ML20138N700

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Revs 0-5 to Instruction QI-QP-11.4-26, Insp of Steel Substrate Surface Preparation,Primer Application,Primer Repair,Seal & Finish Coat Application & Repair
ML20138N700
Person / Time
Site: Comanche Peak, 05000000
Issue date: 05/04/1984
From:
TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
ML20138M609 List: ... further results
References
FOIA-85-59 QI-QP-11.4-26, NUDOCS 8511050326
Download: ML20138N700 (200)
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Text

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REVISICN PAGE TEXAS UTluT!ES GENERATING CO. h8ER CPSES  ;

QI-QP-11.4-26 5 i f 35 0 4 gg,g I INSPECTION OF STEEL PREPARED BY: b SUBSTRATE SURFACE CATE  :

PREPARATION, PRIMER APPLICATION, PRIMER APPROVED BY: .__

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REPAIR, SEAL AND CATE FINISH COAT APPLICATION AND REPAIR APPROVED

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  • g$ Ta 1.0 Q$D.ih5)$$Q. U GL' GENERAL 1.1 PURPOSE AND SCOPE l

I The pu nose of this instruction is to outline methods utilized by Quality Control personnel in inspection of steel substrate surface preparation, primer application, primer repair, seal and finish coat application and repair for Unit 1 Reactor Building.

2.0 INSTRUCTION Visual inspection of su rfaces as addressed by this instruction shall be mede at approximately 30" in distance or an anns length from the surface being inspected. The area of inspection shall be adequately lighted during the inspection activity. is defined as the I mininun light produced Adequate by a lighting two (2) 0-cell battery flashlight.

Visual aids fabricated on site and approved by Quality Assurance and Engineering may be used by Inspectors as an ,

aid in the perfonnance of their inspections.

For definitions, refer to Attachmenc 7.

If a conflict arises between the requirenents of this procedure and the requirements of the site specification, the requirenents of the site specification shall prevail.

2.1 PRE-BLAST CLEANING OPERATIONS

' 2.1.1 Abrasive Acceptability The Inspector shall obtain a sample of the abrasive to be used fram each work area. The abrasive shall be verified to be dry by feel wi th no grease, oil and deleterious material . Verify that proper blast abrasive is used 8511050326 851016 PDR FOIA GARDE 85-59 PDR TUGCC CA hous res, a I

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I CTION REVISION ISSUE PAGE CAM TEXAS UTILITIES GENER TING CO.

CPSES QI-QP-11.4-26 5 35 MAY 0 41984 2.1.2 Blast Equipment Acceptability .

The inspector shall perfonn the following inspections / tests to detemine acceptability of blast cleaning equipment prior to use:

a. Air supply (refer to Attachment 18).
b. Ambient conditions (reference Attachment 1A and 6).

2.1.3 Solvent cleanino (If contamination Is Present)

If oil, grease, or other contamination is present, verify that, solvent cleaning is perfomed and that contamination is removed prior to blast / power tool cleaning steel surfaces.

2.2 POST SURFACE PREPARATION OPERATION 2.2.1 Blast Cleanup The inspector shall visually check the blasted substrate su rface.

The surface shall be air blasted or solvent wiped to the extent required for final surface inspection. The adjacent areas shall be cleaned to the extent necessary to avoid -

contamination during subsequent coating applications.

1 2.2.2 Blasted or Power Tooled Surface Acceptability The inspector shall perfonn the following inspections to detennine acceptability of the blast cleaned or power tooled surface:

. a. Absence of Foreign Matter -- A vi sual inspection shall be perfomed to detennine that all oil and grease, di rt, millscale, rus t, corrosion products, oxides, paint or other foreign matter have been completely renoved fran the su rface except for light shadows, very slight streaks or slight discolorations caused by rust stains, mill scale ,

oxides, or slight, tight residues of paint or coating that may renain. At least 95 percent of each square inch of surface area shall be free of all residues, and the renainder shall be limi ted to light discolorations as mentioned above.

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I INSTRUCTION REVISION ISSUE PAGE ER DATE TEXAS UTILITIES GENERATING CO.

CPSES QI-QP-11.4-26 5 g 0 4 $84 3 of 35 NOTE: For power tooled surfaces, in addition to the 5 l percent of tight residue of paint or coating which is pennissible, shadows or tightly adhering residues of primer may remain (without limit) in the profile of the previously prepared substrate.

However, areas with residues of Carboline 191 primer shall be recoated with Carboline 191 primer.

Areas with residues of inorganic zinc may be coated with either inorganic zinc or Carboline 191 primer. .

b. Shan Projections -- An inspection for shan projections that were not rounded during blast cleaning or power tooling shall be perfonned. Sharp projections are unacceptable and shall be ground to a rounded contour.

Weld spatter on structural steel which remains after power tooling and/or sand blasting will be acceptable. l

c. Anchor Pattern Depth -- The anchor pattern depth of s

surfaces shall be inspected at random locations as necessary using a Keane-Tator Surface Profile Comparator (model 373) or approved equal.

The anchor pattern depth for all surfaces shall be a mininun of 1.0 mils. .

Surfaces that have been power tooled with "3M Clean-N-Strip", 60 grit and coarser " flapper wheels", provide acceptable surface profile, when properly used over a previously blasted and coated surfaces.

For power tooled steel surfaces, the 1 mil minimum profile shall be verified by visual comparison to a standard of known profile or other approved methods.

2.3 PRIER PRE-APPLICATION INSPECTIONS 2.3.1 Anbient Conditions The inspector at the " paint distribution point" in Reactor i shall verify ambient conditions in accordance with Attachment 1-A.

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INSTRUCTION ISSUE SER ED DATE N TEXAS UTluTIES GENERATING CO.

CPSES QI-QP-11.4-26 5 g 4 of 35 2.3.1.1 Documentation of Enviromental Conditions

a. The inspector assigned to the " paint distribution po int" in the Reactor building shall, as a minimum, take a complete set of readings (air tempera ture, relative humidity, dew point and surface taperature) on each floor elevation at least three (3) times each shift (preferably, the beginning, mid point and just prior to the end of each shift). More readings may be taken den necessary (i.e., noticeable change in air temperature, request by field inspector to take readings in a specific area, etc.).
b. The inspector at the " paint distribution point" shall doc m nt these readings on Attachment 6 as follows:
1. The inspector shall fill in the applicable information as delineated on the fonn, except for the " Report No. "

. (The Report No, will be filled in by the Paper Flow Group when they assign numbers, prior to transmitting to the QA Vault.

2. Upon empletion of the shift, the inspector shall turn all of the environnantal log sheets for that shift into the lead inspectors,
c. The lead inspector (s) shall review the log sheets for .

! completeness and correctness, sign and date the i "QC Review" block, obtain copies for QC reference and

transmit the originals to the Paper Flow Group.

I d. If at any time the inspector determines readings which do not conply with the parameters set forth in this procedure, he shall proceed in the following manner:

l 1. Immediately take an additional set of readings in i

' the immediate area of the first set of unacceptable readings and record them on the environmental log.

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2. If the additional set of readings are acceptable, j take a third set of readings for referee purposes and record them. If the referee set of readings l are acceptable, then the area in question is acceptable but should be closely monitored with readings as necessary.

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  • TEXAS UTIUTIES GENERATING CO.

CPSES ER lEN NE QI-QP-11.4-26 5 0 4 gg 5 of 35

3. If the additional set of readings is unacceptable and/or the referee set of readings is unacceptable, the inspector is to notify the coatings inspectors and/or craft personnel in the areas affected so that coating work my be stopped at that time.

Coating work shall not continue until the ambient conditions resume an acceptable status.

4. When unacceptable ambient conditions occur and are verified by step 3 above, the inspector shall document it on a Nonconformance Report (NCR) in accordance with CP-QP-16.0 and adequately identify the affected areas, elevations and items.

2.3.2 Substrate Surface Acceptability The Inspector shall visually reinspect the sandblasted or powertooled surface of the substrate just prior to primer application for evidence of contamination (oil, grease, arkings, rust, etc.) Contamination must be removed prior to priming.

If rust foms after Blasting or Power Tooling, the surface shall be recleaned before priming.

2.3.3 Air Supply Acceptability The Inspector shall inspect the air per Attachment 18. -

2.3.4 Qualification of Applicator (s)

The Inspector shall verify (by Qualification Record or list of qualified applicators from QA file) that the coating applicators are The applicator (s) badge qualified for safety-related number shall be listedcoating work.

on the back of the traveler.

2.3.5 Mixina Operations 2.3.5.1 Coating Materials Identification An inspector shall inspect the coating sterial containers prior to mixing contents for product identification and verify that all storials are correct for coating application. ,

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INSTRUCTION ISSUE TEXAS UTIUTIES GENERATING CO. DAM N

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QI-QP-11.4-26 5 6 of 35 MAY 0 .t 1984 I

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Approved materials are:

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Carto Zinc 11 bcse Carbo Zinc filler i Carboline #21 or 33 Thinner OINTCOTE-6 Dimetcote 6 base Dimetcote filler 1

Amercoat #65 or 101 Thinner CARO 0LINE 191 Carboline 191 Primer Carboline 191 Catalyst Carboline #15 Thinner -

( PHEN 0LINE 305 i Phenoline 305 base i Phenoline 305 catalyst ,

Phenoline thinner An inspector shall also verify that each component container is identified by batch number and that the shelf life has - .

not expired. Carbo Zinc 11 base and Carboline 191 has' a .

shelf life of 12 months. Carbo Zinc filler, Dimetcote 6 base and filler, and Phenoline 305 all have a shelf life of 24 months. Pot life shall be monitored in accordance l with Attachment 8.

2.3.5.2 Mixing Operations .

An inspector shall witness each mixing / thinning operation.

The inspector shall verify that mixing operations are perfomed in accordance with Attachment 2.

Prior to distribution of CZ-11 or 0-6 inside the building it l shall be power mixed or boxed.

2.3.5.3 Thinning Operation Coating materials (if thinned) viscosity control shall be accomplished by adding thinner as required, but shall not exceed two quarts of thinner per gallon of material .

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I CTION TEXAS UTIUTIES GENERATING CO.

REVISION IhI E PAGE CPSES 1 QI-QP-11.4-26 5 0 4 gg 7 f 35 2.3.5.4 When coating noterials are niixed/ thinned , the inspector verifying the mixing operation shall fill out the Paint Mix Slip, Attachment 3. The inspector perfonning the pre-application inspection shall record the mix sheet number on the travelers. The Mix Slip shall be returned to the Paper Flow Group at the end of each shift to be sent to the vault.

2.4 PRIER APPt.ICATION INSPECTION 2.4.1 Monitoring of Primer Acolication During application operations of 0-6 and CZ-11, the QC Inspector shall monitor that the pressure pot is continuously agitated. The QC Inspector shall also verify that the .

hose length does not exceed 75 feet. CZ-11 and D-6 shall '

not be brush applied to areas larger than i sq. ft.

2.4.2 During appitcation - of Carboline 191 the inspector will monitor to assure that no fisheyes appear in the applied

( coating. If detected, the inspector shall infom the paint foreman of their presence and that they should be removed while coating is still wt, surface cleaned with solvent and coating reapplied.

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2.4.3 The inspector shall monitor the pot life in accordance with Attachment 8.

2.5 INSPECTION OF PRIMER 2.5.1 Primer Inspection Prior to Acolication of Seal or Finish Coat

{ a. Merify the primer has cured sufficiently for the top

coating (as detennined by the use of a nickel test on l D6andCZ-11). Cure to top coat of Carboline 191 shall be the same as time to recoat for Phenoline 305, stated in Sec. 2.9.1.

I b. Perfom a visual inspectfNn of the primed surface in j accordance with the following:

1. Runs / sags which do not exceed the maximum dry film thickness for each coating applied and show t no evidence of mud cracking or loss of adhesion are acceptable. Repairs for runs / sags other than i the aforenentioned shall be per Sec. 2.6.2 or .

2.6.3, as applicable.

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1 INSTRUCTION I88U3 SER REVISION PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES QI-QP-11.4-26 5 MY 0 4 g4 8 of 35

2. Dry Spray - Mus t be removed before overcoating per Sec. 2.6.3.
3. Contamination - unacceptable; reove and repair per Sec. 2.6.2 or 2.6.3, as applicable.

Oil and arease - unacceptable; reove and repair per Sec. 2.6.2 or 2.6.3, as applicable.

4 Skips / damaged areas / holidays or voids .-

unacceptable; repair per Sec. 2.6.2 or 2.6.3, as applicable.

5. Orange peel - Moderate amounts are acceptable.

, Other than moderate amounts; repair as Sec. 2.6.3.

6. Bubbling - unacceptable; repair per Sec. 2.6.2 or 2.6.3, as applicable (does not apply to CZ11 or .

4 D-6). l

( c. The inspector shall perfonn a OFT inspection of the cured primer film. A calibrated 0-25 E1cometer Inspector OFT gage Model III/1E, 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, measurments less than 1 inch from the edge or a hole should be -

avoided .(See Note 3).

, Dry Film Thickness shall be as follows:

4 Min. (mils) Max. (mils)

. Carboline 191 spot test 1.6 7.0 CZ-II spot test 1.5 7.0 D6 spot test 1.5 5.5 ,

D6 average DFT 2.0 5.0 CZ-II average DFT 2.0 6.0 i Cartoline 191 average DFT 2.0 6.0 NOTE 1: A spot ' measurement is a series of three  :

measurments 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 gig, spot measurement.

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l CTION ISSUE REVISION PAGE TEXAS UTILmES GENERATING CO. DAM CPSES QI-QP-11.4-26 5 9 f 35 04W In the event that any spot is found to be outside of the acceptable thickness range,

, three addi tional spots shall be taken at approximately 6 inches fram the failing spot and spaced radially at approximately 120 degree intervals to detemine the extant of

~ the unacceptable area. Unnacceptable areas shall be repaired per Sec. 2.6.3 or 2.6.4.

i NOTE 2: Five spo t tests shall be taken for every 100 square feet of coated surface. For areas less than 100 square feet, the following shall apply:

j Area Sq. Ft. No. Spots i 100-80 5 80-50 .

4 50-10 3 10-3 2

3-0 1 l

NOTE 3: Itans with appreciable surface curvature and other geometrical di scontinuities, such as handrail s, gratings, stairs, sway struts, checker plate, etc., shall be exempt from dry film thickness measurement. For piping ,

struts, spring canisters, ate, appreciable -

curvature will be considere1 as less than 4"

, in diameter.

l 2.6 PRI;fR REPAIRS 2.6.1 Saas and Runs I

Runs / sags which do not exceed the maximum dry film thickness for each coating applied and show no evidence of mud cracking or loss of adhesion are acceptable. Repairs for runs / sags

, other than the aforementioned shall be removed. Repair per Sec. 2.6.2 or 2.6.3, as applicable.

2.6.2 Primer Touch-uo Repair (Primer Damaged to Steel Surface) 1 The coating inspector shall conduct the following inspections to document primer touch-up . repair operations the damage is to the steel surface and spo t when sandblasting or power tool abrading is performed for surface

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4 INSTRUCTION ISSUE SER REVISION PAGE TEXAS UT!UTIES GENERATING CO. DATE CPSES QI-QP-11.4-26 5 PAAY 0 41984 10 of 35

a. Surface preparation Ref. Sec. 2.2.2.
b. Verify that the blasted or power tooled surface has been high pressure air blowdown, and/or solvent wiped to the extent required for final surface inspection.

The adjacent areas shall be cleaned to the extent necessary to avoid contamination during subsequent 1

coating applications.

c. Anbient Conditions: Ref. Attachment 1A and 6.

