matter, except for light shadows, slight streaks, or slight discolorations caused {
I by rust stain, mill scale oxides, or slight, tight ,
residues of pain' i
- 2. Removal of Sharp Projections -- A reinspection for l sharp projections that were not blended (rounded) l
' during blast cleaning or power tooling shall be :
perfo med.
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/ ' l l QI-QP-11.4-5 6 ! DEC 2 51 5 of 17
\ * ;
Sharp projections (including weld spatter) are not acceptable.
l Protrusions and peaks shall be ground to a rounded l contour.
NOTE: Any mechanical surface preparation other than sandblasting or hand or power tooling of sharp edges or weld spatter i
will require a 83R NDE visual inspector's ,
acceptance of the work performed. !.
! 3.
I Anchor Pattern Depth -- The anchor pattern depth
' of the blasted or power tooled surface shall be inspected at random locations using a Keane-Tatar Surface Profile Comparator (model 373) or equiva-lent. A power tooled surface shall be inspected l
with use of either a. roughness gage and/or :
- comparator plate which has been approved by the 8 coating manufacturer. 7
(
The anchor pattern depth f,or a blasted or power tooled surface shall be a minimum of 1.0 mils, j j
No maximum profile will be specified, providing that correct mill, age and surface unifomity requi remen ts can be obtained after primer application. ;
l l e) Veri fy applicator qualifications per Section 3.3.1.
l l f) Verify ambient conditions per Section 3.3.2.
g) Verify air supply acceptability per Section 3.3.4.
h) Verify that mixing operations are per Reference 1-8 or 1-C. The inspector shall record ba tch number of materials used. Additionally, the inspector shall verify that the shelf Iffe has not been exceeded.
- 1) Veri fy that primer is applied in accordance with l Reference 1-B and 1-C and pot life is not exceeded.
i j) Visually inspect per Sect on 3.1(a). i f
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INSTR TON l REVISION ! PAGE !
TEXAS UTILITIES GENERATING CO. ! E I
cPSES f
QI-Q P-11. 4-5 6 DEC 2 anl ,
6 of 17 l
i k) Perfom dry film thickness measurement per Section 3.1(b).
- 1) Verify primer cure per Section 3.1(c). !
3.2.3 Primer Touch-up Repair (Primer Damage Does Not Extend to Steel Surface The coating inspector shall conduct the following inscections for primer touch-up repair operstions when the da age is within the primer coat and sandblasting to tne steel substrate is not required. ,
l a) Verify surface is abraded lightly then wiped clean per-Reference 1-8 and 1-C.
b). Perform inspections (e) through (1) in paragraph 3.2.2.
l 3.2.4 Repair of Primer by Recoating
( '
The coa ting inspector shall conduct the followina inspections for primer recoating repair. Only two (2} ;
overcoats shall be applied. ~ .
a) Veri fy that the surface has been solvent cleaned or i cleansed in accordance with Reference 1-A and 1-8. A ,
clean white cloth shall be used to check primed surface cleanliness. Contamination, other than rust (red) and ;
zinc oxide (white) stains, is unacceptable and require ,
l further cleaning, j l b) Perfom inspection's (e) through (1) in Section 3.2.2. i 3.2.5 Documentation of Primer Repair Insoections l' All inspections required by Section 3.2 shall be documented on an IR, Attachment 3, in accordance with Reference 1-0.
fl0TE: If the repair is of an item which is fabricated ,
out of several pieces of steel bearing different j QP numbers, all QP numbers will be recorded in j the " Remarks" section of the IR. '
l
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F I
! I i INSTRUCTION ISSUE
" l REVISION ^ PAGE l
TEXAS UTILITIES GENERATING CO. I l CPSES l /
QI-QP-11.4-5 l
6 DEC 2 1981 ,
7 f 17 t
I 3.3 PRE-APPLICATION INSPECTIONS i
The QC inspector shall verify the following items prior to f applying coatings:
3.3.1 QUALIFICATIONS The Inspector shall verify (by Qualification Record or list !
of qualification records in QA File) that the coating applicators on each shi't are qualified for safety-related coating work.
3.3.2 Ambient Conditions l The Inspector shall determine substrate surface temperature, l air te:nperature, relative humidity and dew point in the area l of the item to be coated. A calibrated non-mercury filled '
l dry bulb ther ometer or a calibrated temperature recorder shall be used for air temperature determination. A
( calibra ted non-mercury filled wet bulb thermometer or a l calibrated humidity recordsr shall be used to determine relative humidity. The dew point sha.ll be detennined by the i
' dif ference in dry and wet bulb temperatures using the U.S.
Depart:nent of Commerce 'Jeather Bureau Psychrometric Tables, i W. B. No. 235. The su rface- tempe ra tu re thermometer i
(Omega-Amprobe-Fastemp,10-250*F range or equivalent) shall be placed in contact with the surface to be coated. The thermometer probe shall remain in contact with the substrate surface until the temperature reading stablizes.
~
The permissible range of surface and ambient temperature for application of finish coat shall be 50-120*F.
Maximum values of relative humidity shall be 85t.
The surface temperature shall be a minimum of 5*F above the dew point. '
3.3.3 Coated Surface Acceotability i i
The Inspector shall visually reinspect the previously coated ;
surface just prior to finish coat application for evidence of contamination (oil, g re'a s e , foreign matter) and stains. '
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, a-CORRECTED COPV: 12/7/81 This page provides missing line i Pa ra. 3. 3.4 f
f INSTRUCTION ISSUE REVISION .
