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) | |
Text
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INSTRUCTION REVISION PAGE NUMBER ES GENERATING CO.
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-l TEXAS UTILIT]CPSES
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26 l *f 27
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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:
I 1.
Verifying that water separators are installed in l
the air supply system anti that separators have 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 l
paper or cloth to the blast of air (no sand) for 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.
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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 i
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 without limit) in the CARDE85-59 PDR profile of the previously prepared substrate.
TUGCO CA
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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 f
discolorations caused by rust stains, mill scale, l
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 i
all residues, and the remainder shall be limited l
to light distalorations as mentioned above.
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4 INSTRUCTION ISSUE REVISION NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.
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.
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The anchor pattern depth for a blasted surface 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 l
DATE TEXAS UTILITIES GENERATING CO.
QI-QP-11.4-5 24 to of 27 l
OCT 101983 i
03 TORT!ATON OLV l
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
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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.
l d)
Perfonn a visual inspection of the primed surface in
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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
abrading before overcoating.
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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.
l e)
The inspector shall perfom a 0FT inspection of the cured primer film. A calibrated 0-25 Elcometer
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l INSTRUCTION ISSUE REVISION PAGE i
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TEXAS UTILITIES GENERATING CO.
I CPSES i
01 -Q P-11.4-5 22 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
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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, l
etc., shall be exempt from dry film thickness measurement per Reference 1-B and 1-C.
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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
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TEXAS UTILITIES GENERATING CO.
i CPSES i
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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
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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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INSTRUCTION l' '
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ISSUE l REVISION OATE PAGE N
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TEXAS UTIUTIES GENERATING CO.
g CPSES 22 QI-QP-11 4-5 EP 2 31C0 l 9 f 27 i
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h) 1.
Coating Materials Identification I
The inspector shall inspect the coating material
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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
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Carboline #15 thi'nner Cartoline 191 catalyst 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.
1 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.
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SES lSEP 2 3198313 f 27 i lQI-Q P-11.4-5 22 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 are approved cleaners for seal coat. Thinner wiping is not 5
I 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
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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
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. are perfonned in accordance with References 1-8 and 1-C.
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Thinning may be done up to two quarts of Phenoline Thinner per gallon of Phenoline 305.
j 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
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d)
Contamination - Embedded foreign materials unacceptable.
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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ISSUE REVISION 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
NOTE 3:
Items with appreciable surface curvature and other geometrical di scontinui ties such as handrails, gratings, stairs, sway struts, etc. shall be exempt from DFT measurement (See DCA 11421).
NOTE 4:
In the event that any spot is found to be outside 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.
TUGCO CA
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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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l INSTRUCTION ISSUE NUMBER RNSION PAGE DATE TEXA5 UTI'_ITIES GENERATING CO.
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.
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l c)
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
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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 - rust (red) and zinc oxide (white) stains i
are acceptable provided loose particles are removed prior to application of finish coat.
i l
S.
Skips / damaged areas / gross discontinuities such as 3
holidays or voids - unacceptable.
I e)
The inspector shall perfom a 0FT inspection of the
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i cured primer film. A calibrated 0-25 E1cometer i'
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INSTRUCTION ISSUE RNSION NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.
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:
l 1
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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
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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 l
magnetic gage is sensitive to geometric discontinuities in the steel, measurements less than 1 incn from an edge or a hole shall be avoided where possible.
f TUGCO CA
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' INSTRUCTCN ISSUE
~ T#~AS UT1JTIES GENERATING CO.
NUMBER REVISICN CATE PAGE CPSES I
i QI-QP-11.4-5 18 1 f 24 AUG 10 1983 PREPARED BY:/ fy[ d c / /J 4
INSPECTION OF STEEL j
f Op TE REPAIR AND SEAL AND lAPPROVEDBY: /J g, /
SUBSTRATE PRIMER
/
oA.-
57d.5 FINISH C0AT APPLICATION '
I AND REPAIR
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APPROVED BY:
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DATE
1.0 REFERENCES
1-A QI-QP-11.4-1,
" Inspection of Steel Subs tra te Su rf ace i
Preparation and Primer Application ano Repair" i
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
l and Radiation Areas" i
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" (us k#
[&t Y'h b5!
g 1-F CP-QP-lS.0, " Tagging Sys tem"
g.
Dg.,?, f'<V'.
l t
s 'o 2.0 GENERAL U
i g 5 %.i,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
~
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.
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, 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:
)
%g, TUGCC CA
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 - rust (red) and zinc oxide (white) stains
~
are acceptable provicea loose particles are l
removed prior to application of finish coat.
l
,. p 5.