The surface tanperature shall be a minimum of 5* above the dew point.

d. Verify applicator qualifications per 2.3.4.
e. Verify air supply acceptability per Attachment 18.
f. Mixing operatioit, Reference Sec. 2.3.5.

f g. Verify that primer is applied in accordance with Sec. 2.4.

i NOTE 1: (If applicable) Coating interface - at coating interface for finish and/or primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smoth final

l coating sys ten. When inspecting coating -

interface the interface of the coating or systems shall be a neximum of Ils inch in

width. Within the interface area, overlapping l of any aterials or systens is acceptable.

i NOTE 2: When inorganic zinc is applied at an interface, the cured inorganic zine shall be screened or abraded - prior to application of next coat.

2.6.3 Primer Touch-up Repair (Primer Damage Does Not Extend to Steel Surface The coating inspector shall conduct the following inspections

! for primer touch-up repair operations when the damage is within the primer coat and sandblasting to the steel substrate is not required.

a. Verify surface is abraded lightly then wiped clean.

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INSTRUCTION ISSUE REVISION PAGE TEXAS UTil.lTIES GENERATING CO. DAM CPSES 4

QI-QP-11.4-26 5 MAY 0 41584 11 of 35

b. Farfonn inspections in Sec.(s) 2.3 (except 2.3.2) and 2.4.
c. Visually verify acceptability of repaired area per Sec. 2.5.

2.6.4 Repair of Primer by Recoating The coating inspector shall conduct the following inspections for primer recoating repair. Only two (2) overcoats my be applied of inorganic zinc primer.

a. Verify that the surface has been solvent cleaned or blown down with high air pressure. Contamination

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is unacceptable and requires further cleaning.

b. Derfonn inspections in Sec.(s) 2.3 (except 2.3.2) and

. 2.4.

c. Minor defects (mechanical damage such as construction

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damage or exposing substrate during surface preparation operations, etc.) perfonn inspection in Sec. 2.10.2.

Reference Attachment 7.

d. Major 6er :s (mechanical damage such as construction damT c e Josing substrate during surface preparation op;r ,r.):" etc.) perfonn inspections in Sec. 2.10.3.

Reg. enc /.dachment 7. -

2.6.5 Complete Primer Repair (Primer Damage to Steel Surface Extends Over Entire Iter.)

The coating inspector shall conduct the following inspections to document primer repair when the damage is to the steel surface and requires surface preparttion to steel substrate over entire item:

a. Verify ambient conditions per Attachment 1A prior to surface preparation. See Attachment 6.
b. Perfonn inspections (a) through (g) in Sec. 2.6.2.

2.6.6 In-process repairs shall be documented on the Traveler (Attachment 4) showing their status and/or canple tion.

2.7 FINISH COAT PRE-APPLICATION INSPECTIONS The QC inspector shall verify the following itens prior to

, applying coatings:

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INSTRUCTION ISSUE N M ER EN DATE N TEXAS UT1UTIES GENERATING CO.

CPSES QI-QP-11.4-26 5 g 0 41934 12 of 35

-2.7.1 Coating Applicator Qualifications The Inspector shall verify (by Qualification Record or list of qualification records in QA File) that the coating

. applicators on each shift are qualified for safety-related ccating work.

2.7.2 Ambient Conditions (Refer Attachment 1A and 6)

The pennissible range of surface and ambient tanperature fo.r application of finish coat shall be 50-120'F.

The maximum humidity shall be 857, for Phenoline 305.

4 The surface tenperature shall be a minimum of 5'F above the dew point.

2.7.3 Coated Surface Acceptability 4

The Inspector shall visually reinspect the previously coated surface just prior to finish coat application for evidence of contamination (oil, grease, foreign matter). The defective areas shall be removed and repaired per Sec. 2.6 as applicable-

. 2.7.4 Air Supply Acceptability (Per Attachment IB) 2.7.5 Finish Coat Mixing Operations 2.7.5.1 Prior to mixing, the mixing inspector shall verify that each component is identified by batch numbers and that the 24 month shelf life has not been exceeded.

2.7.5.2 The mixing inspector shall verify that mixing / thinning operations are perfonned in accordance with Sec. 2.3.5.

Thinning may be done up to two quarts of Phenoline Thinner per gallon of Phenoline 305.

2.7.5.3 Mixing operation shall be documented on the traveler per Sec. 2.3.5.4.

I 2.8 MONITORING OF SEAL OR FINISH COAT APPLICATION 2.8.1 The Inspector shall verify that hose length does not exceed

75 feet.

2.8.2 The inspector shall also verify that the seal coat (if present) is solvent with xylol or 305 thinner wiped prior to finish coat application.

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I CTION ISSUE REVISION PAGE TEXAS UT1UTIES GENERATING CC. DATE CPSES .

QI-QP-11.4-26 5 13 of 35 l MAY 0 41984  !

l 2.8.3 The inspector shall nonitor to assure ' that no fisheyes appear in the applied coating.

  • If detected, the inspector shall infona the paint forenan of their presence and that

, they should be removed while coating is still wet, surface cleaned with solvent and coating reapplied.

2.8.4 The inspector shall monitor the pot life in accordance with Attachment 8.

2.9 FINISH COAT FINAL ACCEPTANCE INSPECTION ,

i The inspector shall perfonn a final acceptance inspection of each finish coated item (s) in acconfance with Paragraphs 2.9.1 through 2.9.4.

NOTE 1: (If applicable) Coating interface - at coating interface for finish and/or primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smooth final coating systen. When inspecting coating interface

( the interface of the systems shall be a maximum of 1 inch in width. Within the interface area, overlapping of - any materials or systems is acceptable.

NOTE 2: If present, the tie in interface between concrete coatings and steel coatings shall be vi sually l

inspected during the finish coat final acceptance of both systems.

NOTE 3: When inonjanic zinc is applied at an interface, the cured inorganic zinc shall be screened or abraded prior to application of next coat.

2.9.1 Finish Coat Cure Final QC inspection nay be perfonned 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 /> and cure to recoat time has been met.

Curing and time to recoat for Cartoline 191 and Phenoline 305 shall be as shown below:

Between Coats Tenperature "F 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> 50 - 59 36 hours4.166667e-4 days <br />0.01 hours <br />5.952381e-5 weeks <br />1.3698e-5 months <br /> 60 - 74 18 hours2.083333e-4 days <br />0.005 hours <br />2.97619e-5 weeks <br />6.849e-6 months <br /> 75 - 89

+- 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> 90 and above penn pen, , TUGCC CA

i INSTRUCTION ISSUE TEXAS UTILITIES GENERATING CO. WM DAM CPSES QI-QP-11.4-26 5 MAY 0 41984 14 of 35 Phenoline thinned at 50% and applied as a seal coat may be .

recoated after 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> of cure at or above 75'F. ,

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2.9.2 Visual Defects Inspection The Inspector shall perfonn 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 systen is 15.0 mils or less thick, which show no evidence of mudcracking, are acceptable. Those greater than 15.0 mils shall be repaired per Sec. 2.10.1.

b) Skips, damaged areas, holidays, voids, bubbles, and blisters are not acceptable and shall be repaired per Sec. 2.10, as applicable.

c) Pinholes -- acceptable to. the extent' allowed by Attachment 5; areas not acceptable shall be repaired

( per Sec. 2.10.5.

"d) Contamination - unacceptable; areas shall be repaired per Sec. 2.10.4. Ref. Attachment 7.

e) Ory spray - unacceptable; shall be repaired per Sec.

2.10.6. A minor amount of adherent dry spray is acceptable on the final finish coat. Ref. Attachment 7. .

f) Color and gloss non-unifomity - unacceptable; shall be repaired per Sec. 2.10.8. Ref Attachment 7.

l g) Orange Peel: Moderate amount is acceptable, other than nederate amounts to be reparied per Sec. 2.10.7.

NOTE 1: Top coated areas which have been abraded for various reasons (runs , sags, high millage, and contamination) and are within acceptable procedural thickness following repairs, do not require recoating for gloss enhancing.

NOTE 2: For small repair areas such as pinholes, color

l. and gloss unifonni ty is not required, provided the coating is smooth and continuous.

2.9.3 Dry Film Thickness (DFT) .

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The Inspector shall perfonn a OFT of the cured coating i

system. A calibrated 0-25 Elcometer Inspector DFT Gage I -

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I CTION ISSUE FIEVISION PAGE

' TEXAS UTILmES GENERATING CO.

- DAM CPSES QI-QP-11.4-26 5 MAY 0 4 $84 15 of 35 Model III/1E, 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, 4

measurements less than 1 inch from an edge or a hole should be avoided. (See Note 3).

The average DFT of the total coating system shall be a minina of 6.0 mils and a maximum of 13.0 mils. The spot test DFT of the total coating system shall be a minimum of 6.0 mils and a maximum of 15.0 mils.

The finish coated systen shall exhibit 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.

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 renent.

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 unacceptable spot and spaced radially at approxima tely 120 degree intervals to detennine -

the extent of the unacceptable area. Dimensions and locations of unacceptable areas and results of additional testing shall be documented on the traveler / sketch. Unaccpetable areas shall be repaired per Sec. 2.7, 2.8, and 2.9.

NOTE 2: Five spot tests shall be taken for every 100 square feet of coated surface. 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

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INSTRUCTION ISSUE NWBER EN DATE N TEXAS UTIUTIES GENERATING CO.

CPSES QI-QP-11.4-26 5 MAY 0 4 sg4 16 of 35 NOTE 3: Items with appreciable surface curvature and other geometrical discontin'uities such as handrail s, checker plate, gratings, stairs, sway struts, etc.

shall be exempt from DFT measurement. For piping. -

struts, spring canisters, etc., appreciable surface curvature will be considered as less tha 4" diameter.

2.9.4 Continuity Inspection The Inspector shall test the continuity of the cured finish coat on liner plate using a- Tinker and Rasor Model M1 (67.5 volt) holiday detector. 100% of the finish coated surface area shall be tested.

The applied film should contain only a minor nunber of points of di scontinui 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 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 nunber of pinhole discontinuities allowed is defined in Attachment 5. No gross discontinuities are allowed.

2.10 REPAIRS OF FINISH COAT  ! .

2.10.1 Repairs of Runs and Saqs, .

The QC inspector shall verify that the area is abraded until the DFT of the total coating system is within 6.0 and 15.0 mils, and examined for mudcracking. Muderacking, if present shall be removed and repaired in accordance with Sec. 2.10.2 or 2.10.3.

2.10.2 Repair of Minor Defects The QC inspector shall perfonn the following inspection when repairing minor defects:

a) Verify ambient conditions per Attachment 1A prior to surface preparation.

b) Verify that the damaged area is blasted or abraded by hand or power tool until all loosely adherent particles are removed. ,

Pornose. , TUGCC CA

1 TEXAS UTluTIES GENERATING CO.

CPSES QI-QP-11.4-26 5 MAY 0 41984 17 of 35 c) Verify damaged area is solvent wiped.

d) Perfonn inspections described in Sec. 2.7, 2.8 and 2.9.

as applicable.

e) Minor defects any be repaired at the time of final inspection without later reinspection of the repair.

2.10.3 Repair of Ma.ior Defects The QC inspector shall perfonn the following inspection when repairing major defects; if damage goes to substrate power tools shall be used in lieu of handsanding.

a) Verify ambient conditions per Attachment 1A and 6.

b) Verify area is power tooled or spot blasted until all loosely adherent particles are re loved.

c) Verify area is solvent wiped.

d) Perform inspections in Sec. 2.2.2, 2.7, 2.8 and 2.9.

2.10.4 Repair of Contamination The QC inspector shall verify that contamination is removed.

If contamination can be removedJ 'y abrasion without affecting the continuity of the systen, recoating of the area after -

removal is not required if the coating systen thickness is

-within procedural limits. (Reference Sec. 2.9.2 Note 1).

2.10.5 Repair of pinholes and Small Discontinuities a) Verify all loose particles are renoved and area is solvent wiped.

b) Pinholes and small. discontinuities may be repaired at i the time of final inspection without a later

reinspection of the repair. The inspections in l Sec. 2.7 and 2.8 still apply.

2.10.6 Repair of Dry Spray Repair of dry spray identifiable by vi sual inspection l defined within this procedure shall be removed.

i

( p ,,, g , TUGCC CA l

TEXAS UT1UTIES GENERATING CO.

CPSES.

QI-Q P-11.4-26 5 r,MY 0 41984 18 of 35 a) Verify all loose particles ,are renoved.

b) Verify coating film thickness is still within allowable range.

c) If film thickness is not within allowable range perfonn inspections in Sec. 2.7, 2.8 and 2.9.

NOTE: A minor amount of adherent dry spray is acceptable on the final finish coat.

2.10.7 Repair of Other Than Moderate Amounts Of Orance Peel Verify the affected area is abraded and solvent wiped.

, a) 4 b) Verify the affected area is refinished and perfonn the inspections delineated in Sec. 2.7, 2.8 and 2.9.

2.10.8 Repair of Gloss and Color Nonunifonnity i

g a) Verify the affected area is abraded and solvent wiped.

b) Verify the affected area is recoated without exceeding the maximan film thickness and perfonn inspections in Sec. 2.7, 2.8 and 2.9.

c) Top coated areas which have been abraded for various reasons (i.e., runs, sags, high millage, and -

contamination)' and are within acceptable procedural thickness, following repairs, do not require recoating for gloss enhancing.

i d) For small repair areas such as pinholes, color and

. gloss unifonnity is not required, provided the coating j- is smooth and continuous.

2.10.9 Documentation of In-Process Repairs u

In-process repairs shall be doctanented on the traveler (Attachment 4) showing their completion and/or sta tus .

2.11 NONCONFORMANCES 2.11.1 Nonconfonning conditions such as coating failure due to loss of adhesion or indetenninate/ unacceptable conditions which 1

. cannot be repaired or corrected as per existing procedures shall be documentaa on a Nonconfonnance Report (NCR) in i

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REVISION ISSUE h8ER DATE PAGE TEXAS UTIUTIES GENERATING CO.

CPSES ,

QI-QP-11.4-26 5 MAY 0 41984 19 of 35 i' accordance wi th CP-QP-16.0. The NCR ntmber shall be referenced on the inspection traveler, if applicable.

1-2.12 ' DOCUMENTATION (REFER TO ATTAcetENT 4) i 2.12.1 All inspections required by this procedure shall be recorded in the inspection attributes on the back of the travelers (Attachment 4). Preparation and processing of the traveler shall be per QI-QP-11.4-28.

! 2.12.2 When the inspections required by Sections 2.1 through 2.2 have been satisfactorily capleted, Step 1 shall be signed and dated by the inspector. ,

1 2.12.3 When the inspections required by Sections 2.3 through 2.7 have been satisfactorily capleted. Step 2 shall be signed and dated by the inspector.

4 2.12.4 When the inspections required by Sections 2.8 through 2.8.4 have been satisfactorily empleted. Step 3 shall be signed and dated by the inspector.

2.12.5 When the inspections required by Sections 2.9 through 2.10.9 have been satisfactorily empleted, Step 4 shall be signed and dated by the inspector.

2.13 SPECIAL COATINGS PROCEDURES Special coatings procedures and instructions set forth in CCP-30-M procedures as applicable under the scope of this procedure, shall be inspected as per the guidelines of this procedure using the criteria established in the special coatings procedures.

3.0 CLARIFICATION -

3.1 SHOP COATED IT9iS 3.1.1 Items reoved from the building for coating at the paint shop shall be the responsibility of the craft department.

3.1.1.1 The craft shall be responsible for identifying each piece by work package number.

, 3.1.1.2 The craft shall be responsible for returning and installing the shop coated iten in the same area it was removed from.

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_ e__ __ . _ . _ _ _ . _ . . . _ _ . . . _ - _ _ _ - . ~ . , . . _ . _ . . _ . . . _ _ _ _ _ . _ . _ . _ . . . .

REVISION I UE TEXAS UTiuTIES GENERATING CO. h8ER M PAGE CPSES OI-QP-11.4-26 5 MAY 0 4 leB4 s

20 of 35.