PAGE
' TEXAS UTILITIES GENERATING CO. '
I
^ I CPSES i i QI-QP-11.4-5 6 }
is2 El! 30# 17 l
Contamination is unacceptable. l All contamination must be reinoved per Reference 1-A or 1-8 prior to finish coating.
' Rust (red) and zinc oxide (white) stains are acceptable provided all loose particles have been removed (as evidenced by existence of no stain on cloth) from the primer surface by approved cleaning operations. Carboline d33 is approved
, cleaner for carbo cinc primer. Phenoline Thinner or Xylol j are approved cleaners for seal coat. Thinner wiping is not ,
recommended for Dimetcoat primer.
j 3.3.4 Air Supolv Acceotability '
The Inspector shall inspect the air suoply system (pressure i
pots and spray guns) for the existence of suitable filters / h traps / separators. i l
6 The
- effectiveness of these items shall be verified by placing l a clean piece of cheesecloth (or white fabric) over the exit
?
of the air lines and allowing air to flow for 30 seconds l ninimum. The cloth shall show no evidience of moisture, oil 5
or foreign natter when examined. -
i
, 3.3.5 Mixing Goerations '
f j 3.3.5.1 Materials t
i The inspector shall verify that Phenoline 305 Finish Coat, i Parts A (base) and 8 (catalyst) are used and their
! respective batch numbers are recorded. In addition, the inspector shall verify that the shelf life (24 months) has not been exceeded. '
i 3.3.5.2 Mixing / Thinning I, The inspector shall witness each mixing / thinning operation
- and shall verify that it is in accordance with requirements of Reference 1-B and 1-C. Thinning may be done up to two 1
i quarts of Phenoline thinner per gallon of Phenoline 305. [
Pot life shall be ,7er Reference 1-8 or 1-C (as appifcable). '
. 3.4 SURVEILLANCE OF SEAL OR FINISH COAT APPLICATION !
The Inspector shall verify that nose length is less than i .
75 feet. If a brush technique is used, the inspector shall
! verify that a short bristle brush is used and rebrushing is avoided.
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INSTRUCTION ISSUE i REVISICN PAGE TEXAS UTILITIES GENERATING CO. I j AE
, CPSES l i
QI-QP-11.4-5 j i 6
DEC 2 iSal ' 9 Of II l
The inspector shall also verify tha t the seal coat (if present) is solvent wiped with Phenoline 305 thinner or Xyloi prior to finish coat application.
3.5 FINISH C0AT POST APPLICATION OPERATIONS 3.5.1 Visual Defects Insoection The Inspector shall perfom a visual inspection of the finish l coated substrate surface in accordance with the following:
a) Runs / sags - Runs or sags in which the DFT of the total l coating system is 11.5 mils or less thick, which show ,
no evidence of evidence of mudcracking, are acceptable.
Those greater than 11.5 mils shall be repaired in accordance with Reference 1-B or 1-C.
b) Skips / damaged areas / gross discontinuities such as holidays, voids, and bubbles are not acceptable.
I c) Pinholes - acceptable to the extent allowed b'y ;
Attachment 2.
, I d) Contamination - Embedded foreign materials unacceptable. .
i l
3.5.2 Finish Coat Cure i i
l The Inspector shall monitor the ambient tempera tu re and j humidi ty after the finish coat is applied (including touch-up). A calibra ted non-mercury filled wet / dry bulb themometer, a calibrated temperature / humidity recorder, or local weather station data may be used. ,
I The inspector shall verify that the finish coat has cured l the time described in References 1-8 and 1-C before l
perfoming dry film thickness determination and continuity checks, and final acceptance.
3.5.3 Ory Film Thickness (DFT) l The Inspector shall perfom a DFT of the cured coating i system. A calibrated 0-25 Elcometer Inspector CFT Gage tiodel III/IE, or equivalent, shall be used. A minimum of five separate spot measurements (See Note 1) spaced evenly over the structure (See Note 2) shall be taken. Since the magnetic gage is sensitive to geanetric discontinuities in 6
, TUGCO CA
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{ INSTRUCTION REVISION ISSUE pp3, TEXAS UTILITIES GENERATING CO. l '
CPSES j j QI-0P-11.a-5 ; 6 , DEC 2 IS61 to of 17 i 4
l-
' the steel, measurements less that 1 inch from the edge or a l
' hole shall be avoided where possible.
The average DFT of the total coating system shall be a m e. .
of 7.0 mils and a maximum of 11.0 mils. The spot test Dri of the total coating system shall be a minimun of 7.0 mils and a maximum of 11.5 mils.
NOTE 1: A spot measurement is a series of three measure-ments in the same general area. The probe shoulc ;
l be moved a short distance for each gage reading.
Discard any unusually high or low gage reading l
that cannot be repeated consistently. Take an ;
average of these three gage readings as one spot measurement.
I NOTE 2:
For small areas of coating, 5 separate spot i measurements .shall be taken. For larger areas, 5 spot measurements shall be taken for every 100 i square feet of coating.
NOTE 3: I Items with appreciable surface curvature and other i geometrical discontinuities such as handrails,
' gratings, stairs, sway struts, etc. shall be exempt j from DFT measurement (See DCA 11421). i 3.5.4 Continuity Insoection i
The Inspector shall test the continuity of the cured finish coat using a Tinker and Rasor Model M1 (67.5 volt) holiday detector.
tested. 100% of the finish coated surface area shall be i
The applied film should contain only a minor number of '
points ofi discontinuity. No more than two points of discontinuity should occur within an area having a radius of 6 inches as measu' red from a point of di scon tinui ty (pinholes). ,
' No more than 40% of the total number of ?
allowable points of discontinuity should occur within any one area equal to 25% of the total area being coated. The l' total number of pinhole discontinuities allowed is defined !
in Attachment 2. No gross discontinuities are allowed.