,~
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Skips / damaged areas / gross discontinuities such as l
holidays or voids - unacceptable.
I N"A l
e)
The inspector shall perfonn a 0FT inspection of the 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 l
shall be avoided where possible.
(See Note 3) 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 Tuoco o4
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i i
i INSTRUCTION ISSUG REVISION PAGE i - TEXAS UTILITIES GENERATING CO.
l14of24 l
QI-QP-11.4-5 20 i
t 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 measurements shall be taken.
For larger areas, i
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 I'
one area equal to 25t of the total area being coated. The 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
~
Results of inspections described in Sections 3.6 shall be documented on an Inspection Report (IR). Attacnment 4, in TUGCO CA
t INSTRUCTION ISSUE RESION NUMBER DATE GE TEXAS UTILITIES GENERATING CO.
I i
Ql-QP-11.4-5 l
! AUG 18 i983l / of 24 l
j 20 l
l l
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 TUGCO CA coen reo e
{
I INSTRUCTION ISSUE SiON AGE NUMBER DATE TEXAS UTIUTIES GENERATING CO.
QI-QP-11.4-5 20 3 of 24 ggg 7 g igg 3 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.
}
c)
Verify the primer has cured required amount of time per
'I
?d Reference 1-B or 1-C, as applicible.
d)
Perfom a visual inspection of the primed surface in
~f27 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
Oil and arease - unacceptable 3
Embedded foreign materials - unacceptable l
Stains - rust (red) and zinc oxide (white) stains i
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
.. GO 1
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TUGCO CA
,~?'
TEXAS UBUDES GENERADNG CO.
. REVISION O
PAGE CPSES
.QI.0P.11.4 5 h 4, 3 aca,
1 of 24 17 PREPARED SY:
4
/
f/f3 fN APPROVED BY:
I P
N FINISH C0AT APPLICATION '
E g 4 'f J
//
i AND REPAIR i
APPROVED BY:
'/ z' _
DATE
.. m
_h
'5 h
1.0 REFERENC ES
' C. ' ' ',<
u C aus 2mm 489pection - bf' Ste61,~ i 1.A QI.QP.11.4 1, 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 inspect on of i
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 f
k l
^
- eue Ms 4 l
l i
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 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 V0ID dollies should tes t below the minimum acceptable strength, the prime coat shall be 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.
I
-maco ce
I l
l i
INSTRUCTION REVISION pAGE NUMBER TEXAS UM ?'ES GENERATING CO.
!.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 01%
References 1.B and 1.C for repair of runs / sags A
exceeding 5.5 mils.
9'g NOTE:
Mudcracking is defined as irregula r cracking as in a dried mud puddle.
2.
Dry Spray.
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 holidays or voids. unacceptable.
i 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
(.
fh-
--XAS UtutES GENERAUNG CC.
U E.q m:SICN
? 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 4FD"CVED 3Y:
//
M 1 '/ 7 l FINISH COAT APPLICATION
'd WE g[g ff AND REPAIR
/
l r
3g t
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 #' I* E O f "
h
(: D.
t
,s.
F.
g 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.
r:
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.
- saco c4
m
(
i
, INSTRUCTION i
ISSUE I-TEXAS UTILITIES GENERATING CO. !
NUMBER l REVISION OATE PAGE l
' 8 jQI-QP-11.4-5 11 iMAR 01 1983 [2 of 24 i
i i
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 tem " Equipment" is not to include pipe hangers, cable j
tray hangers, conduit supports, or structural steel.
They will all have Protective Coating unique identification numbers assigned.
l b)
For all prime coated items which do not exhibit a i
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 entire item.
t Prime coated items which are acceptable shall be l
stamped with a "QP" number by Construction.
The QC l
Inspector shall maintain a protective coatings unique i
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.
aco oA
=,
o r
INSTRUCTION b
REVISICN DAGE TEXAS UTILITIES GENEPATING CO CPSES Ql-0P-11.4-5 13
.,iAR 01.E
- 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 Contamination i
Oil and arease - unacceptable Embedded foreton materials - unacceptable Stains - rust (red) and zinc oxide (white) stains are 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 Inspector DFT gage Model !!!/IE, or equivalent, shall i
i 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, i
measurements less than 1 inch from the edge or a hole j
shall be avoided where possible.
(See Note 3) h
=
t t
l INSTRUCTION REVISION ISSUE NUMSER DATE PAGE TEXAS UTluTIES GENERATING CO i
cmES Ql-QP-11.4-5 13 MAR 01 1% '
4 of 24 :
I 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 l
CZ-II average DFT 2.0 4.5 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. Olscard any unusually high
,l
'or low gage reading that cannot be repeated i
consistently. Take an average of these three 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
I measurement per Reference 1-8 and 1-C.