3.1.2 The shop QC Inspector shall inspect the itan(s) in accordance with QI-QP-11.4-1 and QI-QP-11.4-5, as applicable, and document his inspections on an Inspection Report (IR) in accordance with those procedures.

3.1.2.1 In addition to the infonnation required by 11.4-1 or 11.4-5, the shop inspection shall reference the work package number identified on the itan(s) on the Inspection Report (IR).

3.1.2.2 The IR, upon completion, shall be transmitted to the Pape'r Flow Group (PFG) for inclusion in the work package.

3.1.3 The QC Inspector (in the field) shall verify that itens prepared / coated in the shop, which are included in the scope of the traveler, have the applicable inspection reports (IR) from the shop included in the work with the identification on the item (s) package and correspond 3.1.4 Itans dich have been finaled in the shop but incur mechanical damage during reinstallation shall be repaired in acconiance wi th QI-QP-11.4-26 and docunented on- the traveler accordingly.

3.2 REPAIR OF ECHANICAL DAMAGE TO COMPLETED ITEMS 3.2.1 Areas that have been completed, inspected, accepted and traveler package closed dich incur major damage at a later -

date may be repaired, inspected and documented on the supplemental traveler Attachment 9 "S teel Protective Coating Inspection Repair Traveler". Otherwise, the minor areas of mechanical damage, which occur after completion of an area, will be repaired during the final protective coatings walkdown.

3.3 INACCESSIBLE /LINTED ACCESS AREAS

, If questions arise concerning inaccessible or limited access areas per specifications 2323-AS-31 and/or nondeleterious embedded foreign material in the final finish coat, the above condition (s) will be evaluated by the Project Civil Engineer or designee. Clarification and acceptance of the above stated condition (s) shall be so denoted by signature of the engineer with date and comments as required, in the comments section of the applicable step.

4.0 ATTACHENTS O

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' ISSUE h8ER REVISION PAGE TEXAS UT1UTIES GENERATING CO. DAM CPSES QI-Q P-11.4-26 5 MAY 0 41984 21 of 35 4.1 Attachment 1, " Ambient Condi tions" 4.2 Attachment 18. " Air Supply Acceptability" 4.3 Attachment 2. " Preparation of Coating Materials" 4.4 Attachment 3. " Paint Mix Slip" 4.5 Attachment 4. " Steel Protective Coating Inspection Traveler" 4.6 Attachment 5, " Total Number of Allowable Points of Diseontinui ty" 4.7 Attachment 6, " Environmental Log Sheet" 4.8 Attachment 7. " Definitions" 4.9 Attachment 8. " Pot Life Reference Sheet" 4.10 Attachment 9. " Steel Protective Coating Inspection Repair I Traveler" I

e penn m TUGCC CA

. _ _ . . . _ _ . _ . _ _ _ .-. _ . _ _ . . _ _ _ _ . _ _ . _ . . _ . _ . . _ . _ _ _ _ _ _ _ _ . , _ . . . . . _ _ _ .__. .~ __,

INSTRUCTION ' ISSUE NUM8ER MSION QATE PAGE i

TEXAS UTIUTIES GENERATING CO.

CPSES QI-QP-11.4-26 5 MAY 0 4 584 22 of 35 ATTACHMENT 1A Ambient Conditions The inspector shall detennine against the Envirornental Sheet (Attachment 6) air temperature, surface temperature, relative humidity and dew point of substrate structures.

A calibrated non-mercury filled dry bulb thermometer or

. calibrated tenperature recorder (Bristol 4069TH or equivalent) shall be used for air tempera ture detennination. A calibrated non-mercury wet bulb thermometer or a calibrated humidity recorder (Bristol 4069TH or equivalent) shall be used to detennine relative humidity. The dew point shall be detennined by the difference in dry and wet bulb tenparatures using the U.S. Department of Commerce Weather Bureau Psychometric Tables, W8 No. 235. When dry bulb readings are greater than 100*F, the dew point and relative humidt ty should be detennined using the 100*F dry bulb reading.

If the dry bulb thermometer exceeds 100*F, the instrument

( shall be returned to the calibration lab for recalibration.

The surface temperature shall be detennined by placing a calibrated surface tenperatu re thennometer (Omega-Amprobe fast tenp. range of 10*-250*F) in contact with the substrate su rface until the tenperatu re reading stabilizes.

Final su rface preparation shall not begin unless the

  • temperature of the surface is a minimum of 5'F above the dew point.

Nonnal conditions of ambient and su rface tenperatu re for application of primer shall be as follows:

Ambient Teno. (*** Surface Teno. (*F)

Dimetcoto 6 40-120 40-130 Carto Zinc 11 40-95 40-110 Carboline 191 50-120 50-120 Phenoline 305 50-120 50-120 Inorpnic zinc primer may be applied within an ambient range of 0 F to 130*F and surface tenperature range of O'F to 200*F.

Humidi ty values may va ry from 05 to 95% for inorganic primers; however, primers shall not be applied to a wet or damp surface.

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INSTRUCTION IO3U3 SM REVISION PAGE TEXAS UTIUTIES GENERATING CO. OATE CPSES l

QI-QP-11.4-26 5 MAY 0 4 1984 23 of 35 ATTAONENT 1A (Cont.)

Minimum and maximum values of relative humidity for Phenoline 305 and Cartoline 191 shall be 0% to 85%.

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pain m , TUCCC CA

INSTRUCTION ISSUE NUMSER RESION PAGE TEXAS OTIUTIES GENERATING CO. DATE CPSES QI-QP-11.4-26 5 tAAY 0 ! 1984 24 of 35 ATTACM ENT 18 Air Sucoly Acceptability An inspector shall inspect the air supply systen of blast and spray equipment for suitable filters / traps / separators and that they are left i: racked open. The effectiveness of these items shall be verified by exposing a piece of white cloth to the air outlet for approximately 30 seconds. The white cloth shall be examined for evidence of contamination (oil, water, foreign matter, etc.). No evidence of contaminah4n is acceptable.

Pwas mm TUCCC CA

INSTRUCTION IO8U8 U REVISION N TEXAS UTluTIES GENERATING CO. DATE CPSES QI-QP-11.4-26 5 MAY 0 > 1984 25 of 35

^

AT1'AOMENT 2 ,

PREPARATION OF COATING MATERIALS Primer - The -primer, Carbo Zinc 11, is packaged in a two component kit consisting of a base and a zinc filler. First the base shall be thoroughly mixed. Ifnc filler shall then be added under constant agitation and mixed untti free of lumps. Partial mixes shall be mixed by weight in a proportion of 10 parts base to 22 parts zinc filler using a suitable scale to achieve a plus or minus 2 percent accuracy. The mixture shall then be strained through a ,

30-mesh screen.

Viscosity shall be controlled by adding thinner, as required, but shall not exceed two quarts of thinner per gallon of Carto Zinc 11.

Primer - The primer. Dimetcote 6, is packaged in a two

( camponent kit consisting of a base and zine filler. The base shall be thoroughly mixed first. Zinc filter shall then be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in a proportion of 6.4 parts base to 15 parts zinc filler using a suitable scale to achieve a plus or minus 2 percent

, accuracy. The mixture shall then be strained through a 30-mesh screen. Viscosity shall be controlled by adding

  • thinner as required up to the maximum of 2 quarts of thinner per gallon of Dimetcote 6. Primer coat shall be reddish gray.

Primer - The primer, Carbo 11ne 191, is packaged in a two component kit consisting of Carbo 11ne 191 base, Part A, and l a catalyt. Part 8. Mixes are' sade by cambining and thorough y mixing the base and catalyst. Partial mixes may be made by cambining, in a ration by volume, two parts base to one part catalyst. Viscosity shall be controlled by adding thinner as required, but shall not exceed two quarts of th< nner per gallon of Carbo 11ne 191.

Finish Coat - The finish coat, Phenoline 305, is packaged in a two component kit consisting of Phenoline 305 base Part A.

and a Fhenoline catalys t, Part 8. Mixes are made by combining and thoroughly mixing the base and catalyst.

Partial mixes may be made by canbining, in a ration by volume, four parts base to one part catalyst. Viscosity shall be controlled by adding thinner as required, but shall not exceed two quarts of thinner per gallon of Phenoline 305.

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INSTRUCT 18N ISSUE NUMSER REVISION PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES QI-QP-11.4-26 5 r26 of 35 MAY 0 41984 ATTAONENT 3 PAINT M!I $ LIP

  • deport No. .

81d9 DATE POT LIFE $HIFT TIME MII NUSMER ELEVATION MTERIAL GAL, Mixto

$NELF LIFE ACC U ATSLE: YES N0 M it 8'S DATE & TIME M!IED BA$t CURING AGENT FILLER THINNER ACCEPTED 17 DATE PCT LIFE $HIFT TIME MII NWIBER *-

u- . _ ELEVATION MTERIAL GAL.111XED

$M LF LIFE ACCU TABLE: ft3 NO MATE l'$

0471 & TIME MIIto Bast CURING AGENT FILLER THINNER ACCEPTED ST

~.~ .

0471 POT LIFE $N!FT TIME MIX NWISER ELEVATICM MTTRIAL GAL. MIXT 0 SHELF LIFE ACCIPTABLE: fts No M4TE #'s Daft & TIME M!It0 SA$t CURING AGENT FILLER THINNER ACCEPitO 87

.. . Ga , -

QC REVIEW 4 ACCEPTANCE signature date

, TUGCC CA

INSTRUCTION ISSUE NUMSER W SION CATE PAGE TEXAS UTILITIES GENERATING CO.

CPSES QI-QP-11.4-26 5 MAY 01584 27 of 35 ATTACHMENT 4 STEIL PROTECTIVE COATING #eSPECTION TRAVELER wens Pus,w Pct Tnavn.sn s 6:0Ns rTee as /oE3cA4PT1oM MER nW48,e MeEP - SYt 0 Aft STEP sunPAct PatPAaATion msPtcTro Amo Pound AccEPTA4LE .

Ptn @ cPIL4 24 ANo AELEASEo POR PRiesEn APPuCATION.

lee $PECTOR Daft I

contesENrs STEP peneta APrucAftose usescTEo Amo rouseo AcctPTAets Ptn ot*QPIL4=18 Amo AELEASto POR 79eBN coat APPUCAfl0N.

- ar- DATE E

condescers STEP Piensw coat APrucarum insPscTEo Amo roumo AccEPTAsts

Ptn O!=0PIL4-36 seereC1 cat "TE 3

contestmTs . .

STEP Pinesn coat sospecTED Pon rimas. AcctPTAnca Amo 70uno AccEPTAALE Ptn 08-ePIL4-88 BIAPECT" 0 Aft 4

GeesteENTS STEP Cosen.AT10m GP se8PEcTlem TRAVELEn yansPito.

Sc Review OAT

  • 4 S

I) occusesNT tesePecT1oM ATTRISUTESo81 ATTAcMEo SuPPORTises N 90euesENTAftese smEETts)

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0 ) oosunserf nsPains Asso ATTnievTes.tP nEcuinto,ess ATTAcmEn

, T suPPe# Time sospesENTAftese SMEETts)

E 31 PO88 ENvWeessedesTAL c00estfloses nEPEnceCETHE l 3 Envia*#mEnfu Lee.

! Pen me, i TUGCC CA s

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INSTMUCTION I NUMBER REVISION PAGE

. p UTluTIES GENERATING CC.

CPSES gt.gp.11.4 26 5 GAY 0 4 W 28 of 35

~

ATTACHMENT 4 (Cont.)

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11 I is 15 i

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INSTRUCTION issus TEXAS UTIUTIES GENERATING CO.

SM DAM NE CPSES QI-QP-11.4-26 5 MAY 0 4 M4 29 of 35 ATTAONENT 5,

/

TOTAL NUM8ER OF ALLOWABLE POINTS OF OISCONTINUITY SURFACE AREA COND. "C" BEING COATED COMMERCIALLY (50. FT.) CONTINUOUS ,

10 5 10 50 10 50-100 20 100-500 30

. 500-1000 50 I

1000-5000 75 Gross Discontinuities - None Allowed.

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  • PROCEDURE ISSUE NUMSER REVISION DATE pggg TEXAS UTIUTIES GENERATING CO.

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QI-QP-11.4 26 h MAY 0 41984 ,

30 of 35 :

ATTACHMENT 6 Report No.

. w et - oe sneet,_

ENVIRONMENTAL LOG $NEET MSTE 8's Elevation _ , 31dg.

Date shift Unit INSPECTOR TIME DAf SULO '

WCT GULO SUAFACE STEEL f TEMP. 0(W PolNT i CONCRETE HUMIDITY l

~.

4 a.as .

QC REVIEW t

ignature De te h -me GIS ++ emenu w___- _____ _- - - . _ _ _ - -

S O PAGE

. TaxAs UTiuTiss GaNaRADNG CC.

CPSES

  • QI-QP-11.4-26 5 W0 4 g 31 f 35 ,

ATTACHMENT 7, DEFINITIONS Color and Gloss Nonuniformity: A milky haze or mist in the finish of '

j a recently applied coating.

Contaminant: A foreign substance, inadvertently added to a coating or found on the substrate that adversely affects the application, adhesion, curing and/or subsequent performance of the applied coating.

Dry Snray: A dry powdery primer or finish coat readily removed by ight sanding with either sandpaper or a wire screen. A minor ,.

amount of adherent dry spray is acceptable on the final finish coat. '

Featherinet An area that is roughened and tapered to obtain a smooth a% continuous surface with an existing coating.

Fisheves: Small openings (" fisheyes") in wet film exposing old

( surface or previous coat.

Full Hidina: The coating provides sufficient coverage so that the  :

preceding coat is not readily visible with an unaided eya.

t Holiday: A pinhola, skip, discontinuity or void in coating film.

Ms.ior Defect: Defined as an area, either circular or linear, in which -

a 1/Z" diameter circle could be inscribed at any point' or along

the entire length.

Minor Defect: Defined as an area, either circular or linear, in which a 1/z" diameter circle could not be completely inscribed at any  ;

point along the entire length.

j 331,tgy,:fomed per on a periodic or random basis.Conforwence verification by physica 4

Muderackina: Irregular cracking as in a dried mud puddle (applicable to inorganic zinc primers).

Orance Peel: Dents in the surface resembling orange skin. A moderate r

amount is acceptable.

Verify: Confim or make certain.

Pinholes: Minor discontinuities in coating which wxposes primer or substrate.

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  • INSTRUCTION l33yg
  • TEXAS UTluTIES GENMATING CO. OE DATI '^

CPSES QI-QP-11.4-26 5 32 of 35 ATTAQWENT7(Co,nt.)

DEFINITIONS Seal Coat: Finish coat applied at approximately 1 mil DFT over primer to protect the prime coat. I Visual: To examine with an unaided eye (correctional eye glasses or contactlensareacceptable). ,

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INSTMUCTION ISSUE

. TEXA8 UT!UTIES GENERATING CO. CAM N

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CPSES QI-QP-11.4-26 5 MAY 0 4 W 33 of 35 ATTACHMENT 8 POT LIFE REFERENCE SHEET Normal Pot Life CZ 11 8 Hours Pot Life

, 04 ,

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l e in w, o.r- ,u., *. iln" Pot life stated above for unthinned coatings are the reconsnended ..

times and shoul.t be utilized as a guideline for coatings usage time, however, actural pot life may be longer. For unthinned coatings or coatings thinned 50% or less, acutal pot life is determined by f applicability of the coating.

l l POT LIFE - DIMETCOTE 6 Pot life for Dimetcote 6, thinned or unthinned, shall be 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> .

regardless of temperatures.

l l

l POT LIFE PHEN 0LINE 305 & CAR 80LINE.191 TEMPERATURE (O F ) UNTHINNED THINNED 50%

50-54 Ers . 24 hrs.