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TUGCC OA l
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! INSTRUCTION l REVISION ISSUE '
^ PAGE TEXAS UTILITIES GENERATING CO. l I CPSES l t 1
01-0P-11.4-5 ! 6 11 of 17
, i l DEC 2 1981'
+
-l !
3.6 00CUMEtlTATI0tl Results of inspections described in Sections 3.2, 3.3, 3.4 i and 3.5 shall be documented on an inspection report (IR),
Attachment 1, in accordance ~ with Reference 1-0. The completed IR shall be forwarded to the PPRV fo. retention.
3.7 REPAIRS 3.7.1 Repairs of Runs and Saas !
1, l-
' The QC inspector shall verify that the area is abraded until the DFT of the total coating system is within 7.0 and 11.5 mils, and examined for cracks.
The presence or absence of cracks shall dictate the type of repair required per Reference 1-B or 1-C.
3.7.2 Repair of flinor Defects The OC inspector shall perform the following inspection when repairing minor defects (as defined by Reference 1-8 or 1-C.): l I
a) Verify that the damaged area is blasted or abraded and any exposed steel is ground per Reference 1-B or 1-C.
, j b) Verify damaged area ic solvent wiped in accordance with Reference 1-B or 1-C. ,
l t
c) Perfom inspections described in 3.3.1, 3.3.2, 3.3.3, i 3.3.4, 3.3.5, 3.4 and 3.5. I 3.7.3 Repair of Major Defects The QC inspector shall verify the following for repair of major defects (as defined by Reference 1-8 or 1-C):
a) Verify area is abraded or spot blasted per Reference 1-B or 1-C.
b) Perfom inspections in Section 3.2.2.
c) Perfom inspections 'in Section 3.7.2(c). .
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INSTRUCTION ISSUE NWBER REVISION PAGE TEXAS UTILITIES GENERATING CO. , DATE ,
CPSES QI-0P-II.4-5 6 DEC 2 J3gt 12Of17li l
3.7.4 Repair of Embedded Forefon Particles The QC inspector shall veri fy that embeddtJ foreign ?
particles are removed and recoated per Section 3.7.5.
3.7.5 Repair of Pinholes and Discontinuities, and/or Overcoatina a) Veri fy all loose particles are removed and area is solvent wiped, b) Perform inspections described in 3.7.2 (c).
3.7.6 Documentation of Recairs All repairs shall be documented on an Inspection Report, I I Attachment 1. Repairs involving application of primer will i be documented on Attachment 1, Reference 1-A.
f l
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I j i INSTRUCTION ' ISSUE
~'f NUMBER REVISION : PAGE TEXAS UTILITIES GENERATING CO. I DATE
- CPSES ; ;
.l' ,
Q I-QP- 11. 4-5 ,
6 i DEC 2 1961 13 of 17 ATTACFUENT 1 i.
- - CCMAMCMC FEAX STEA'A E' EOTRIC SI ATICN .' 9 M r* re -
INSPECT!CN REFCR. p
\ ats at:.wsr.cw . ;L5 r.mr.cs w. 3rs:cu, sn.c .at ;giwra op0TEC f7E CCATINGS s d .
vu.sc. .n.
AS-31 .I a e c; ;cc. s 4tv a c.w.a wo.
O!-CP-11.4-5. Rev. .
go n a rur I;..e ;o.: a Giu**cetss mast:7.:s par =s sp..,t::=
vteca
- wsw.2re,s
, mut: : F* rw
sse:r.:
r
~ per ts-
- g. sst:r:n .
g asp. assus s C aset:T::= ::w.stra . at. asaacaau attws sar:rs:!:m-O msat: ei :: u za. .asir:sract:.. irtus s ts it;.:. * '"$ * ';*
e .
i iTLW Mo. t l l =.1 .
l Il43Ff:T:CN AT 05GTIS l.; g y :2;g i 3;,, a
-. o . s i r.pt ..
l.
I $EAL COAT _
FINISH COAT U ' ' ' I i ' 02fG!r:AL i REPAIR I .
- f 1 ! Derfor-r CFT cf prirer C st :er Para. 3.1.b i .
- i I
I RECOP.D: flinirun 5:ot *est: ! *
- i Maximum Soot Test
- i i i
! l Average CFT: ; ;
l
- 2. i Record all Proteett.e Coatings Untoue I.D. flo.'s: 1 Il 1 l 1 i ! i e I
l I t i I . I I '
t i 3. I Ancient ccnditions c':ecked er Para. 3.3.2 crier is >
s l I coating 4:olication ano retcrd below: I e i .
l l CATE: TIME: WET But.3 TEPP:
I 8
! l ORY BULB TE"P: RELATIVE Huit!DIT/: i 5 .
l 4 DEW POINT: SURFACE TEP: i
. 4 I Perform Visual Inspection of Oreviousiv coated .
I surface ee- 0 9ea. 1.3.1 : '
i
- 6. I Verfiv tur'sce e-.rarneen .e .ete t, e r rao. .n er yr: .
- 6. f Verify air sveelv aceeotaole :er pare.1.3.4. i ! ' I u
- 7. l Verify mining c:erations are See CCP-30 or 30A and . ? .
l Paragracn 3.3.5. . . I
- 8. I Coatino material creduct identification
- ; i l i !
'l l RECCDD SATCH 'Jtr'9EPS: I 8 I i
- 8 PART A: '"' * '
~l* l l l t I PART 8: i l i t l THINNER: 1 I I i '
l TIME MIXED: l l i l l
- 9. I Verify that snelf life of coating ratertals has not I
. t l enoired. I t I
- 10. I Verify that not life is not exceeded. I i !