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.
l ruoco o.
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h i
INSTRUCTION ISSUE i
ESION PAGE NUM8ER DATE TEXAS UTILITIES GENERATING CO.
QI-QP-11.4-5l 13
, MAR 01 !$dj, 5 of 24
{
t 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.
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 The surface temperature shall be a minimum of 5' above l
t l
the dew point.
l I
i TUGCO OA
..m
I INSTRUCTION I
l REVISION O
PAGE NUMBER TEXAS UTILITIES GENERATING CO.
s CPSES lQI-QP-11.4-5 13 MAR 01 1983 6 of 24 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 final surface inspection.
The adjacent areas shall be i
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.
" 0"
l e
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TEXAS UTluTIES GENERATING CO.
l CPSES l MAR 01 19837 Of 24 al-QP-11.4-5 13 6
l f
,i 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.
l Anchor Pattern Oepth -- The anchor pattern depth l
of the blasted surface shall be inspected at random locations using a Keane-Tator Surface Profile i
Camparator (model 373) or equivalent. A power 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.
mocooA
l i
INS ON REVISION PAOI O
)
TaxAS UTiuTIES GENERATING CO.
l
{
QI-QP-11.4-5 13 MAR 01 !%
8 of 24 l
l l
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 is identified by batch number and that the shelf i
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
.f Reference 1-A and 1-B.
l
\\
i 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 Paint Mixing Slip, Attachment 5.
The inspector g
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.
NI
l
~
l I
t
}
INS C ON REVISION PAGE i
TEXA8 UTILITIES GENEMA"'NG CO.
]!-QP-11.4-5 13 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 by approved cleaning operations. phenoline Thinner or Xylol I
l are approved cleaners for seal coat. Thinner wiping is not l
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
1
(
INS]U ON REVISICN PAGE TEXA8 UTILITIES GENERATING CO.
i QI-QP-11.4-5 13 12 of 24 MAR 01 @
\\
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.
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
N CA pem sem i
(
71xAs urtuttES caNERAriNo Co.
WSgegyN hg N
nE'/ISICN anoE CP583 QI-QP-11.4-5 12 Sp g toog 1 of 22 l
3953aRE SY:
w$/d//L
> led?ce **e i f Para. 3.5.I. i t 3 53
- yeet ry euesne es e.
to.?* 3-ct?.3na,a1 Diet. ?.9 ?. s i e 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 10. der'Crw Lutat o riu s ty i. ;09. L.On e i t n tin C0a t Cn i v e Lee t 4 e otra. 3.5.4 I i i j t i I t e I 4 l l g e 4 ) I l l I e 4 i ADAM $t c:was,snes,stcJ 1-e i ,I t e MM 'GA '* s LN. Casc ,I ' C'*^ .s l i oc =sn..* 9 . p.,,,, g, TUGCO OA t"T i i INSTRUCTION l REVISION ISSUE i PAGE TEXAS UTILITIES GENERATING CO. NUMBER DATE I i CPSES l 5 i -/ .W; '01-0P-11.4-5 5 DEC 2 i 15 of 17 l I ATTACHME'tlT 2 i I TOTAL NUMBER OF ALLOWASLE POI'ITS OF DISCONTItJUITY l SURFACE AREA COND. "C" BEING C0ATED C0tWERCIALLY (50. FT.) CONTINUGUS l 10 5 10-50 10 50-100 20 i 100-500 30 l 500-1000 50 ( 1000-5000 5 l 75 I Gross Discontinuities - None Allowed. l I i ,i l i t l 4 TUGCO CA INSTRUCTION ISSUE
- D 1 TEXAS UTILITIES GENERATING CO.