55-59 7 hrs . 24 hrs. ,

60-64 44 hrs. 24 hrs.

. 65-69 3h hrs. 24 hrs.

, 70-74 2 hrs. 24 hrs.

! 75-79 1h hrs. 24 hrs.

80-84 1 hrs. 24 hrs.

I 85-89 1 hrs. 24 hrs.

90-95 1 hrs. 24 hrs.

Pot life stated above for unthinned coatings are the reconsnended i times and should be utilized as a guideline for coating usage time, l however, actual pot life may be longer. For unthinned coatings or l coatings thinned 50% or less, actual pot life is determined by the applicability of the coating.

%, fuococ4 l

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s PMCCEDURE REVISION ISSUE NUM8EM OME PME TEXAS UTILITIES GENERATING CO. _

CPSES 01-QP-11.4-26 ' 5 HAY 0 41984 34 of 35 ATTACHMENT 9 STEEL PftOTICTNE COATING INSPECTION REPMt TMMELEM soms Pua.

ELD 8f383h MOa*

17:30 a /CEstnerflom nurowes' e epasst 079 *att SHf CF STEP sunPass pasPam.ir.m waspecito me PCWS ACcsPfASW PER E=ePIL4*34 Ase AELEAasD POR PousG a#pucATICM. g IMSPEC*0A GATE I -

ommsprs STEP P*MER A8'usaften m ame Poume accarfasu .

Pen es-epIL*-as amo asksAaso P0n Puusu caar appucAften.

r WWar!" 0AT' 2

seamacets STEP Psean cuat aspucArz:n sePec7E2 MER P0ume ACcEFTA4LE PsR 48-0PfL4-88 ,

gegmig awr 3

commerfs As:sPrAal.E PSA 48-4PIL4-a#

4 BESPW:T"* Cait osmaserfs

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' 4 3 ccc:.msnt cusMctcm al""tituT13 c4 AT"A@.So SUPr.K7'.te 244WastafatC.4 SafK."33 C si tec:ssant aspains ao amtsutts.:p as:uisc.cx 47 Acats l

l 7 suPMAtN4 Ccc:.ascefatcN t> G Tlal E si pen enviacmasentaa. e:nCaf: ens narus.ws THE S 8'visemmentaa. Laa.

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7 ,-- - . . -

TEXAS UTILITIES GENERATING CO.

%Ih S MEVISION I88 D EAOI CPSEB QI-QP-11.4-26 5 !AAY 0 4 5 4 35 of 35 ATTACHMENT 9 (Continued) 8 I

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TEXAS UT1UTIES GENERATING CO. NSER , REVISICN , PAGE f CPSES ,

~

Q I-Q P-11.4-26 4 .yAR 0 3 igg 4 l 1 of 34  !

INSPECTION OF STEEL PREPARED BY: - -I M  :( -

3[8/'k SUBSTRATE SURFACE CATE l PREPARATION, PRIMER i

- APPLICATION, PRIMER APPROVED BY:

~'

. 3-rf- A/ i REPA!R, SEAL AND CAIE ,

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FINISH C0AT APPLICATION .

. _. AND REP _ AIR APPROVED BY: 7// fl

,0A T.E I

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1.0 GENERAL l 1.1 PURPOSE AND SCOPE ggy 3 UllE U R Eb i

! . The purpose of this instruction is to outline me thods utilized by Quality Control personnel in inspection of steel  !

substrate surface preparation, primer application, primer i repair, seal and finish coat application and repair for l Unit 1 Reactor Building. '

. , , . .  : n .a m. V j I

l .

2.0 INSTRUCTION - IV' i. A * * * " ' ' * * ' ' ' ' cd b VO n

l I

Visual inspection of surfaces as addressed by this  ;

instruction shall be made at approximately 30" in distance or. t i an ams length from the surface being inspected. The area i of inspection shall be adequately lighted during the i inspection activity. Adequate lighting is defined as the minimum light produced by a two (2) 0-cell battery i flashlight. Flashlight shall be held perpendicular to the '

surface during visual inspection.

! Visual aids fabricated on site and approved by quality '

Assurance and Engineering may be used by Inspectors as an

. aid in the performance of their inspections. i l

For definitions, refer to Attachment 7.

If a conflict arises between the requirements of this procedure and the requirements of the site specification, the requirscents of the site specification shall prevail. ,

2.1 PRE-BLAST CLEANING OPERATIONS l l.

2.1.1 Abrasive Acceptability l The Inspector shall obtain a sample of the abrasive to be  !

used from each work area. The abrasive shall be verified to be dry by feel wi th no grease, oil and deleterious I material. Verify that proper blast abrasive is used. j l

%%, TUCCC CA

  • ~

. INSTRUCTICN MEVISION ISSUE TEXAS UTluTIES GENERATING CO. l UAII CPSES QI-QP-11.4-26 4 MAR u 3 jgg4 2 of 34 2.1.2 Blast Eauipment Acceptability The inspector shall perfonn the following inspections / tests to detemine acceptability of blast cleaning equipment prior to use:

a. Air supply (refer to Attachment 18).
b. Ambient conditions (reference Attachment 1A and 6).

2.1.3 Solvent Cleanina (if Contamination Is Present)

If oil, grease, or other contamination is present, verify that solvent cleaning is perfonned and that contamination is removed prior to blast / power tool cleaning steel surfaces.

2.2 POST SURFACE PREPARATION OPERATION 2.2.1 Blast Cleanup The inspector shall visually check the blasted substrate surface.

The surface shall be air blasted or solvent wiped to the extent required for final surface inspection. The adjacent areas shall be cleaned to the extent necessary to avoid contamination during subsequent coating applications. ,

2.2.2 81asted or Power Tooled Surface Acceptability .

The inspector shall perfom the following inspections to determine acceptability of the blast cleaned or power tooled surface:

a. Absence of Foreign Matter -- A visual inspection shall be perfonned to detemine that all oil and grease, di rt, millscale, rus t, corrosion products, oxides, paint or other foreign matter have been capletely reoved from the surface except for light shadows, very slight streaks or slight di scolo rations caused by rust stains, mill scale , ,

oxides, or slight, tight residues of paint or coating that my remain . At least 95 percent of each square inch of surface area shall be free of all residues, and the rea tnder shall be limi ted to light discolorations as mentioned above, n,. , tuoco oa

INSTRUCTON REVCoe, 1 NUMSER 0 PAGE

  • TEXAS UrutES GENERAMNG CO.

CPSES QI-QP-11.4-26 4 -

ag 0 g gg4 3 of 34 NOTE: In addition to the 5 percent of tight residue 'of paint or coating which is pemissible, shadows or tightly adhering residues of primer may renain (without limit) in the profile of the previously prepared substrate.. However, areas with residues

  • of Carboline 191 primer shall be recoated with Cattoline 191 prime r. Areas with residues of inorganic zinc.may be coated with either inorganic zine or Carboline 191 primer. l
b. Sharp Projections -- An inspection for sharp projections that were not rounded during blast cleaning or power tooling shall be perfomed. Sharp projections

, are unacceptable and shall be ground to a rounded contour.

Weld spatter on structural steel which renains after sand blasting will be acceptable.

c. Anchor Pattern Depth -- The anchor pattern, depth of surfaces shall be inspected at randan locations as necessary using a Keane-Tator Surface Profile Canparator (model 373) or approved equal.

g The anchor pattern depth for all surfaces shall be a l minimun of 1.0 mils.

Surfaces that have been. power tooled with "3M Clean-N-Strip", 60 grit and coarser " flapper wheels", provide acceptable surface profile, when properly used over a previously blasted and coated surfaces.

I For power tooled steel surfaces, the 1 mil minimum profile shall be verified by visual compasion to a standard of known profile or other approved method.

2.3 PRIER PRE-APPLICATION INSPECTIONS 2.3.1 Anbient Conditions The inspector at the " paint distribution point" in Reactor 1 shall verify ambient conditions in accordance with Attachment 1-A.

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INSTRUCTION ISSUE NUMBER REVISION PAGE TEXAS UT1UTIES GENERATING CO. DATE CPSES QI-Q P-11.4-26 4 MRUo @ 4 of 34 2.3.1.1 Documentation of Envirornental Conditions

a. The inspector assigned to the " paint distribution point" in the Reactor building shall, as a minimum, take a complete set of readings (air taperature, relative humidity, dew point and surface temperature) on each floor elevation at least three (3) times each shift (preferably, the beginning, mid point and just prior to the end of each sh?ft). More readings may be taken when necessary (i.e., noticeable change in air temperature, request by field inspector to take readings in a specific area, etc.).
b. The inspector at the " paint distribution point" shall doctanent these readings on Attachment 6 as follows:
1. The inspector shall fill in the applicable infonnation as delineated on the fann, except for the " Report No. "

. (The Report No7 will be filled in by the Palier Flow Group den they assign numbers, prior to transmitting to the s QA Vault.

2. Upon completion of the shift, the inspector shall turn all of the environmental log sheets for that shift into the lead inspectors.
c. The lead inspector (s) shall review the log sheets for conpleteness and correctness, sign and da te the "QC Review" block, obtain copies for QC reference and transmit the originals to the Paper Flow Group.
d. If at any time the inspector determines readings which do not comply with the parameters set forth in this procedure, he shall proceed in the following manner:
1. Immediately take an additional set of readings in j the insnediate area of the first set of unacceptable readings and record them on the envirornental log.
2. If the additional set of readings are acceptable, take a third set of readings for referee purposes 4

and record them. If the referee set of readings are acceptable,. then the area in question is acceptable but should be closely monitored with 4

readings as necessary.

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CPSES-QI-QP-11.4-26 4 S R J 3 igg 4 5 of 34

3. If the additional set of readings is unacceptab~1e and/or the referee set of readings is unacceptable, the inspector is to notify the coatings inspectors and/or craft personnel in the areas affected so that coating wort nay be stopped at that time.

Coating work shall not continue until the ambient conditions resume an acceptable status.

4. When unacceptable ambient conditions occur and are verified by step 3 above, the inspector shall document it on a Nonconfonnance Report (NCR) in acconiance with CP-QP-16.0 and adequately identify the affected areas, elevations and itens.

l 2.3.2 Substrate Surface Acceptability The Inspector shall visually reinspect the sandblasted or powertooled surface of the substrate just prior to primer application for evidence of contamination (oil , . grease, markings, rust, etc.) Contamination must be removed prior to priming.

If rust fonns after Blasting or Power Tooling, the surface shall be recleaned before priming.

2.3.3 Air Supply Acceptability The Inspector shall inspect the air per Attachment 18.

2.3.4 Qualification of Apolicator(s)

The Inspector shall verify (by Qualification Record or list of qualified applicators from QA file) that the coating applicators are qualified for safety-related coating work.

The applicator (s) badge number shall be listed on the back of the traveler.

2.3.5 Mixino Operations 2.3.5.1 Coating Materials Identification An 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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s I CTION REVISION PAGE TEXAS UTIUTIES GENERATING CO.

CND 4

l QI-QP-11.4-26 PR08 m 6 of 34 t

Approved materials are:

CZ-11 Carto Z'inc 11 base Carbo Zinc filler Carboline #21 or 33 Thinner DIETCOTE Dimetcote 6 base Dimetcote filler Amercoat #65 or 101 Thinner CAR 80LINE 191-l Cartoline 191 Primer Carboline 191 Catalyst Cattoline #15 Thinner -

PHENGt.INE 305 ,

Phenoline 305 base

. Phenolint 305 catalyst Phenoline thinner An inspector shall also verify that each component concainer is identified by batch nunber and that the shelf life has not expired. Carto Zinc 11 base and Cartoline 191 has a shelf life of 12 months. Carbo Zinc filler, Dimetcote 6 base and filler, and Phenoline 305 all have a shelf life of 24 months. Pot life shall be monitored in accordance with Attachment 8.

2.3.5.2 Mixing Operations An inspector shall witness each mixing / thinning operation.

The inspector shall verify that mixing operations are performed in accordance with Attachment 2.

Prior to distribution ( . CZ-11 inside the building it shall be power mixed or boxed.

2.3.5.3 Thinning Operation Coating materials (if thinned) viscosity control shall be accomplished by adding- thinner as required, but shall not exceed two quarts of thinner per gallon of material .

k lNSTRUCTION ISSUE REVISIOPe PAGE TEXAS UT1UTIES GENERATING CO. DAM CPSES QI-QP-11.4-26 4 *

,,;M u o go, 7 of 34 2.3.5.4 When coating naterial s are mixed / thinned, the inspector verifying the mixing operation shall fill out the Paint Mix Sli p, Attachment 3. The inspector perfo nning the pre-application inspection shall record the mix sheet number on the travelers. The Mix Slip shall be returned to the Paper Flow Group at the end of each shift to be sent to the vault.

2.4 PRIER APPLICATION INSPECTION 2.4.1 Monitoring of Primer Application During application operations of D-6 and CZ-11, the QC Inspector shall monitor that the pressure pot is continuously agitated. The QC Insptctor shall also verify that the hose length does not exceed 75 feet. CZ-11 and D-6 shall not be brush applied to areas larger than 1 sq. ft.

2.4.2 During . application of Carboline 191, the inspector will

- monitor to assure that no fisheyes appear in the applied coating. If detected, the inspector shall infonn the paint forenan of their presence and that they should be removed while coating is still wet, surface cleaned with solvent and coating reapplied.

2.4.3 The inspector shall monitor the pot life in accordance with Attachment 8.

2.5 INSPECTION OF PRIMER .

2.5.1 Primer Inspection Prior to Application of Seal or Finish Coat

a. Verify the primer has cured sufficiently for the top coating (as detennined by the use of a nickel test on 06 and CZ-11). Cure to top coat of Carboline 191 shall be the same as time to recoat for Phenoline 305, stated in Sec. 2.9.1.
b. Perfonn a visual inspection of. the primed surface in accordance with the following:
1. Runs / sags which do not exceed the maximum dry film thickness for each coating applied and show no evidence of mud cracking or loss cf adhesion are acceptable. Repairs for runs / sags other than the aforenentioned shall be per Sec. 2.6.2 or 2.6.3, as applicable.

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CPSES QI-QP-11.4-26 4 M R 0 8 ig g a of 34

2. Dry Spray - Must be renoved before overcoating per Sec. 2.6.3. -
3. Contanination - unacceptable; renove and repair per Sec. 2.6.2 or 2.6.3, as applicable.

Oil and arease - unacceptable; renove and repair i per Sec. 2.6.2 or 2.6.3, as applicable. I

4. Skips / damaged areas / holidays or voids .-

unacceptable; repair per Sec. 2.6.2 or 2.6.3, as applicable.

5. Orange peel - Moderate amounts are acceptable.

Other than moderate amounts; repair as Sec. 2.6.3.

6. Bubbling - unacceptable; repair per Sec. 2.6.2 or 2.6.3, as applicable (does not apply to CZ11).
c. The inspector shall perfonn a DFT inspection of the cured primer film. A calibrated 0-25 Elcometer
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. Sirice the magnetic gage is sensitive to gemetric discontinuities in the steel, measurenents less than 1. inch from the edge or a hole should be avoided (See Note 3).

Dry Film Thickness shall be as follows (See Note 4):

Min. (mils) Max. (mils)

Carboline 191 spot test 1.6 7.0 CZ-II spot test 1.5 7.0 l D6 spot test 1.5 5.5 06 average DFT 2.0 5.0 CZ-II average DFT 2.0 6.0 Carboline 191 average DFT 2.0 6.0 l NOTE 1: A spot measurenent 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 measurenent, s

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i 3 s INSTRUCT!CN ISCUE DATE N TEXAS UTluTIES GENERATING CO. l CPSES QI-QP-11.4-26 4 MAR 0 3 g 9 of 34

. NOTE 2: Five spot tests shall be taken for every 100 square feet of coated surface. 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 '

143 2 3-0 1 NOTE 3: Itans with appreciable surface curvature and other geometrical di scontinuities, such as handrail s, gratings, stairs , sway struts,

, checker plate, etc., shall be exempt from dry tilm thickness measurenent. For piping, struts, soring canisters, etc. Appreciable curvature will be considered as less that 4" in diameter 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 soaced radially at . approximately 120 degree intervals to detamine the extent of

, the unacceptable area. Unnacceptable areas shall be repaired per Sec. 2.6.3 or 2.6.4.