(Continued on Next Sheet...) f 1
p, g , TUGCO CA
g l INSTRUCTION ISSUE DATE N TEXAS UTILITIES GENERATING CO..
CPSES I
,QI-QP-11.4-5 W ; 14 ot
- 6 7 3 DEC 2 ATTACSMENT 1 (Continued)
QI QP-11.4 5, Rev., _
Sheet 2 of 2 CC M nC*t at:x s~ tau t.E:~mC $~ T;CN INSPECTION RIFCK7
($498'EJ t.*l*AL! ,
h i 2: I
, m,e l ms s- ica am: suits ijp:4?di e w .n:
q**.. '
tt 11 ' Vset Fv cu314 89 citiOn of m?aliester See 29ea. 3,J.1 1 li1* I?Slic?*aes! ' I I I I t 6 :
I?. Verify Mose ! enc!* it lest t*In 75 #s*t. '
s t it i Der
- Sea visu31 fet **tia9 S' CS9tet >> led?ce **e '
i f Para. 3.5.I. ' '
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3 53 : yeet ry euesne es e . to.?* 3- ct?.3na ,a1 Diet. ?.9 ?. > s
, e .
i ,
3 1s e e. ,s-- C F ? -- can'ai saede-e esa'sa -??? ?niv ' as
- I cer para. 3.3.3. e . 8 i ra q
- e ac ey ... c . . . w . .n , . ,
I Coattne syst < se-; tes "an w.f , , ,
I Sv**?ce CFT C?ttt*c $sSt***
- 6 I
I 4
- 10. e der'Crw Lutat o riu s ty i. ;09. L .On e i t n tin C0a t Cn i v e Lee
. t otra. 3.5.4 I i i . , , j
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- i
! i INSTRUCTION l REVISION ISSUE NUMBER ;
DATE i PAGE TEXAS UTILITIES GENERATING CO. i I i CPSES :
-/ l 5
.W;
'01-0P-11.4-5 ; 5 DEC 2 i 15 of 17 l I
ATTACHME'tlT 2 i I
TOTAL NUMBER OF ALLOWASLE POI'ITS OF DISCONTItJUITY l SURFACE AREA COND. "C" BEING C0ATED C0tWERCIALLY (50. FT.) CONTINUGUS l 10 5 10-50 10 '
50-100 20 i 100-500 30 l
500-1000 50
( ;
1000-5000 75 5 l
- I !
Gross Discontinuities - None Allowed. l I
i
,i l
. i t
l 4
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INSTRUCTION ISSUE N ER *D PAGE 1 TEXAS UTILITIES GENERATING CO. ,
DATE
! CPSES .
i QI-QP-ll.4-5 l 6 'DEC 2 1S81 ' 16 of 17 I
! ATTACHMENT 3 I
ccuAncME PEAK STEAM 0 !:T*IC STATT N w e-1 2
lhSPECTICN . REPCRT y cm r. m a w
.rgw 3Ni s er :,TIVE COATI *;35
. ROI e .!s es tw s w :.u. at a.: e. .
ysc.sc. .ac. 3au u ::c. e acw a c.,.nu so reous ei y s ;..e st.: w AS-31 .l ,1 QI-QP-11.4-5. Rev._ J ,
C %s7tE*:' U',I*7de'}fW'*" CiTsisYEc3 C %m. C ~'.'8- 5 .
JESP. AssA!: .
C 'espec cm ::vai.stro . c Wat irtws sars/act:n i "";" '
O asst:me= ::w zets. .as2r:si.: :n- asvs : sets ic. :. *:
f INSPECT:cN A77154*!$ .!=
l .) PRIMER REPA!RS ,/ . ! *. 3! !-
- Art ' 8'8 #1
- j. 1. t For re:atr r+ !ans ana runs over 5.5 mils CFT. erform i e ' i
- DFT of Prfrer C04t in areas wnic't nave been sa' iced ce i .
screened Der Para. 3.2.1. I i e i g i RECCRO: titntrutt Scot Test: 1 I i , i t Maximum Scot Test: I ! I i '
Aversoe DFT:
( I t 1
- 2. i Abrasive acceotaole per Para. 3.2.2.a. I l i i !
! 3. :Secarators installed, cratres, anc crains left '
I I t i .
feartially c:en. I t ' i j a. 6Aie suaal. feem of eantam nt tan I - 1 I
- 5. Slasted surtice and orofile: I e
- 3 ;a. Blasted sur' ace anc surroundine areas cleaned :e* 6 i 'l
!- l Para. 3.2.2.c. I i ! I
- l. b Surface free of foreien matter incl. crease 1 oil . 8 f ' '
te. Sharo (non-rounded) orojections r- oved,. t i e (d. Ancnor cattern deotn 1.0 mil. minimum. '
- i t le. Surface ligntly abraced eer Para. 3.2.3 4 i i i If. Surface wiped clean per Para. 3.2.3 or 3.2.4 Ie 6 .
l- (Repairs Only) i ,
~
- 6. lunique 'tumber stamoed on eieceis). Record Unicue i i i l l I l Number (s) in "Per. arks" below. 1 I t ! I
- 7. I Aneient conditions enecked ee- Dira. 3.3.2 orter to e i i i f
lorimer aeolicatien and record belew: CATE: 6
f IRELATIVE HUMIDITY: DEW POINT: SURF .TE!*P : 1 i i i f l
- 8. 15ubstrate surface free of contaatinants and less t'ian i l l l24 hours elacsed since clasting. I ! I i e
- 9. l Trap. filter or separator installed er Para. 3.3.4 l l l
- 10. late sucoIv free of coatsmication. I ! I ?
i l l 1 i ;
i (Continued on Sheet 2. .) i i i l i .