N ER DATE PAGE CPSES i QI-QP-ll.4-5 l 6 'DEC 2 1S81 ' 16 of 17 I ATTACHMENT 3 I ccuAncME PEAK STEAM 0 !:T*IC STATT N 1 2 w e-lhSPECTICN. REPCRT y .rgw 3Ni s er :,TIVE COATI *;35 .!s es tw s w :.u. at a.: e. cm r. m a w . ROI e ysc.sc. .ac. 3au u ::c. e acw a c.,.nu so reous ei y s ;..e st.: w AS-31 .l ,1 QI-QP-11.4-5. Rev._ J C %s7tE*:' U',I*7de'}fW'*" CiTsisYEc3 C %m. C ~'.'8-5 JESP. AssA!: C 'espec cm ::vai.stro. c Wat irtws sars/act:n i O asst:me= ::w zets..as2r:si.: :n-asvs : sets ic :. f .!= l .) PRIMER REPA!RS ,/. ! *. 3! : INSPECT:cN A77154*!$ 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 i RECCRO: titntrutt Scot Test: 1 I i i g 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 a. 6Aie suaal. feem of eantam nt tan I - 1 I j 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. Surface free of foreien matter incl. crease 1 oil. 8 f b 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 f - 7. I Aneient conditions enecked ee-Dira. 3.3.2 orter to e i i i lorimer aeolicatien and record belew: CATE: 6
- I I
i j ITIME: WCT BULS TE.MP.: CRY BULS TETtP.* i ! l f IRELATIVE HUMIDITY: DEW POINT: SURF.TE!*P : 1 i i i f l l 8. 15ubstrate surface free of contaatinants and less t'ian i 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 ? l l 1 i i i (Continued on Sheet 2..) i i i l i
- Pennmeg, TUGCO OA 2
-_. - ~ I .i I l INSTRUCTION. ISSUE NWBR DATE N-b TEXAS UTILITIES GENERATING CO.., CPSES f .,QI-CP-il.4-5 6 l 2 SU I7 Of I7 t 5 ATTACH'Erii 3 (Continued', t f Q!-CP-11.4-5. Dev. l Sheet 2 of 2 l 'CCMACE*Em I?!Au 0 !:~me 5 a?:cra INSPECTICt1 R E?CF'T Isup*.! w s?:u l ..l ! c9 gm :,d, i ,rw g g INSFEC*iC;; 2;;argy g3 .::r i i 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: f' a. Shel' te M t E<e**ead l I 14 p re s si;ea nt sa t3**c. 6 'l 15. Pot I t f a not a ersatao. i l j 16. I 5asa imit tain '5 w. i i l 11. .r i,. visnel i ns-me
- i en -
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 f_ O ry f i l e' inickness 20. eh s: I Minieurt Sect Peasur**ent l + 'l t n ,4~ e--e ......_.e...at ie i t 8 Avertee CFT: j i i l l } } RDAA* 3 : (: cs.sM:3 trc 3 t I I s t l I i I 'l i l t 6 4 WE i simaus j l g,a g;,, g g 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 {QI-QP-11.4-5 5 NOV 1 o !$61-1 of 12 l PREPARED ST: bwob) to ftb l & INSPECTION OF STEEL [/ [/- ~
- I SUBSTRATE SEAL AND
// // O/ FINISH C0AT APPLICATION : APPROVED Bv- / L AND REPAIR /- d n -- ~ 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 immediately prior to seal coat application. i 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: 1 i TL'GCC CA n ( 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 l the Elcometer 0FT ~ gage. Runs / sags 5.5 mils or 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 - rust- (red) and zinc oxide (white) stains are acceptable provided. loose particles are removed prior to appifcation of finish coat. 5. Skips / holidays - unacceptable. 1 i Primer repairs shall be made per Reference 1-A except visual acceptance criteria shall be per above. e f)- The I 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: Min (mils) Max. (mils) t i CZ-II spot test 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 r I f k. INSTRUCTION ISSUE REVISION PAGE TEXAS UTILITIES GENERATING CO. CPSES 8 NOV 1 S 1981 l3 of 12 ! QI-QP-11.4-5 5 g 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) Provide traceability to primer application records by l recording (all Protective Coatings Unique Identification } Numbers "QP" Numbers) on Inspection Report (IR), I. 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 The QC inspector shall monitor ambient curing conditions to i assure curing is performed in accordance with Reference 1-8 l 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 PAGE TEXAS UTILITIES GENERATING CO. ^ .CPSES QI-QP-11.4-5 5 NOV I 8 1981 l 4 f12 l 3.2 QUALIFICATIONS 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 removed per Reference 1-A or 1-8 prior to finish coating. 1 I TUGCO CA T 4 ( ~ INSTRUCTION REVISION ISSUE TEXAS UTluTIES GENERATING CO. DAM PAGE ( 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 ( TUGCC oA p-t INSTRUCTION M SION ISSUE NUM8ER DATE PAGE TEXAS UTILITIES GENERATING CO. 7 CPSES l QI-QP-11.4-5 j 5 No" l *
- 4*