2.6 PRIMER REPAIRS

, 2.6.1 Sacs and Runs Runs / sags which do not exceed the maximum dry film thickness for each coating applied and show no evidence of mud cracking or loss of adhesion are acceptable. Repairs for runs / sags other than the aforementioned shall be removed. Repair per Sec. 2.6.2 or 2.6.3, as applicable.

2.6.2 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 performed for surface i

preparation. -

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hSER REVISION l PAGE TEXAS UTluTIES GENERATING CO. I O

QI-QP-11.4-26 4 i.2a? O 3 icg4 10 of 34 l

a. Surface preparation Ref. Sec. 2.2.2.

i b. Verify that the blasted or power tooled surface has been high pressure air blowdown, and/or solvent wiped to the extent required for final surface inspection.

The adjacent areas shall be cleaned to the extent necessary to avoid _ contamination during subsequent coating applications.

c. Ambient Conditions: Ref. Attachment 1A and 6.

The surface temperature shall be a minimum of 5' above the dew point. .

d. Verify applicator qualifications per 2.3.4.
e. Verify air supply acceptability per Attachment 18.
f. Mixing operation, Reference Sec. 2.3.5.
g. Verify that primer is applied in accordance with Sec. 2.4.

NOTE 1: (If applicable) Coating interface - at coating interface for finish and/or primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smooth final coating sys tem. When inspecting coating interface the interface of the coating or systens shall be a naximum of 14 inch in width. Within the interface area, overlapping of any naterials or systens is acceptable.

NOTE 2: When inorganic zinc is applied at an interface, the cured inorganic zinc shall be screened or ,

abraded prior to application of next coat.

2.6.3 Primer Touch-up Repair (Primer Damaae Does Not Extend to Steel Surface The coating inspector shall conduct the following inspections for primer touch-up repair operations when the damage is within the primer coat and sandblasting to the steel substrate is not required,

a. Verify surface is abraded lightly then wiped clean.

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CPSES '

QI-QP-11.4-26 4 'A~D 01 534 11 of 34

b. Perfonn inspections in Sec.(s) 2.3 (except 2.3.2) and 2.4. ,
c. Visually verify acceptability of repaired area per Sec. 2.5. I 2.6.4 Repair of Primer by Recoating The coating inspector shall conduct the following inspections for primer recoating repair. Only two (2.)

overcoats may be applied of inorganic zine primer,

a. Verify that the surface has been solvent cleaned or blown down with high air pressure. Contamination is unacceptable and requires further cleaning.
b. Perfonn inspections in Sec.(s) 2.3 (except 2.3.2) and 2.4.

NOTE: After application of primer to the spot primed area, the only additional feathering required is at the outer edge of the primed area. Sanding of the primed area is not required. ,

2.6.5 Caplete Primar Reoair (Primer Damage to Steel Surface Extends Over Entire Item)

The coating inspector shall conduct the following inspections to document pri:ner repair when the damage is to the steel surface and requires surface preparation to steel substrate over entire itsu:

a. Verify anbient conditions per Attachment IA prior to l surface preparation. See Attachment 6.

~

b. Perfonn inspections (a) through (g) in Sec. 2.6.2.

2.6.6 In-process repairs shall be documented on the Traveler (Attachment 4) showing their . status and/or capletion.

2.7 FINISH COAT PRE-APPLICATION INSPECTIONS The QC inspector shall verify the following itens prior to applying coatings:

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INSTRUCTION m ISSUE 8B EO N TEXAS UTIUTIES GENERATING CO. DAM CPSES QI-QP-11.4-25 4 I',"^

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12 of 34 2 '. 7.1 Coating Applicator Qualifications The Inspector shall verify (by Qualification Record or list of qualification reconis in QA File) that the coating applicaton on each shift are qualified for safety-related coating work.

2.7.2 Ambient Conditions (Refer Attachment 1A and 6)

The pennissible range of surface and ambient tenperature for application of finish coat shall be 50-120*F.

The maximum humidity shall be 85% for Phenoline 305, and Cartoline 191. The neximum humidity shall be 95% for inorganic zines.

The surface tenperature shall be a minimum of 5'F above the dew point.

2.7.3 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). The defective areas shall be removed and repaired per Sec. 2.6 as applicable, 2.7.4 Air Supply Acceptability (Per Attachment IB)

^

2.7.5 Finish Coat Mixing Operations 2.7.5.1 Prior to mixing, the mixing inspector shall verify that each camponent is identified by batch ntsnbers and that the 24 month shelf life has not been exceeded. Pot li,fe shall be monitored in accordance with Attachment 8.

2.7.5.2 The mixing inspector shall verify that mixing / thinning operations are perfonned in accordance with Sec. 2.3.5.

Thinning may be done up to two quarts of Phenoline Thinner per gallon of Phenoline 305.

2.7.5.3 Mixing operation shall be documented on the traveler per Sec. 2.3.5.4.

2.8 MNITORING 0F SEAL OR FINISH COAT APPLICATION no. , moco cA

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INSTRUCTION ISSUE N SER E" DAM N TEXAS UT!UTIES GENERATING CO. l .

CPSES QI-QP-11.4-26 4 MAh v a ed4 13 of 34 2.8.1 The Inspector shall verify that hose length does not exce.ed 75 feet. .

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2.8.2 The inspector shall also verify that the seal coat (1f l present) is solvent with xylol or 305 thinner wiped prior i to finish coat application.

2.8.3 The inspectc" shall monitor to assure that no fisheyes appear in th applied coating. If detected, the inspector shall infonn the point foreman of their presence and tha.t they should be reoved while coating is still wet, su rface cleaned with solvent and coating reapplied.

2.8.4 The inspector shall monitor the pot life in accordance with Attachment 8.

2.9 FINISH COAT FINAL ACCEPTANCE INSPECTION-The inspector shall perfonn a final acceptance inspection of each finish coated .itan(s) in accordance with Paragraphs 2.9.1 through 2.9.4.

NOTE 1: (If applicable) Coating interface - at coating interface for finish and/cr primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smooth firal coating systs. When inspecting coating interface the interface of the systems shall be a maximtsn of th inch in width. Within the interface area, overlapping of any materials or systems is acceptable.

NOTE 2: The tie in interface between concrete coatings and steel coatings shall be visually inspected during the finish coat final acceptance of both systems.

NOTE 3: When inorganic zine is applied at an interface, the cured inorganic zinc shall be screened or abraded prior to application of next coat.

l 2.9.1 Finish' Coat Cure Final QC inspection may be perfomed 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 /> and cure to recoat time has been met.

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INSTRUCTION ISSUE PAGE TEXAS UTIUTIES GENERATING CO.

NU K ER WS[N DATE CR Es Ql-QP-11.4-26 4 MARO R icy zgof Curing and time to recoat for Cartoline 191 and Phenoiine 305 shall be as shown below: -

Between Coats Tenperature 'F 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> 50 - 59 '

36 hours4.166667e-4 days <br />0.01 hours <br />5.952381e-5 weeks <br />1.3698e-5 months <br /> 60 - 74 18 hours2.083333e-4 days <br />0.005 hours <br />2.97619e-5 weeks <br />6.849e-6 months <br /> 75 - 89 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> 90 and above Phenoline thinned at 50% and applied as a seal coat may be recoated after 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> of cure at or above 75'F.

- 2.9.2 Visual Defects Inspection -

The Inspector shall perfonn 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 15.0 mils or less thick, which show no evidence of mudcracking, are acceptable. Those greater than 15.0 mils shall be repaired per Sec. 2.10.1.

b) Skips, damaged areas, holidays, voids, bubbles, and blisters are. not acceptable and shall be repaired per Sec. 2.10, as applicable.

Pinholes c) ' Attachment

- acceptable to the extent allowed by 5; areas not acceptable shall be repaired per Sec. 2.10.5.

d) Contamination - unacceptable; areas shall be repaired per Sec. 2.10.4. Ref. Attachment 7. I e) Dry spray - unacceptable; shall be ~ repaired per Sec.

2.10.6. A minor amount of adherent dry spray is acceptable on the final finish coat. Ref. Attachment 7. i f) Color and gloss non-unifonnity - unacceptable; shall l be repaired per Sec. 2.10.8. Ref Attachment 7.

g) Orange Peel: Moderate amount is acceptable, other than moderate amounts to be reparied per Sec. 2.10.7.

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. INSTRUCTION REVISION ISSUE ER OATE PAGE TEXAS UTIUTIES GENERATING CO. .

l j CPSES i QI-QP-11.4-26 4 t,M 0 3 g 15 of 34 j l

l NOTE 1: - Top coated areas which have been abraded for various

- reasons (runs , sags, high millage, and '

~ contamination) and are wi thin acceptable  !

procedural thickness following repairs, do

, not require recoating for gloss enhancing.

NOTE 2: For small repair areas such as pinholes, color and gloss unifonnity is not required ,

provided the coating is smooth and continuous.

2.9.3 Ory Film Thickness (DFT)

The Inspector shall perfonn a DFT of the cured coating system. A calibrated 0-25 E1cometer 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 fram an edge or a hole should be avoided. (See Note 3).

The average DFT of the total coating systen shall be a minimum of 6.0 mils and a maximum of 13.0 mils. The spot test OFT of the total coating systen shall be a minimum of 6.0 mils and a maximum of 15.0 mils (Ste Note 4).

The finish coated sys ten shall- exPibit ful1 " hiding" properties of the primecoat.

4 NOTE 1: A spot measurement is a series of three measure-ments in the same general area. The probe should be noved 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 rment.

NOTE 2: Five spot tests shall be taken for every 100 square feet of coated surface. For areas less than 100 square feet, the following shall apply:

Area Sq. Fti. No. Spots 100-80 5 80-50 4 50-10 3 10-3 2 3-0 1 me nu Tuoco cA ,

. - . ~ - . . _ , - - - _ _ _ _ _ . _ _ __ _ _ - . _ . - _ _ _ _ _ . - . , . - . _ . . . _ _ _ _ . . . _ _ _ _ _ - _ . . _ _ - _ . _ _ _ - , . - . _ . - _ _ _ _ . , _ . - . .

g INSTRUCTION ISSUE NUMBER REVISION t AGE TEXAS UTIUTIES GENERATING CO. I DATE CPSES QI-QP-11.4-26 4 W d i E4 16 of 34 i

. NOTE 3: itms with appreciable surface curvature and other

. ge wetrical discontinuities such as handrails.

checker plate, gratings, stairs, sway struts, etc.

shall be exmpt from DFT measurement. For piping, struts, spring canisters, etc., ap'preciable surface curvature will be considered as less than 4" diameter.

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 unacceptable spot and spaced radially at approximately 120 degree intervals to detennine a the extent of the unacceptable area. Dirensions and locations of unacceptable areas and results of additional testing shall be documented on the traveler / sketch. Unaccpetable areas shall be repaired per Sec. 2.7, 2.8, and 2.9.

2.9.4 Continuity Inspection

~

The. Inspector shall test the continuity of the cured finish coat on liner plate using a Tinker and Rasor Model M1 (67.5 volt) holiday detector. 100% of the finish coated surface area shall be tested.

The applied film should contain only a minor nunber of points of di scontinuity. No more than two points of discontinuity should occur within an area having a radius of 6 inches as measured from a point of discontinui ty (pinholes). No nere than 40% of the total nunber of allowable points of discontinuity should occur. within any one area equal to 251 of the total area being coated. The

, total number of pinhole discontinuities allowed is defined in Attachment 5. No gross discontinuities are allowed.

2.10 REPAIRS OF FINISH COAT.

2.10.1 Repairs of Runs and Saas The QC inspector shall verify that the area is abraded until the DFT of the total coating syste is within 6.0 and 15.0 mils, and examined for mudcracking. Mudcracking, if present, shall be removed and repaired in accordance with Sec. 2.10.2 or 2.10.3.

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INSTRUCTION ISSUE DAM N TEXAS UTILITIES GENERATING CO.

CPSES QI-QP-11.4-26 4 MAR J 8 ic34 17 of 34 2.10.2 Repair of Minor Defects The QC inspector shall perfonn the following inspection when repairing minor defects:

a) Verify anbient conditions per Attachment 1A prior to surface preparation.

b) Verify that the damaged area is blasted or abraded by hand or power tool until all loosely adherent particles are renoved. l c) Verify damaged ared is solvent wiped.

d) Perfonn inspections described in .Sec. 2.7, 2.8 and 2.9.

as applicable.

e) Minor defects may be repaired at the time of final inspection without later reinspection of the repair.

..- 2.10.3 Repair of Major Defects

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The QC inspector shall perfonn the following inspection when repairing major defects; if damage goes to substrate power

tools shall be used in lieu of handsanding. ,

a) Verify ambient cc.1ditions per Attachment 1A and 6.

b) Verify area is power tooled or spot blasted until alI i

loosely adherent particles are removed. I c) Verify area is solvent wiped.

d) Perfonn inspections in Sec. 2.2.2, 2.7, 2.8 and 2.9.

2.10.4 Reoair of Contamination The QC inspector shall verify that contamination is removed.

If contamination can be removed by abrasion without affecting the continuity of the systen, recoating of the area after removal is not required if the coating system thickness is within procedural limits. (Reference Sec. 2.9.2 Note 1).

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f .s 1NSTRUCTION

  1. ISSUE 82 DAM N TEXAS UT1UTIES GENERATING CO.

CPSES QI-QP-11.4-26 4 fJAR0 o isg4 18 of 3

, 2.10.5 Repair of Pinholes and Small Discontinuities a) Verify all loose particles are removed and area is solvent wiped.

b) Pinholes and small discontinuities may be repaired at the time of final inspection without a later -

reinspection cf the repair. The inspections in Sec. 2.7 and 2.8 still apply.

2.10.6 Repair of Dry Spray Repair of dry spray identifiable by visual inspection defined within this procedure .ihall be removed.

a) Verify all loose particles are renoved.

b) Verify coating film thickness is still within allowable range.

c) If film thickness is not within allowable range perfonn inspections in Sec. 2.7. 2.8 and 2.9. ,

NOTE: A minor amcunt of adherent dry spray is acceptable on the final finish coat.

2.10.7 Repair of Other Than Moderate Amounts Of Orance Peel l

a) Verify the affected area is abraded and solvent wiped.

b) Verify the affected area is refinished and perfonn the inspections delineated in Sec. 2.7, 2.8 and 2.9.

2.10.8 Repair of Gloss and Color Nonunifonnity a) Verify the affected area is abraded and solvent wiped. l b) Verify the affected area is recoated without exceeding the maxina film thickness and perfonn inspections in Sec. 2.7, 2.8 and 2.9.

c) Top coated areas which have been abraded for varfous reasons (i.e., runs, sags, high millage, and contamination) and are within acceptable procedural ~l thickness, following repairs, do not require recoating for gloss enhancing.

d) For small repair areas such as pinholes, gloss and gloss unifomity is not required, provided the coating is

smooth and continuous.

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INSTRUCTION ISSUE DAM N TEXAS UTluTIES GENERATING CO.

CPSES QI-QP-11.4-26 4 MAR 0 8 1984 19 of 34 2.10.9 Docunentation of In-Process Repairs In-process repairs shall be' documented on the traveler (Attachment 4) showing their capletion and/or status.