Pennmeg, TUGCO OA 2
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!. I .i I l INSTRUCTION . ISSUE b TEXAS UTILITIES GENERATING CO. ., NWBR DATE N-CPSES .. . ,
t .,QI-CP-il.4-5 f 6 l 2 SU I7 Of I7 5
! ATTACH'Erii 3 (Continued',
t l f Q!-CP-11.4-5. Dev.
,' Sheet 2 of 2 l 'CCMACE*Em I?!Au 0 !:~me 5 a?:cra INSPECTICt1 R E?CF'T Isup*.! w s?:u l
,rw i
- i g
g INSFEC*iC;; 2;;argy g3
. .l*:! c9 igm :,d,
.::r .
11 Quelificatien of stolicit:r. I','s t acclic at 0rs ! ' '
t t?. < ya ri ev utsten c: aria taes ter Jaet 1 2.?.n. t I
11 t
+
Centtec "9tmet il Jeacu-- 'cea* iattea?
- _ \
. 9 es e Let *:c . 3:37 L. ' ' e t ,
j '
- b. F 41 f ee 'N 'la . 8 i L ,; r. *ws, .. tat *w . 4 e s *
- d. Tire Mirea: #
' ' a. Shel' te M t E<e**ead ' '
l I '
14 p re s si;ea nt sa t3**c. 6 f'
'l 15. Pot I t f a not a ersatao. i j 16. I 5asa imit tain '5 w.
- i l
< .r i, .
- 11. . visnel i ns-me
- i en - . i l
' i
,_ e.es.c. sea. as ag- .e . , ii e i t !
.) 6 0. Surf ace tree or ea;nr cerects. , .- i e .
! . i ;
, ,1 18. '
- a ' t ' n ' c' ** s u * " c ' *a t in creexe taca -"ac surr2:e- t ,
t i D. . Ar: er ... , i . ic.- to :::::c.; j L 20. ' O ry f i l e' inickness f_
, eh s: .. . ;
I +
Minieurt Sect Peasur**ent .-
, l t n ,4~ e--e
'l ......_.e...at ie i t
- 8 Avertee CFT
- : . j i i l ,
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} RDAA* 3 : (: cs.sM:3 trc 3 t I I
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- * ' l g,a g;,, g g WE i simaus j is s 6 oc ism:r.* .e ,
- p.,,,, w , TUGCO CA i-t .
m..
o .
INSTRUCTION ISSUE '
TEXAS UTtuTIES GENERATING CO. . NUMBER REVISION CATE PAGE CPSES l
{QI-QP-11.4-5 5 NOV 1 o !$61- 1 of 12 bwob)
PREPARED ST: to ftb l &
' ~
INSPECTION OF STEEL #I SUBSTRATE SEAL AND [/ / L [/- // // O/
FINISH C0AT APPLICATION : APPROVED Bv- ,
n --
AND REPAIR /- d ~
APPROVED BY: - '
OATE l
1.0 RerER nCES
- 0R NFORMK~01\ 0\!Y 1-A QI-QP-11.4-1, " Inspection of Steel Substrate Surface Preparation and Frimer Application and Repair" 1-8 CCP-30 " Coating Steel Substrates Inside Reactor Buildings and Radiation Areas" 1-C CCP-30A, " Coating Steel Stubstrates Inside Reactor Buildings and Radiation Areas"
.. . ;-r
, 1-0 CP-QP-18.0, " Inspection Reports" ~
~
2.0 CENERAL 1* '"
3.0 INSTRUCTION 'g _ .
3.1 ' SEAL COAT APPLICATION 3.1.1 pre-application Inspection '
The QC inspector shall verify the following:
a) Applicators are qualified per paragraph 3.2.
b) Primed surface is acceptable per pa ragraph 3.3.2 i
immediately prior to seal coat application.
l c) Air supply is acceptable per paragraph 3.3.3.
j
.l d) tilxing operations are acceptable per paragraph 3.3.4 '
e) Primer surface is visually examined in accordance with the following:
l 1
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n
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I:
i INSTRUCTION f REVISION ISSUE
" PAGE h TEXAS UTIUTIES GENERATING CO. ! 8 I
CPSES 1 i QI-QP-11.4-5 5 jNOV I 8 19 8 ; ;
2of12l
. ,I i
- 1. _ Runs / sags - A 0FT measurement shall be made with the Elcometer 0FT ~ gage. Runs / sags 5.5 mils or l less thick (DFT) which show no evidence of mudcracking (See NOTE) are acceptable. Refer to !
References B and 1-C for repair of runs / sags exceeding 5.5 mils.
NOTE: Mudcracking is defined as irregular '
cracking as in a dried mud puddle.
- 2. Dry Spray - tius t be removed by screening or abrading before overcoating. -
- 3. Overspray - Must be removed before overcoating.
4 Contamination Oil and arease - unacceptable t Embedded foreton materials - unacceptable
~l Stains are - rust- (red) and zinc oxide (white) stains acceptable provided . loose particles are removed prior to appifcation of finish coat.
, 5. Skips / holidays - unacceptable.
1 i
e Primer repairs shall be made per Reference 1-A except visual acceptance criteria shall be per above.