6 of 12 f. 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. 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 ) ruoco c4 r I l.> } INSTRUCTION ISSUE REVISION PAGE ^ TEXAS UTIUTIES GENERATING CO. CPSES i i QI-QP-11.4-5 l 5 , gi3 Q 7 of 12 i 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 l Take an average of these three gage readings as one spot j measurement. NOTE 2: For small areas of coating, 5 separate spot I i measurements shall be taken. For larger areas, i 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 allowable points of discontinuity should occur within any I 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 T1JGCO CA F INSTRUCTION l ISSUE I REVISION NUM8ER I I. DATE AGE TEXAS UTILITIES GENERATING CO. / CPSES ' " ~ ' QI-QP-11.4-5 j t 5 i I i Nov I S 19811 c of 12l 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 j any exposed steel is gro, area is blasted or abraded and i und per Reference 1-B or 1-C. 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 i 3.3.4, 3.4 and 3.5. l t 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 c) Verify ambient conditions per Section 3.3.1. 3 I d) Verify air supply acceptability per Section 3.3.3. l l Tuoco oA i ~ r-l 5 l l INSTRUCTION REVISION ISSUE PAGE TEXAS UTILITIES GENERATING CO. ^ I i-CPSES 6 i i QI-QP-11.4-5 l lNcv I S 1981 ; 9of12l 5 f 6 i 1 l i e) Verify mixing operations per Section 3.3.4 f) Verify primer application per Reference 1-A, 1-B or i 1-C. 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). f 3.7.4 Repair of Embedded Foreton Particles l' - l The Oc inspector shall veri fy tha t embedded foreign 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 I Documentation of Renairs All repairs shall be documented on an Inspection Report, i. Repairs involving ~ appifcation of primer will be documented on Attachment 1. Reference 1-A. I i i i I I l 1 l I e tuoco oA r I f i. INSTRUCTION REVISION ISSUE CATE PAGE TEXAS UTILITIES GENERATING CO. NUMBER I i CPSES j / OI-QP-11.4-5 1 5 gy 1
- 7 10 of 12 l
ATTACHttENT 1 i I ) l COM AN CHE sta st!Au ELE TRic s?A tCN i 3-n* g INSPECT!CN REPCRT e t y .rtw usu.n.c3
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PPOTECTIVE '.0Aff NGS r = msa .n, i u u
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- 1;.
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A5 31 ,l ,1 O!-CP-11.4-5 Rev. e O n",,, W y, P,[.yc'fty,,":a C.ihdIN CF2ee re. CP,ey, Tsas. euues O.wcenc= ce airco..u. - ue2.cc irews sar u.cre, { j C mset:-cm c mat 4*ts, osar:snc?:sc i*tus ws73 scu:w
- 8 IrEw 4o l
INSPTC?:CN AT*Aleu!IS /
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i ,4 / si $EAI, CCAT Figf5H COAT ! i 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 f I i l I t ' I I i
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i i l e l 3. 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 l l T!NE MIXED: 4 l l I i l 9. l Verify that SPelf life of coattaa enterials has not ! ' I e l espired. l I i ^ 10. I Verify that cot If fs is not esceeded. I i ! (Continued as Nest Sheet...) pe,m No. t CO CA p-- j r l P INSTRUCTION { ISSUE TEXAS UTILITIES GENERATING CO. NUM8ER REVISION PAGE DATE i l i t CPSES I OI-QP-ll.4-5 5 g 13,qn' 11 of 12 ' 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 _ twen"2avn?10 I '",e' INSMCTICN Afteiguitt 3 I .,. e. E 11. vertrv mialt'feitton of aesticator ner Para. 3. 2. i t ts t A ot teatres - r i i e i g e e i .i I j .. i e e t-
- 12. 4 vertfy hose tenetsi is less tnan 75 feet.
i e e 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. 6 8 e is ' p.ef m CFf op ecated surface (Fentia feat eniv) as r oer Para. 3.5. 3. i ( 6 caatene tvt.. eea. tet e we n t -,.. i i i l Coattne Sys'ea teet fest P'trtw a e i I t Avertee DFT r;t*1ee systemt I I e
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,,l t.m c' *sts 'same.se ,l 1 ,,,t,, %g, TUOCO OA e i + t l. i 1 l-INSTRUCTION l l ISSUE l TEXAS UTILITIES GENERATING CO. l DATE N 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 [ 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 (50. FT.) C0' lit tlV0US 4 i i 10 I 5 l 10-50 to i s 50-100 20 100-500 30 1 I' '( 500-1000 50 1000-5000 75-i Gross Discontinuities - flone allowed. I-j. 1 f I s I, t { i l I i I p.,,,,,, TUGCO CA ,., y y. . ).. - _q . -+. <,,.,.,.,. .. 3.j& : v. 1 . l 7 - - e- -, 3 - _ _ 7 ~ CPSGS T4L W h .) i
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