2.11 NONCONFORMANCES 2.11.1 Nonconforming conditions such as coating failure due to loss of adhesion or indetenninate/ unacceptable conditions which cannot be repaired or corrected as per existing procedures shall .be documented on a Nonconfonnance Report (NCR) in accordance wi th CP-QP-16.0. The NCR nunber shall be referenced on the inspection traveler, if applicable.

2.12 DOCUMENTATION (REFER TO ATTACHMENT 4) 2.12.1 All inspections required by this procedure shall be recorded in the inspection attributes on the back of the travelers (Attachment 4). Preparation and processing of the traveler j shall be per QI-QP-11.4-28.

2.12.2 When the inspections required by Sections 2.1 through 2.2.2 have been satisfactority capleted, Step 1 snall be signed vid dated by the inspector.

2.12.3 When the inspections required by Sections 2.3 through 2.6.5 hacie been satisfactorily capleted. Step 2 shall be signed and dated by the inspector.

2.12.4 When the inspections required by Sections 2.7 through 2.8.4 have been satisfactorily capleted, Step 3 shall be signed and dated by the inspector.

2.12.5 When the inspections required by Sections 2.9 through 2.10.8 have been satisfactorily capleted, Step 4 shall be signed and dated by the inspector.

2.13 SPECIA, COATINGS PROCEDURES Special coatings procedures and instructions set forth in CCP-30-M1 through CCP-30-M9, as applicable under the scope of this procedure, shall be inspected as per the guidelines of this procedure y.ing the criteria established in the special coatings procedures.

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' lNSTRUCTION R I NUM8ER 33CN PAGE O

  • TEXAS UTluTIES GENERATING CO.

CPSES QI-QP-11.4-26 4 MAR 0 3 1334 20 of 34 3.0 CLARIFICATION 3.1 SHOP COATED ITEMS 3.1.1 Itens reoved fram the building for coating at the paint shop shall be the responsibility of the craft department.

3.1.1.1 The craft shall be responsible for identifying each piece by work package number.

3.1.1.2 The craft shall be responsible for. returning and installin'g the shop coated iten in the same area it was removed from.

3.1.2 The shop QC Inspector shall inspect the itan(s) in accordance with QI-QP-11.4-1 and QI-QP-11.4-5, as applicable, and document his inspections on an Inspection Report (IR) in accordance with those procedures.

3.1. 2.1 In addition to the information required by 11.4-1 or 11.4-5, the shop inspection shall reference the work package number identified on the itan(s) on the Inspection Report (IR).

3.1.2.2 "The IR, upon completion, shall be transmitted to the Paper Flow Group (PFG) for inclusion in the work package.

3.1.3 The QC Inspector (in the field) shall verify that itens prepared / coated in the shop, which are included in the scope

  • of the traveler, have the applicable inspection reports (IR) from the shop included in the work with the identification on the item (s) package and correspond 3.1.4 Items which have been finaled in the shop but incur mechanical damage during reinstallation shall be repaired in accordance with QI-QP-11.4-26 and docunented on the traveler accordingly.

3.2 REPAIR OF ECHANICAL DAMAGE TO COMPLETED ITEMS 3.2.1 Areas that have been completed, inspected, accepted and r traveler package closed Witch incur najor damage at a later date may be repaired, inspected and documented on the supplemental traveler Attachment 9, "S teel Protective Coating Inspection Repair Traveler". Otherwise, the minor areas of mechanical damage, which occur after completion of an area, will be repaired during the final protective coatings walkdown.

Pusue sem t

m INSTRUCTION ISSUE TEXAS UTIUTIES GENERATING CO.

8 OAM CPSES QI-QP-11.4-26 4 upo n g g 21 of 34 3.3 EXCLUSION AREAS ,

3.3.1 Clarification / Definition 3.3.1.1 Areas dich are scheduhd to be paintad but due to limited or no access are not possible to be painted at the present time and are beyond the control of protective coatings craft or quality control .

3.3.1.2 Building Management and/or the Paper Flow Group (PFG) shal.1 detennine the legitimacy of excluding an area.

3.3.2 Areas dich are detennined as exclusions shall be so noted on the original traveler and a new traveler will be generated by PFG to encanpass the exclusion (s). -

l l 3.4 INACCESSIBLE / LIMITED ACCESS AREAS 3.4.1 Clarification / Definition 3.4.1.1 Areas dere, due to pennanent installation configuration, a dry film thickness (OFT) gauge cannot be properly engaged.

l 3.4.2 These areas shall be visually inspected to verify that the primer is applied and the finish coat is applied over the primer. No other inspection is required.

4.0 ATTACHMENTS 4.1 Attachment 1, " Ambient Condi tions" 4.2 Attachment 18. " Air Supply Acceptability" 4.3 Attachment 2 " Preparation of Coating Materials" 4.4 Attachment 3. " Paint Mix Slip" 4.5 Attachment 4. " Steel Protective Coating Inspection Traveler" 4.6 Attachment 5 " Total Naber of Allowable Points of Discontinuity * .

4.7 Attachment 6. " Environmental Log Sheet" 4.8 Attachment 7. " Definitions" 4.9 Attachment 8. " Pot Life Reference Sheet" 4.10 Attachment 9 " Steel Protective Coating Inspection Repair Traveler" am , moco on

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' N ISSUE 8 RL .dlON PAGE 4 TEXAS UT1UTIES GENERATING CO. DAM CPSES

, QI-QP-11.4-26 4 AIAR u 6 ba4 22 of 34 ATTACHMENT .1A

, Ambient Conditions The inspector she.11 detennine against the Envirorinental Sheet (Attachment 6) air temperature, surface tenperature, relative humidi ty and dew point of substrate structures.

A calibrated non-mercury filled bulb thennometer or calibrated tanperature reconfer dry (Bristol 4069TH or equivalent) shall be used for air temperature detennination. A calibrated non-mercury wet bulb thennameter or a calibrated humidity recorder (Bristol 4069TH or equivalent) shall be used to detennine relative humidi ty. The dew point shall be determined i by the difference in dry and wet bul b taperatures ,

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 detennined using the 100*F dry bulb reading.

If the dry bulb thermometer exceeds 100*F, the instrument ,

, shall be returned to the calibration lab for recalibration.

The surface tanperature shall be detennined by placing a calibrated surface taperature thennometer (Omega-Amprobe fast temp. range of 10*-250 *F) in contact with the substrate surface until the taperature reading stabilizes. .

Final surface preparation shall not begin unless the temperature of the surface is a minimim of 5*F above the dew point.

) Nonnal condi tions of ambient and surface tenperature for application of primer shall be as follows:

Ambient Teno. (*F) - Surface Teno. (*F)

Dimeteote 6 40-120 40-130 Cadm Zinc 11 40-95 40-110 Carboline 191 50-120 50-120 Phenoline 305 50-120 50-120 Inorganic zinc primer may be applied within an ambient range of 0 F to 130*F and surface tanperature range of 0*F to 200*F.

Hupiidity values nay vary from 0% to 95% for inorganic

. primers; however, primers shall not be applied to a wet or damp surface.

n, Tuococ4

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INSTRUCTION I NUMBER RL.olCN O PAGE TEXAS UTIUTIES GENERATING CO.

CPSES ,

QI-QP-11.4-26 4 M4P 0 ? ie , 23 of 34 l ATTA0iMENT 1A (Cont.)

Minimum and maximum values of relativt humidity for Phenoline 305 and Carboline 191 shall be 0% to ,853.

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. INSTRUCTION ISSUE 8 OAM N I TEXAS UT1UTIES GENERATING CO.

QI-QP-11.4-26 4 # 0 6 1984 24 of 34 ATTACHMENT 18 Air Supply Acceptability An inspector shall inspect the air supply systen of blast and spray equipment for suitable filters / traps / separators and that they are lef t cracked open. The effectiveness of these items shall be verified by exposing a piece of white cloth to the air outlet for approximately 30 seconds. The .

white cloth shall be examined for evidence of contamination (oil, water, foreign ma tter, e tc . ) . No evidence of contamination is acceptable.

paim m TUGCC CA ,

INSTRUCTION ISSUE ER O DATE N

. TEXAS UTluTIES GENERATING CO.

CPSES QI-QP-11.4-26 4 M 0 S i934 25 of 34 ATTACHMENT 2 PREPARATION OF COATING MATERIALS Primer - The primer, Carbo Zinc 11, is packaged in a two component kit consisting of a base and a zinc filler. First the base shall be thoroughly mixed. Zinc filler shall then be added under constant agitation and mixed until free of lumps. Partial' mixes shall be mixed by weight in a proportion of 10 parts base to 22 parts zinc filler using a sui table scale to achieve a plus or minus 2 percent accuracy. The mixture shall then be strained through a

, 30-mesh screen.

Viscosity shall be controlled by adding thinner, as required, but shall not exceed two quarts of thinner per gallon of

, Carbo Zinc 11.

Primer. - The kimer, Dimetcote 6, is packaged in a two component kit consisting of a base and zine filler. The base shall be thoroughly mixed first. Zinc filler shall then be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in a proportion of 6.4 parts base to 15 parts zinc filler using a suitable scale to ' achieve a plus or minus 2 percent accuracy. The mixture shall then be strained through a 30-mesh screen. Viscosity shall be controlled by adding

. thinner as required up to the maximisn allowed by the latest revision of Dimetcote 6 application instructions. Primer

coat shall be reddish gray. i Primer Coat - The primer coat, Carboline 191, is packaged in a two component kit consisting of Carboline 191 base, Part A, and a catalyst, Part B. Mixes are made by combining and thoroughly mixing the base and catalyst. Partial mixes may be made by combining, in a ration by volume, two parts base to one part catalyst. Viscosity shall be controlled by adding thinner as required, but shall not exceed two quarts j of thinner per gallon of Carboline 191.
' Finish Coat - The finish coat, Phenoline 305, is packaged in a two component kit consisting of Phenoline 305 base, Part A, i and a Phenoline catalys t, Part B. Mixes are nude by combining and thoroughly mixing the base and catalyst.

Partial mixes may be made by combining, in a ration by

. volume, four parts base to one part catalyst. Viscosi ty shall be controlled by adding thinner as required, but shall not exceed two quarts of thinner per gallon of Phenoline 305.

p .a , TUGeo cA

l lNSTRUCTION ISSUE WMBER RE. 41CN AGE TEXAS UTIUTIES GENERATING CO. DATE CPSES QI-QP-11.4-26 4 26 of 34 MAR U o 4 ATTACHMENT 3 PAINT MIX SLIP *

<eport No. _ . ,

Sidg.

DATE POT LIFE SHIFT TIME Ml! NUSMER ELEVATION _

MATERIAL GAL. MIXED SHELF LIFE ACCEPATBLE: TES NO M6TE s's DATE & TIME M!IED BASE CURING AGENT FILLER THINNER ACCEPTED 11Y

. I i

DATE POT LIFE SHIFT T!!E MII NUM00t_ _..._. ELEVAT10N MATERIAL GAL. tt!IED SHELF l!FE ACCEPTA4LE: YES NO MATE d's DATE & TIME MIXED BASE CURING AGENT FILLER THINNER ACCEPTED BY DATE POT LIFE SHIFT TIME MIX NUESER ELEVATION MTERIAL GAL. M!IED SHELF LIFE ACCEPTABLE: TES NO MSTE l'1 DATE & TIME M!IED BASE CURING AGENT FILLER THINN01 ACCEPTTO ST QC REVIEW & ACCEPTANCE sIgneture da te Muut h 1 N M

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l  !

PROCECURE ISSU NUMBER I

DATE PAGE l AEVISION l TEXAS UTIUTIES GENERATING CO.

g CPSES  !

4 MAR 0 3 19c4 28 of 34 '

l01-0P-11.4-26 A~TACHMENT 4 (Cont.)

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6 INSTRUCTION ISSUE OAM N TEXAS UT1UTIES GENERATING CO.

CPSES QI-QP-11.4-26 4 :AR 0 3 sg4 29 of 34 ATTA0iMENT 5 T0TAL NUMBER OF ALLOWABLE POINTS OF DISCONTIP!UITY SURFACE AREA CONO. "C" BEING C0ATED COMMERCIALLY (50. FT.) CONTINUOUS 10 5 10-50 10 50-100 20 100-500 30 500-1000 50 9

1000-5000 75 Gross Discontinuities - None Allowed.

O

PROCEDURE REVISION ISSUE NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.

CPSES QI-QP-11.4-26 4 MAR 0 9 824 30 of 34 ATTACHMENT 6 i

Report No.

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ENVIRONMENTAL LOG SHEET MSTE 8's hee --

8189-Shift Unit TIM ORY GULS WET GULS RFACE T Mp M IDITY gg e 8 O

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INSTRUCTION ISSUE N

8 OATE

. TEXAS UTIUTIES GENERATING CC.

CPSES QI-QP-11.4-26 4 MA5 u o .; 31 of 34 4

ATTA04 MENT 7 OEFINITIONS Color and Gloss Nonunifomity: A milky haze or mist in the finish of a recently applied coating.

Contaminant: A foreign substance, inadvertently added to a coatino or found on the substrate that adversely affects the applicatio,,n, adhesion, curing and/or subsequent perfonnance of the applied coating.

Ory Spray: A dry powdery primer or finish coat readily renoved by

. light sanding with either sandpaper or a wire screen. A minor amount of adherent dry spray is acceptable on the final finish coat.

j Feathering: An area that is roughened and tapered to obtain a smooth and continuous surface with an existing coating.

Fisheyes: Small' openings (" fisheyes") in wet film exposing old surface or previous coat.

! Full Hiding: The coating provides sufficient coverage so that the  ;

preceding coat ts not readily visible with an unaided eye.

Holiday: A pinhole, skip, discontinuity or void in coating film.

Ma.ior Defect: Defined as an area, either circular or linear, in which a 1/2" diameter circle could be inscribed at any point or along the entire length.

1

, Minor Defect: Defined as an area, either circular or linear, in which a 1/Z" diameter circle could not be completely inscribed at any point along the entire length.

Monitor: Confomance verification by physically observing a task being perfomed on a periodic or random basis.

Muderacking: Irregular cracking as in a dried mud puddle (applicable to inorganic zinc primers).

i Orance Peel: Dents in the surface resanbling orange skin. A moderate amount is acceptable.

Verify: Confinn or make certain.

Pinholes
Minor discontinuities in coating which w40ses primer or t substrate.

Visual: To examine with an unaided eye (correctional eye glasses or contact lens are acceptable).

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TEXAS UTIUTIES GENERATING CO.

CPSES QI-QP-11.4-26 4 jWAR0 8 ga 32 of 34 ATTACHMENT 8 POTLIFEREFERdNCESHEET Normal Pot Life - CZ 11 8 Hours Pot Life 04 '

. n 284- - -

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, O as f-  !'  !> >*I' ge go 4e rs's los*! ust.: I1E'* -

Pot life stated above for unthinned coatings are the recommended times and should be utilized as a guidel.ine for cotins usage time, however, actural pot life may be longer. For unthinned coatings or coatings thinned 50% or less. acutal pot life is determined by-

' applicability of the coating.

POT LIFE PHENOLINE 305 & CAR 80LINE 191 TEMPERATURE (OF) UNTHINNED THINNED 50%

50-54 10 hrs. 24 nrs.

55-59 7 hrs. 24 hrs.

60-64 4h hrs. 24 hrs.

65-69 3 hrs. 24 hrs.

70-74 2 hrs. 24 hrs.

75-79 1 hrs . 24 hrs.

80-84 1 hrs. 24 hrs.

85-89 1\ hrs. 24 hrs.

90-95 1 hrs. 24 hrs.

Pot life stated above for unthinned coatings are the reconnended 3 times and should be utilized as a guideline for coating usage time, however, actual pot life may be longer. For unthinned coatings or coatings thinned 50% or less, actual pot life is determined by

.the applicability of the coating.