I f)- The inspector shall perform a DFT inspection of the cured primer film. A calibrated 0-25 Elcometer I
-Inspector 0FT gage Model III/IE, or equivalent, shall be used. A minimum of five separate spot treasurements t
(See Note 1) spaced evenly over the structure (See Note 2) shall be taken. Since the magnetic gage is i
sensitive to geometric discontinuities in the steel, ,
measurements less than 1 inch from the edge or a hole !
shall be avoided where possible. (See Note 3) e Ory Film Thickness shall be as follows:
i CZ-II spot test Min (mils) Max. (mils) t 1.5 5.5 i 06 spot test 1. 5 5.5 1
' 06 average DFT 2.0 5.0 CZ-II average DFT 2.0 4.5 .
i TUGC0 OA
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INSTRUCTION ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO.
CPSES 8 QI-QP-11.4-5 5 gNOV 1 S 19813l of 12 !
l l
l NOTE 1: A spot measurement is a series of three l measurements in the same general area. The probe should be moved a short distance for each gage reading. Discard any unusually high or low gage reading that cannot be repeated consisten tly. Take an average of these three ,
gage readings as one spot measurement.
NOTE 2: For small areas of coating, 5 separate spot '
measurements shall be ta ken. For larger areas, 5 spot measurements shall be taken for every 100 square feet of coating.
NOTE 3: Items with appreciable surface curvature and other geometrical discontinuities, such as handrails, gra tings , s ta irs , sway s tru ts ,
etc., shall be exempt from dry film thickness measurement. (See OCA 11421) r g) l Provide traceability to primer application records by
} recording "QP" Numbers (all Protective Coatings Unique Identification I Numbers) on Inspection Report (IR),
Attachment 1.
3.1.2 Seal Coat Application The QC inspector shall verify the seal coat is applied per paragraph 3.4 3.1.3 Visual inspection
- The QC inspector shall perfom a visual inspection of the
, seal coat in accordance with paragraph 3.5.1.
3.1.4 Seal Coat Cure i
The QC inspector shall monitor ambient curing conditions to l
assure curing is performed in accordance with Reference 1-8 and 1-C. .
I 3.1.5 _0ccumentation '
l l Results of inspections of seal coat application shall be documented on an Inspection Report (IR), Attachment 1, in l accordance with Reference 1-0.
i
,, TUGCCCA
INSTRUCTION ISSUE RWISION TEXAS UTILITIES GENERATING CO.
" ^ PAGE
.CPSES :
QI-QP-11.4-5 5 4 f12 NOV I 8 1981 l 3.2 QUALIFICATIONS l
The Inspector shall verify (by Qualification Record or list of qualification records in 0A File) that the coating g applicators on each shif t are qualified for safety-related coating work.
3.3 PRE-APPLICATION OPERATIONS i 3.3.1 d'bfent Conditions The Inspector shall determine substrate surface temperature, air temperature, relative humidity and dew point in the area j of the item to be coated. A calibrated non-mercury filled ;
I dry bulb thermometer or a calibrated temperature recorder i j shall be used for air temperature determination. A l 6
calibrated non-mercury filled wet bulb thermometer or a ;
calibrated humidity recorder shall be used to determine i relative humidity. The dew point shall be determined by the difference in dry and wet bulb temperatures using the U.S.
Department of Commerce Weather Bureau Psychrometric Tables, '
W. B. No. 235. The surface tempera ture thermometer (0mega-Amprobe-Fastemp, 10-250*F range o: ecuivalent) shall j
be placed in contact with th'e surface to be coated. The l thermometer probe shall remain in contact eith the substrate surface until the temperature reading stablizes.
The permissible range of surface and ambient temperature for application of finish coat shall be 50-120*F. .
f Maximum values of relative humidity shall be 85t.
I The surface temperature shall be a minimum of 5*F above '
the dew point. '
3.3.2 Coated Surface Acceotability The Inspector shall visually reinspect the previously coated '
surface just prior to finish coat application for evidence of l contamination (oil, grease, foreign matter) and stains. !
Contamination is unacceptable. All contamination must be l
1 removed per Reference 1-A or 1-8 prior to finish coating. 1 I
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, TUGCO CA
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INSTRUCTION ISSUE REVISION PAGE TEXAS UTluTIES GENERATING CO. DAM
( CMH Ql-QP-11.4-5 5 5of12l yny i s ;op l
I Rust (red) and zinc oxide (white) stains are acceptable !
.provided all loose particles have been removei (as evidenced i by existence of no stain on cloth) from the primer surface '
by approved cleaning operations. Carboline #33 is approved cleaner for carbo zinc primer. Phenoline Thinner or Xylol [
are approved cleaners for seal coat. Thinner wiping is not recommended for Dimetcoat primer.
3.3.3 Air Supply Acceotabilf tv The Inspector shall inspect the air supp1'y system (pressure pots and spray guns) for the existence of suitable filters /
traps / separators.
The effectiveness of these items shall be verified by placing l a clean piece of cheesecloth (or white fabric) over the exit i of the air lines and allowing air to flow for 30 seconds minimum. The cloth shall show no evidience of moisture, oil l or foreign matter when examined.
('
j
' 3.3.4 Mixinq Operations i
- 3.3.4.1 Ma terials The inspector shall verify that Phenoline 305 Finish Coat, Parts A (base) and B (catalyst) are used and their respective batch numbers are recorded. In addition, the ,
inspector shall verify that the shelf life (24 months) has not been exceeded. .
3.3.4.2 Mixing / Thinning The inspector shall witness each mixing / thinning operation and shall verify that it is in accordance with requirements !
of Reference 1-B and 1-C. Thinning may be done up to two !
quarts of Phenoline thinner per gallon of Phenoline 305. i Pot life shall be as shown on Attachment 1. l 3.4 SURVEILLANCE OF FINISH COAT APPLICATION The Inspector shall verify that hose length is less than l' 75 feet. If a brush technique is used, the inspector shall verify that a short bristle brush is used and rebrushing is avoided.