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,; . 7-PROCEDURE REVISION ISSUE NUMBER DATE PAGE TEXAS UTIUTIES GENERATING CO.

CPSES -

  • QI-QP-11.4-26 4 'AR 0 8 igg.: 33 of 34 ATTACHMENT 9 STEEL PMOTECTIVE COATING IN,9ECTION REPMt TRMELER

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petMarp 979 _ CATE 9*T OF STEP sunPAca msPAAAT:Cao WesPECTED Aae PCuae W.CEPTA48.3 PER GE=GPIL4*24 Afeo RELEASED POR Mtthet APm.; CAT 1088.

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I STEP Pasaset APPucAT1cm marecTrn Amo Pousso Ac=zPraats PER G8-CPIL4-ta Asso RELEASED POR PteSat CDAT APPUCATION.

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STE.* PosesM CCAT APPuCATlcas isaspt:TE3 Ape Riusso Ac:EPTAaLE PER 48-CPIL4=3a SISPW"CR *N ,

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  • STEP mansn cnAr assPtcTED Pan PmAs. manct Asso Pou.so Ac:EPfaaLE PER 48-4PIL4=RS

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  • a PROCEDURE ISSUE 1 NUMSER REVISION PAGE i DATE TEXAS UTILITIES GENERATING CO.

CPSES -

4 MAR 0 8 iga.:

QI-QP-11.4-26 34 of 34 ATTACHMENT 9 (Continued) 1 l

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, 75XAS UTTUTTE3 GENEAT1NC CO. BE . REVISICN PAGE I CPSES , , ,

3 l l 1 of 34 j QI-QP-11.4-26 l

, l MAR 0 5 1984l l RAT F RED BY v -8

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PREPARATION, PRIMER ' i APPLICATION, PRIMER 7-- / - M ! '

APPROVED BY: e ,u REPAIR, SEAL AND v - -

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FINISH COAT APPLICATION AND REPAIR APPROVED BY: a J[ /f

_. _a+ 1 1.0 GENERAL l

1.1 PURPOSE AND SCOPE The purpose of this instruction is to outline methods l

utilized by Quality Control personnel in inspection of steel  :

substrate surface preparation, primer application, primer  !

repair, seal and finish coat application and repair for  ! ,

Unit 1 Reactor Building. . ;- 7. .1

{/

I 2.0 INSTRUCTION Visual inspection of surfaces as addressed by this instruction shall be made at approximately an anns length  ;

from the surface being inspected. 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) 0-cell battery flashlight. Flashlight shall be held perpendicular to, the surface during visual inspection. ,

Visual aids fabricated on site and approved by Quality

Assurance and Engineering may be used by Inspectors as an ,

j aid in the perfonnance of their inspections. ,

l For definitions, refer to Attachment 7.

l l If a conflict arises between the requirements of this i procedure and the requirements of the site specification, i the requirements of the site specification shall prevail.

2.1 PRE-BLAST CLEANING OPERATIONS

' 2.1.1 Abrasive Acceptability l

l The Inspector shall obtain a sample of the abrasive to be used from each work area. The abrasive shall be verified i to be dry by feel . All grease, oil and deleteri.ous l l

material is unacceptable. j i

i l  !

%%. TUGCC CA o

I -

. INSTRUCTION REVISION ISSUE NUMBER DATE PAGE TEXAS UTIUTIES GENERATING CO.

CPSES QI-QP-11.4-26 3 MAR O 5 1984 2 of 34 Particle size must be suffiedent to achieve 1 mil surface 4

. _ _ _ _ . profile minimum.

2.1.2 Blast Equiament Acceptabil;tv The inspector shall perfom the' following inspections / tests

- = .to determine acceptability of blast t!emaina aa"4 a-at neine to use:

a. Air supply (refer to Attachment 18).
b. Ambient conditions (refarence Attachment 1A and 6).

2.1.3 Solvent Cleanino (If Contamination Is Present)

< If oil, grease, or o:her contamination is present, verify

. that solvent cleaning is performed and that contamination is removed prior to blast / power tool cleaning steel surfaces.

2.2 POST SURFACE PREPARiTION OPERATION l 2.2.1 Blast Cleanup The inspector stall visually check the blasted substrate su rface.

The surface she.11 be air blasted or solvent wiped to the extent required for final surface inspection. The adjacent 4 areas shall be cleaned to the extent necessary to avoid contamination during subsequent coating applications.

1 2.2.2 Blasted or Power Tooled Surface Acceptability The inspector shall perfonn the following inspections to determine acceptability of the blast cleaned or power tooled surface:

a. Absence of Foreign Matter -- A visual inspection shall be performed to determine that all oil and grease, di rt, millscale, rus t, corrosion products, 4

. oxides, paint or other foreign matter have been capletely removed fran the surface except for light shadows, very slight streaks or slight di scolorations caused by rust stains, mill scal e ,

oxides, or slight, tight residues of paint or coating that may renain . At least 95 percent of each square inch of surface area shall be free of all residues, and the renainder shall be limited

to light discolorations as mentioned above.

,,,,,, m Tuoc0 CA

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INSTRUCTION ISSUE NUMBER REVISION PAGE TEXAS UTluTIES GENERATING CO. DATE CPSES MAR 0 S 1ega 3 of 34 QI-OP-11.4-26 3 4

NOTE: In addition to the 5 percent of tight residue of paint or coating wh'ich is pennissible, shadows or tightly adhering residues of primer may remain (without limit) in the profile of the previously prepared substrate. However, areas with residues of Carboline 191 primer shall be recoated with Cartoline 191 primer. Areas wi th residues of inorganic zinc may be coated with either inorganic zine or Carboline 191 primer.

b. Sha m Projections -- An inspection for sharp projections that were not rounded during blast cleaning or power tooling shall be perfonned.

4 Wald spatter on structural steel dich renains after sand blasting will be acceptable.

l

c. Anchor - Pattern Depth -- The anchor pattern depth of surfaces shall be inspected at random locations asi necessary using a Keane-Tator Surface Profile ComparatoF (model 373)'or approved equal .

The ancnor pattern depth for all surfaces shall be a minimum of 1.0 mils.

Surfaces that have been power tooled with "3M Clean-N '

Strip", 60 grit and coarser " flapper wheels", provide acceptable surface profile, when properly used over a previously blasted and coated surfaces.

l 2.3 PRIMER PRE-APPt.ICATION INSPECTIONS 2.3.1 Ambient Conditions The inspector at the " paint distribution point" in Reactor 1

, shall verify ambient conditions in accordance with Attachment 1-A.

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, INSTRUCTION - REVISICN ISSUE PAGE

, TEXAS UTIUTIES GENERATING CC.

CPSES QI-QP-11.4-26 3 l4 of 34

!4Ah0 s 1984 l 2.3.1.1 Doctanentation of Envirormental Conditions

a. The inspector assigned to the " paint distribution point" in the Reactor building shall, as a minimum, take a complete set of readings (air temperature. -

relative humidity, . dew point and surface temperature) on each floor elevation at.least three (3) times each shift (preferably, the ' beginning, mid point and just prior to the end of each shift). More readings may be taken den necessary (i.e., noticeable change in air temperature, request by field inspector to take readings in a specific area, etc.).

b. The inspector at the " paint distribution point" shall document these readings on Attachment 6 as follows:

l

1. The inspector shall fill in the applicable

! information as delineated on the fa nn, excot for the " Report No. "

. (The Report NE will be filled in by the i they assign nisabers, prior ltoPaper Flow Group transmitting to thewhen I tS Vault.

2. Upon completion of the shift, the inspector shall turn all of the environmental log sheets for that shift into the lead inspectors.
c. The lead inspector (s) shall review the log sheets for

! completeness and correctness, sign and date the "QC Review" block, obtain copies for QC reference and transmit the originals to the Paper Flow Group.

d. If at any time the inspector determines readings which do not comply with the parameters set forth in this i procedure, he shall proceed in the following manner:
1. Immediately take an additional set of readings in the tsunediate area of the first set of unacceptable readings and record them on the environmental log.
2. If the additional set of readings are acceptable, i take a third set of readings for referee purposes I and record them. If the referee set of readings i are acceptable, then the area in question is i acceptable but should be closely monitored with I readings as necessary.

%g, TUGCC CA

. . INSTRUCTION ISSUE

~

NUMSER REVISICN PAGE DATE MS UTIUTIES GENERATING Co.

CPSES l QI-QP-11.4 3 y9 5 of 34 3 .' If the additional set of readings is unacceptab.le and/or the referee set of readings is unacceptable, >

the inspector is to' notify the coatings inspectors and/or craft personnel in the areas affected so that coating work nay be stopped at that time.

Coating work shall not continue until the ambient conditions resume an acceptable status.

4. When unacceptable ambient conditions occur and are ve.*1fied by step 3 above, the inspector shall document it on a Nonconfonnance Report (NCR) in '

accontance with CP-QP-16.0 and adequately identify the affected areas, elevations and itens.

[

2.3.2 Substrate Surface Acceptability The Inspector shall visually reinspect the sandblasted or powertooled surface of the substrate just prior to primer application for evidence of contamination (oil , grease, markings, rust, etc.) Contamination must be removed prior to priming.- l If rust fonns after Blasting or Power- Tooling, the surface shall be recleaned before priming.

. 2.3.3 Air Supply Acceptability

~

The Inspector shall inspect the air per Attachment 18.

2.3.4 Qualification of Applicator (s)

The Inspector shall verify (by Qualification Record or list l of qualified applicators from QA file) that the coating i applicators are The applicator (s) badge qualified ntsaber for safety-related shall be listedcoating on the wort. back .

of the traveler. l 2.3.5 Mixina Operations 2.3.5.1 Coating Materials Identification ,

An inspector shall inspect the coating material containers prior to mixing contents for product identification and

! verify that all materials are correct for coating 1

application.  !

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INSTRUCTION ISSUE ago, I REVISION 3 UT1UTIES GENERATING CO.

CPSES QI.qP-11.4-26 3 MAR 0 51984 5 of 34 Approved materials are:

CZ-11 Carto Zinc 11 base Carbo Zinc filler Carboline #21 or 33 Thinner DIETCOTE ,

Dimetcote 6 base Dimetcote filler Amercoat #65 or 101 Thinner CARBOLINE 191 -

Cartoline 191 Primer Carboline 191 Catalyst ,

Carboline #15 Thinner '

l PHENOLINE 305 Phenoline 305 base Phenoline 305 catalyst Phenoline thinner

. ' An inspector shall also verify that each component container is identified by batch n'aber and that the shelf life has not expired. Carbo Zinc 11 base and Carboline 191 has a shelf life of 12 months. Carbo Zinc filler, Dimetcote 6 base and filler, and Phenoline 305 all have a shelf life i of 24 months. Pot life shall be monitored in accordance with Attachment 8. ,

2.3.5.2 Mixing Operations a

An inspector shall witness each mixing / thinning operation.

The inspector shall verify that mixing operations are perfor.ned in accordance with Attachment 2.

Prior to distribution of CZ-11 in to the building it shall -

be power mixed or boxed.

2.3.5.3 Thinning Operation i

Coating materials (if thinned) viscosity control shall be accomplished by adding thinner as required, but shall not exceed two quarts of thinner per gallon of material .

TUGCC CA

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+ . I I hCTION REVIS!CN O DAGE TEXAS UTIUTIES GENERATING CO.

CPSES l QI-QP-11.4-26 3 7 of M MAR 0 a l$34 2.3.5.4 When coating notarials are mixed / thinned , the inspector verifying the mixing operation shall fill out the Paint Mix Sli p, Attachment 3. The inspector perfonning the pre-application inspection shall recoro the mix sheet nimber on the travelers. The Mix Slip shall be returned to the Paper Flow Group at the end of each shift to be sent to the vault.

2.4 PRIMER APPLICATION INSPECTION 2l4.1 Monitoring of Primer Application i'

During application operations of CZ-11, the QC Inspector shall monitor that the pressure po t is continuously agitated. The QC Inspector shall also monitor that the hose length does not exceed 75 feet. CZ-11 shall not be brush applied to areas larger than 1 sq. f t.

2.4.2 During application of Carboline 191, the inspector will monitor to assure that no fisheyes appear in the applied coating. If detected, the inspector shall infonn the paint i foreman of their presence and that they shculd be removed I while coating is still wet, surface cleaned with solvent and coating reapplied.

2.4.3 The inspector shall monitor the pot life in accordance with I

' Attachment 8..

2.5 INSPECTION OF PRIMER l 2.5.1 Primer Inspection Prior to Acolication of Seal or Finish Coat l a. Verify the primer has cured sufficiently for the top coating (as detennined b the use of a nickel test on

D6 and CZ-11). Cure to top coat of Carboline 191 shall be the same as Phenoline 305, stated in Sec. 2.9.1.
b. Perfonn a visual inspection of the primed surface in accordance with the following: a i
1. Runs / sags which do not exceed the maximum dry l film thickness for each coating applied and show no evidence of mud cracking or loss of adhesion 4

are acceptable. Repairs for runs / sags other than i the aforementioned shall be per Sec. 2.6.2 or 2.6.3, as applicable. l l

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. INSTRUCT!CN REVISION ISUE PAGE TEXAS UT1UTIES GENERATING CC.

CPSES I t l QI-Qp-11.4-26 3 o 34  ;

' MAR 0 a l$84 i

2. Dry Spray - Must be renoved before overcoating l per Sec. 2.6.3. ,
3. Contamination - unacceptacle; repair per Sec. l 2.6.2 or 2.6.3, as applicable.

Oil and arease - unacceptable; repair per Sec. l 2.6.3.

4. Skips / damaged areas / holidays or voids -

unacceptable; repair per Sec. 2.6.2 or 2.6.3, as applicable.  !

5. Orange peel - Moderate amounts are acceptable.

Other than moderate amounts; repair as Sec. 2.6.3.

6. Bubbling - unacceptable; repair per Sec. 2.6.2 or 2.6.3, as applicable (does not apply to CZ11).
c. The inspector shall perfonn a' 0FT inspection of t'ie I cured primer film. A calibrated 0-25 Elcometar Inspector DFT gage Model III/1E, or equivalent, sbill be used. Separa te spot measurements (See Note 1) spaced evenly over the structure (See Note 2) s tall l be taken. Since the magnetic gage is sensitivo to l geometric discontinuities in the steel, measure 1ents -

less than 1 inch from the edge or a hole sha 1 be avoided (See Note 3).

Dry Film Thickness shall be as follows (See Note 4):

Min.(mils) Max.(mils)

Carboline 191 spot test 1.6 7.0 l  !

CZ-II spot test 1.5 7.0 06 spot test '

1.5 5.5 06 average DFT 2.0 5.0 CZ-II average DFT 2.0 6.0 Carboline 191 average DFT 2.0 6.0 [ l l

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 measurenent. t I

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INSTRUCTION ISSUE M SER REVISICN AGE DATE

  • TEXES UT1UTIES GENERATING CO.

CPSES i QI-QP-11.4-26 3 9 of 34

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fAR 0 s 1984 NOTE 2: Five spot tests shall be taken for every 100 square feet, of coated surface. For areas less than 100 square feet, the following shall apply:

i 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 cunature and other geometrical discontinuities, such as handrail s, gratings, stairs, sway struts, '

checker plate, etc., shall be exempt from dry film thickness measurement.

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 approximately 120 2

degree intenals to detennins the extent of the unacceptable area.

In the event that the average of the area is unacceptable due to unacceptable spot readings, the unacceptable spots shall be 4

isolated as described above. Additional spot readings shall be taken equal to the number of unacceptable spot readings and the average recalculated .

l NOTE 5: Unacceptable areas shall be repaired per Sec.