4
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t INSTRUCTION ISSUE NUM8ER M SION PAGE TEXAS UTILITIES GENERATING CO. DATE 7
CPSES ,
QI-QP-11.4-5 j 5 No" l *
- 4* 6 of 12 l
f.
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l l The inspector shall also verify that the seal coat (if present) is solvent wiped with Phenoline 305 thinner or ,
l Xyloi prior to finish coat application.
3.5 FINISH C0AT POST APPLICATION OPERATIONS 3.5.1 Visual Defects inspection .
The Inspector shall perform a visual inspection of the finish l '
coated substrate surface in accordance with the following:
a) Runs / sags - Runs or sags 4.5 mils or less thick (DFT) which show no evidence of mudcracking, are acceptable. Those :
greater than 4.5 mils thick shall be repaired in accordance with Reference 1-8 or 1-C. I
. I
, b) Skips / damaged areas / gross discontinuities such as ;
j holidays, voids, and bubbles are not acceptable. :
( c) pinholes - acceptable to the extent allowed by 1
Attachment 2. .
i d) Contamination - Embedded foreign naterials unacceptable. ,
i 3.5.2 Finish Coat Cure The Inspector shall monitor the ambient temperature and humidity after the finish coat is applied (including
! touch-up). A calibrated non-mercury filled wet / dry bulb thermometer, a calibrated temper &ture/ humidity recorder, or local weather station data may be used.
I The inspector shall verify that the finish coat has cured the time described in References 1-B and 1-C before performing dry film thickness determination and continuity !
checks, and final acceptance, i I
3.5.3 Ory Film Thickness (OFT) l l The Inspector shall perfonn a DFT of the cured coating system. A calibrated 0-25 E1cometer Inspector DFT Gage l Model !!!/1E, or equivalent, shall be used. A minimum of !
l five separate spot measurements (See Note 1) spaced evenly -
over the structure (See Note 2) shall be taken. Since the magnetic gage is sensitive to geometric discontinuities in ,
I
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INSTRUCTION ISSUE REVISION PAGE TEXAS UTIUTIES GENERATING CO. ' ^
CPSES i i
- QI-QP-11.4-5 l
5
, gi3 Q i
7 of 12 the steel, measurements less that 1 inch from the edge or a hole shall be avoided where possible.
j The average DFT of the finish coat will be determined by subtracting the average DFT of the primer coat from the average DFT of the total coatino system in the same area.
The average DFT of the total coating system shall be a minimum of 7.0 mfis and a maximum of 11.0 mils. The spot test 0FT of the total coating system shall be a minimum of
- j. 7.0 mils and a maximum of 11.5 mils. .
NOTE 1: A spot measurement is a series of three measure- J ments in the same general area. The probe should '
be moved a short distance for each gage reading.
Discard - any unusually high or low ga tha t cannot be repeated consistently.ge reading Take an l average of these three gage readings as one spot j measurement.
I i NOTE 2: For small areas of coating, 5 separate spot i
measurements shall be taken. For larger areas, 5 spot measurements shall be taken for every 100 i' square feet of coating.
I t NOTE 3: Items with appreciable surface curvature and other geometrical discontinuities such as handrafis, gratings, stairs, sway struts, etc. shall be exempt '
from DFT measurement (See DCA 11421). j 3.5.4 Continuity inspection - i i.
The Inspector shall test the continuity of the cured finish coat using a Tinker and Rasor Model M1 (67.5 volt) holiday detector. 100% of the finish coated surface area shall be tested. j The applied film should contain only a minor number of points of discontinuity. No more than two points of discontinuity should occur within an area having a radius of 6 inches as measured from a point of discontinuity (pinholes). No more than 40% of the total number of '
I allowable points of discontinuity should occur within any one area equal to 25% of the total area being coated. The ;
total number of pinhole discontinuities allowed is defined in Attachment 2. No gross discontinuities are allowed.
I
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F INSTRUCTION l ISSUE I NUM8ER REVISION AGE TEXAS UTILITIES GENERATING CO. I I. DATE
/ CPSES ' " ~ '
j ,
t QI-QP-11.4-5 , 5 i c of 12l; I i Nov I S 19811 i
l 3.6 00CUf4ENTATION Results of inspections described in Sections 3.2, 3.3, 3.4 and 3.5 shall be documented on an inspection report (IR),
Attachment 1, in accordance with Reference 1-0. The <
completed IR shall be forwarded to the PPRV for retention.
3.7 REPAIRS 3.7.1 Reoairs of Runs and Sags ;,
I The QC inspector shall verify that the area is abraded until l'
l the DFT of Phenoline 305 is within 1.9 - 4.5 mils, and examined for cracks. I I
The presence or absence of cracks shall dictate the type of repair required per Reference 1-8 or 1-C.
j ; 3.7.2 Repair of f-tinor Defects
(
l -
The QC inspector shall perform the following inspection when ,
repairing minor defects (as defined bi Reference 1-B or 1-C.): (
- a) Verify that the damaged i
j any exposed steel is gro,und area perisReference blasted or1-B abraded or 1-C.and i
j b) Verify damaged area is solvent wiped in accordance with Reference 1-8 or 1-C.
I c) '
Perform inspections described in 3. 3.1, 3. 3.2, 3. 3. 3, l
t i 3.3.4, 3.4 and 3.5. l i
3.7.3 Repair of fiajor Defects !
I l The QC inspector shall verify the following for repair of major defects (as defined by Reference 1-B or 1-C): ,
a) Verify area is abraded or spot blasted per Reference j 1-8 or 1-C.
b) Verify applicator qualification per Section 3.2.
! I l 3 c) Verify ambient conditions per Section 3.3.1.
I l
d) Verify air supply acceptability per Section 3.3.3.
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INSTRUCTION
- ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO. ^ I i-CPSES 6 i i 5
QI-QP-11.4-5 l lNcv I S 1981 ; 9of12l 6 f i -
1 l i
, e) Verify mixing operations per Section 3.3.4 f) Verify primer application per Reference 1-A, 1-B or 1-C. i g) Visually inspect primer per Section 3.1.1 (e).
h) Verify primer cure per Reference 1-A.
j i) Perfom DFT measurement in accordance with Section 3.1.1 (f).
I j) Perfom inspections described in 3.7.2 (c).
3.7.4 f
Repair of Embedded Foreton Particles !
l' - The Oc inspector shall veri fy tha t embedded foreign l particles are removed and recoated per Section 3.7.5. ;
l
( ; 3.7.5 Repair of Pinholes and Discontinuities and/or Overcoatinq a) Verify all loose particles are' removed and area is
!' solvent wiped, b) Perfom inspections described in 3.7.2 (c).
3.7.6 Documentation of Renairs I
All repairs shall be documented on an Inspection Report, i
' Attachment 1. Repairs involving ~ appifcation of primer will be documented on Attachment 1. Reference 1-A.
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REVISION ISSUE TEXAS UTILITIES GENERATING CO. NUMBER I CATE PAGE i
CPSES j
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OI-QP-11.4-5 1 ,
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- 7 10 of 12 l
ATTACHttENT 1 i I
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, l COM AN CHE sta st!Au ELE TRic s?A tCN g ,
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t INSPECT!CN REPCRT y
.rtw usu.n.c3 ; ;4.4 r w c= w g es:Lw , sr%c r.n .u a :.c.s f PPOTECTIVE '.0Aff NGS r =
msa .n, i u u :.c. e n , e ;,4 m so A5 31 ,l ,1 O!-CP-11.4-5 Rev. .
g e v a e4 rur c; . ;1;.: *+
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I i ORIGINAL E7A!R l I i i
- 1. I Perforce CFT of Prince Coat cer Pars. 3.1.1.F l i ' I !
t REC 090: itinimum Scot Test: ) i . l t i Maximum Scot Test: i I I I '
Average DFT:
- l l ; I
) 2. Record all Protective Ceatings Untos f.D. flo.'s: l l l t 1 l i f f '
I f I t ' i , l I
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- 3. l I Aretent conditions chectes :er Par.t. 3.3.1 Drior to i r i I l coating acoltcation and record below: 1 l . l l CATE: TIME: WET acL5 TEMP: I 1 ! t
, I CRY BUL8 TD*P! RELATIVE MLN!DITf: I ' I i e DEW POINT: $UEFACE TEMP:
- 1 i
- 4. 1 Perform Visual foscectier, of erevf otah coatet I i !
I I surface eer port. 1 1.2 or sie3, t 1,( l e i l i S. ! Ve H 'y e '
tur ne eranentien netectele ee cro.?0 ea ?or ! ' 8 : I
- 6. I Verify air suco1v seceota3fe eer 8see. 1.3.3. I I I l I ,
- 7. I Verify mining ocerations are per CCP-30 or 30A and I i i
- i !
l Paragraon J.J.4 p l 3 i , !
- 8. I Coatino material creduct identif f eatien I i l l i I RECORD 9ATCH 'ru"9E85: I ' I I ,
1 PART At l l l ' '
j i
i PART 8: l l t 1 6 I
l THfNNEe* l l I 1
- 4 .
l T!NE MIXED: l l l . I i
- 9. l Verify that SPelf life of coattaa enterials has not l
! ' I : e l espired. '
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. 10. I Verify that cot If fs is not esceeded. I i ! ,
(Continued as Nest Sheet...)
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! INSTRUCTION { ISSUE NUM8ER REVISION PAGE '
TEXAS UTILITIES GENERATING CO. i t
i DATE CPSES l
' I
! OI-QP-ll.4-5 5 11 of 12 '
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ATTACHMENT 1 (Continued) i I
, Q1 0P 11.4-5, rev. l Sheet 2 of 2 consancwt 711.4 $?!Na OJ:**c $?a?cre INS 9tCilCN RUCRT
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vertrv mialt'feitton of aesticator ner Para. 3. 2.
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- 12. 4 vertfy hose tenetsi is less tnan 75 feet. '
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11 i Perf0 m visu4I tRsraetten Of c33teql gurface cer # 6 i Para. 3.6.1. 3 l l
. . . 6 11 8 Ve ri fy curtmo is ese CCD.20 ae PCP.PA and Dut. 1.6.2.
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- 16. O Per'Orin CCntinuity insDeCt1Ce I f tfit$n Coa t only) Cer e a i Para. 3.9.4.
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N l DATE N j
./ I CPSES i t
l )0!-QP-!!M-5 5 NOV 13 198' t 12 of 12
, i e, ! ,
t ATTACliffEtlT 2 I
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TOTAL NUttBER OF ALLOWAllLE POINr5 0F DISC 0tlTIPilllTY l l l 5 I '
. ! SURFACE AREA C0tl0. "C"
, BEING C0ATED C052fERC I Al.LY I t
4 (50. FT.) C0' lit tlV0US ! .
i i 10 5 I
l, 10-50 to i s 50-100 20
, 1 100-500 30 ;
I
'( 500-1000 50 .
1000-5000 -
75-i
, Gross Discontinuities - flone allowed.
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