2.6.3. ]

i 26 3

PRIMER REPAIRS 2.6.1 Saas and Runs  :

Runs / sags: Ref. Sec. 2.5.1.b if surface is unacceptable.

Repair per Sec. 2.6.2 or 2.6.3.

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INSTRUCTION REVISION ISSUE

  1. PAGE TEXAS UTluTIES GENERATING CO.

CPSES QI-QP-11.4-26 3 MAh 0 a isg4 - 10 of 34 2.6.2 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, hand sanding or power tool abrading is performed for surface preparation,

a. Surface preparation Ref. Sec. 2.2.2.
b. Verify that the blasted or power tooled surface has been high pressure air blowdown, and/or solvent wiped to the extent required for final surface inspection.

- The adjacent areas shall be cleaned to the extent necessary to avoid contamination during subsequent coating applications.

c. $nbientConditions: Ref. Attachment 1A and 6.

The surface tanperature shall be a minimum of 5' above the dew point,

d. Verify applicator qualifications per 2.3.4.
e. Verify air supply acceptability per Attachment 18.
f. Mixing operation, Reference Sec. 2.3.5.
g. Verify that primer is applied in accordance with Sec. 2.4.1.

NOTE: (If applicable) Coating interface - at coating interface for finish and/or primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smooth final coating sys ten. When inspecting coating interface the interface of the coating or systens shall be a eximum of th inch in width. Within the interface area, overlapping of any materials or systens is acceptable.

NOTE: When inorganic zine is applied at an interface, the cured inorganic zine shall be screened or abraded prior to application of next coat.

p.,,,, g , TUGCC CA

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INSTRUCT!CN E3G DAGE M SER l 0

TEXAS UTluTIES GENERATING CO.

Cms l QI-QP-11.4-26 3 MAR 0 5 584 11 of 34 2.6.3 Primer Touch-up Repair (primer Damace Does Not Extend to Steel Surface The coating inspector shall conduct the following inspections for primer touch-up repair operations when the damage is within the primer coat and sandblasting to the steel substrate is not required.

a. Verify surface is abraded lightly then wiped Elean.
b. Verify primer is applied in accordance with' Sec. 2.4.1.
c. Visually verify acceptability of repaired area per Sec. 2.5.1.b.

2.6.4 Repair of Primer by Recoatino The coating inspector shall conduct the following ---

inspections for primer recoating repair. Only two (2) overcoats may be applied of inorganic zine primer.

a. Verify that the surface has been solvent cleaned, or blown down with high air pressure. Contamination is unacceptable and requires further cleaning.
b. Perfonn inspections in Sec. 2.5.2.

NOTE: After application of primer to the spot primed area, the only addi tional feathering required is at the outer edge of the primed area. Sanding of the primed area is not required.

2.6.5 Complete Primer Recair (Primer Damace to Steel Surface Extends Over Entire Iten)

The coating inspector shall conduct the following inspections to document primer repair when the damage is to the steel surface and requires surface preparation to steel substrate over entire item:

I a. Verify ambient conditions per Attachment 1A to surface preparation. See Attachment 6.

b. Perfonn inspections (a) through (g) in Sec. 2.6.2.

2.6.6 In-process repairs shall be documented on the Traveler (Attachment 4) showing their status and/or completion.

hem rem, e TUGCC CA

INSTRUCTION I8OUE REVISION PAGE TEXAS UT!UTIES GENERATING CO.

DAM CPSES

]I-QP-11.4-26 3 MAR 0 51984 12 of 34 2.7 FINISH COAT PRE-APPLICATION INSPECTIONS The QC inspector shall verify' the following items prior to applying coatings:

2.7.1 Coatina-Acolicator Qualifications .

The Inspector shall verify (by Oualification Record or list of qualification records in QA File) that the coating applicators on each shift are qualified for safety-related coating work.

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_ 2.7.2 Ambient Conditions (Refer Attachment 1A and 6)

The permissible range of surface and ambient temperature for application of finish coat shall be 50-120*F.

The maximum humidity shall be 85% for Phenoline 305, and 95% for inonjanic zine and Carboline 191. -

The surface temperature shall be a minima of 5'F above the dew point.

. 2.7.3 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). The defective areas shall be repaired per Sec.(s) 2.6.2, 2.6.3, 2.6.4 and 2.6.5, as applicable.

2.7.4 Air Sucoly Acceotability (Per Attachment 18) 2.7.5 Finish Coat Mixina Operations 2.7.5.1 Prior to mixing, the mixing inspector shall verify that each

camponent is identified by batch nebers and that the

. 24 month shelf life has not been exceeded. Pot life shall

be monitored in accordance with Attachment 8.

2.7.5.2 The mixing inspector shall verify that mixing / thinner I operations are perfonned in accordance with Sec. 2.3.5.2.

Thinning may be done up to two quarts of Phenoline Thinner per gallon of Phenoline 305. '

4 2.7.5.3 Mixing operation shall be documented on the traveler per Sec. 2.3.5.4.

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I CTION I UE REVISION PAGE TEXAS UTluTIES GENERATING CO. . TE CPSES QI-QP-11.4-26 3 13 f 34 EP O e @

2.8 ICNITORING OF SEAL OR FINISH COAT APPLICATION 2.8.1 The Inspector shall monitor tlkat hose length does not exceed 75 feet.

2.8.2 The inspector shall also verify that the seal coat - (if present) is solvent wiped prior to finish coat application.

2.8.3 The inspector shall monitor to assure that no fisheyes appear in the applied coating. If detected, the inspector shall infonn the paint forman of their presence and that they should be removed while coating is still wet, surface cleaned with solvent and coating reapplied.

2.8.4 The inspector shall monitor the pot life in accordance with Attachment 8.

2.9 FINISH COAT FINAL ACCEPTANCE INSPECTION The inspector shall perfonn a final acceptance inspection of each finish coated itan(s) in accordance with Paragraphs 2.9.1 through 2.9.5.

, NOTE: (If applicable) Coating interface - at coating interface for finish and/or primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smooth final

^

coating syste. When inspecting coating interface the interface of the systems shall be a maximum of Ils inch in width. Within the interface area, overlapping of any materials or systems is acceptable.

NOTE: The tie in interface between concrete coatings and steel coatings shall be visually inspected during the finish coat final acceptance of both systas.

NOTE: When inorganic zine is applied at an interface, the cured inorganic zine shall be screened or

. abraded prior to application of next coat.

2.9.1 Finish Coat Cure Final QC inspection may be performed 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 /> and cure to recoat time has been met.

l Pom New , TUGCO CA

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INST 4UCTION ISSUE OAM N

,. TEXAS UTluTIES GENERATING CO. l CPSES QI-QP-11.4-26 3 MAR 0 51cg4 14 of 34 Curing and time Oc recoat Phenoline 305 shall be as shown below: -

8etween Coats Temperature *F ,

72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> 50 - 59 36 hours4.166667e-4 days <br />0.01 hours <br />5.952381e-5 weeks <br />1.3698e-5 months <br /> 60 - 74 18 hours2.083333e-4 days <br />0.005 hours <br />2.97619e-5 weeks <br />6.849e-6 months <br /> 75 - 89 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> 90 and above Phenoline thinned at 50% and applied as a seal coat may be recoated after 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> of cure at or above 75'F.

2.9.2 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 15.0 mils or less, which show no evidence of mudcracking, are acceptable. Those greater than 15.0 ' mils shall be repaired per Sec.

2.10.1.

b) Skips, damaged areas, holidays, voids, bubbles, blisters and excessive orange peel are not acceptable and shail be repaired per Sec. 2.10, as applicable.

c) Pinholes - acceptable to the extent allowed by Attachment 5; areas not acceptable shall be repaired per Sec. 2.10.5.

d) Contamination - unacceptable; areas shall be repaired per Sec. 2.10.4.

e) Dry spray - unacceptable; shall be repaired per Sec. .

2.10.6. A minor amount of adherent dry spray is acceptable on the final finish coat.

f) color ar.d gloss non-uniformity - unacceptable; shall be repaired per Sec. 2.10.8.

g) Orange Peel: Moderate amount is acceptable, other than mderate amounts to be reparied per Sec. 2.10.7.

I CTION ISSUE REVISION PAGE DATE TEXAS UT1UTIES GENERATING CO. ,

CPSES QI-QP-11.4-26 3 MAR 0 51984 15 of 34

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Top coated areas dich .have been abraded for various ,

reasons (i.e., runs, sags, high millage, etc.) and :ra within acceptable procedural thickness following repairs, do not require recoating fon gloss enhancing.

For snall repair areas such as pinholes, gloss and gloss unifonnity is not required, provided the coating is smooth and continuous.

2.9.3 Ory Film Thickness (DFT) .

The Inspector shall perfona a OFT of the cured coating system. A calibrated 0-25 E1cometer Inspector DFT Gage Model III/1E, 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 ,

measumments less, than 1 inch from an edge or a hole shall be avoided. (SeeNote3). ,

The average DFT of the total coatina systen shall be a minimum of 6.0 mils and a maximun of 15.0 mils. The spot test DFT of the total coatine system shall be a minimum of 6.0 mils and a maximum of 15.0 mils for CZ-11/305 and 191/305. For 06/305, average DFT of total systen, shall be a minimum 7.0 mils and a maximus of 11.0 mils. The spot test OFT of the total coatino systen shall be a minimum of 7 mils and a maximum of 11.5 m'Is (See Note 4).

The finish coated systen shall exhibit full " hiding" properties of the primecoat.

NOTE 1: A spot measurenent is a series of three measure-i monts 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 i

that cannot be repeated consistently. Take an j average of these three gage readings.as one spot measu renent.

I NOTE 2: Five spot tests shall be taken for every 100 square feet of coated su rface. For areas less j than 100 square feet, the following shall apply:

Area Sq. Ft. No. Spots 2

100-80 5 t

80-50 4

50-10 3

' 10-3 2 3-0 1 FeME ide, t WW CA l ,

INSTRUCTION ISSUE NUMSER REVISION PAGE TEXAS UTluTIES GENERATING CO. OATE t CPSES QI-QP-11.4-26 3 MAR 0 51984 16 of 34 NOTE 3: Itas with appreciable surface curvature and other geometrical discontinuities such as handrail s, gratings, stairs, sway struts, etc. shall be exmpt fra DFT measurement.

NOTE 4: In the event that any spot is found to be o'Jtsida of the acceptable thickness range, three additional spots shall be taken at approximately 6 inches from the failing spot and spaced radially at approximately 120 degree intervals to detennine the extent of the unacceptable area. Dimensions and locations of unacceptable areas and results of additional testing shall be documented on the traveler / sketch.

In the event that the average of the area is unacceptable due to unacceptable spot readings, the unacceptable spots shall be isolated as described above. Additional spot readings shall be taken equal to the neber of unacceptable spot readings and the average recalculated. If the recalculated average is acceptable, the traveler shall be so marked with an explanation in.

"Rea rks" stating that " average recalculated -

now acceptable", or wording to that effect. If the recalculated average is unacceptable, the unacceptable spots shall be isolated and repaired per Sec. 2.10. .

2.9.4 Continuity Inspection The Inspector shall test the continuity of the cured finish coat on liner plate using a Tinker and Rasor Model M1 (67.5 volt) holiday detector. 1005 of the finish coated surface area shall be tested.

The applied film should contain only a minor number of

. points of di scontinui 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 discontinuity (pinholes). No more than 40% of the ~ total neber . of allowable points of discontinuity should occur within any one area equal to 255 of the total area being coated. The total number of pinhole discontinuities allowed is defined in Attachment 5. No gross discontinuities are allowed.

2.10 REPAIRS OF FINISH COAT i

menn pee. , WGCC CA

INSTRUCTION ISSUE DAM N TEXAS UTlWTIES GENERATING CO.

CPSES QI-QP-11.4-26 3 MAR 0 o iS64 17 of 34 2.10.1 Recairs of Runs and Saas The QC inspector shall verify that the area is abraded until

. the OFT of the total coatig system. is within 6.0 to 13.0 mils, for CZ-11/305 and with a minimum 7.0 to 11.5 for D-6/305, and examined for mudcracking. Muderacking shall be repaired in accordance with Sec. 2.10.2 or 2.10.3.

2.10.2 Recair of Minor Defects The QC inspector shall perfom the following inspection when repairing minor defects; if damage goes to substrate power tools shall be used in lieu of hand sanding:

a) Verify ambient conditions per Attachment 1A prior to surface preparation b) Verify that the damaged area is blasted or abraded until all loosely adherent particles are reoved.

c) Verify damaged area is solvent wiped, d) Perfonn inspections described in Sec. 2.7, 2.8 and 2.9.

e) Minor defects nay be repaired at the time of final inspection without later reinspection of the repair.

2.10.3 Reoair of Major Defects The QC inspector shall perfonn the following inspection when repairing major defects; if damage goes to substrate power

. tools shall be used in lieu of handsanding.

a) Verify ambient conditions per Attachment 1A and 6.

b) Verify area is abraded or spot blasted until all loosely adherent particles are r eoved.

c)* Verify area is solvent wiped.

d) Perfonn inspections in Sec. 2.2.2, 2.7, 2.8 and 2.9.

2.10.4 Repair of Contamination The QC inspector shall verify that contamination is renoved by abrading and the surface recoated. The inspector shall perfor.n inspections delineated in Sec. 2.7, 2.8 and 2.9.

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TEXAS UWUDES GENERADNG CO.

8 0 CPSES QI-Q P-11.4-26 3 AR 0 51984 18 I 34 2.10.5 Repair of Pinholes and Small Discontinuities -

a) Verify all loose particles are removed and area is solvent wiped.

b) Pinholes and small discontinuities may be repaired at the time of final inspection without a later reinspection of the repair. The inspections in Sec. 2.7 and 2.8 still apply.

2.10.6 Recair of Dry Soray Repair of dry spray identifiable by visual inspection defined within this procedure shall be removed.

a) Verify all loose particles are removed.

~ b) Verify coating film thickness is still within

, allowable range, c) If film thickness is not within allowable range perfonn inspections in Sec. 2.7. 2.8 and 2.9.

NOTE: A minor amount of adherent dry spray is acceptable on the final finish coat.

2.10.7 Repair of Other Than Moderate Amodnts Of Orance Peel a) Verify the affected area is abraded and solvent wiped.

b) Verify the affected area is refinished and perfonn the

  • inspections delineated in Sec. 2.7, 2.8 and 2.9 ff repair exceeds minimum 0FT.

2.10.8 Recair of Gloss and Color Nonunifonnity ,

a) Verify the affected area is solvent wiped.

b) Verify the affected area is recoated without exceeding the maximum film thickness and perfonn inspections in Sec. 2.7. 2.8 and 2.9.

c) Top coated areas dich have been abraded for various reasons (i.e., runs, sags, high millage, etc.) and are within acceptable procedural thickness, following repairs, do not require recoating for gloss enhancing.

. d) For small repair areas such as pinholes, gloss and gloss unifonnity is not required, provided the coating is smooth and continuous.

. mere see, i TUGCQ CA _

SER 0 N TaxAs UT1unas osNERADNG CO.

CPSEs QI-QP-11.4-26 3 19 Of 34 MAR 0 5 1984 2.10.9 Documentation of In-Process Reoairs In-process repairs shall be documented on the traveler (Attachment 4) showing their completion and/or status .

2.11 NONCONFORMANCES 2.11.1 Unacceptable conditions which are not readily repaired or corrected per the approved procedures shall be documented as unsatisfactory on the inspection traveler. ,

2.11.2 Nonconforming conditions such as coating failure due to loss of adhesion or indetenninate/ unacceptable conditions which cannot be repaired or corrected as per existing procedures shall be docmented on a Nonconfonnance Report (NCR) in accordance with CP-QP-16.0. The NCR neber shall be referenced on the inspection traveler, if applicable.

2.12 00CUMENTATION (REFER TO ATTACHE NT 4) 2.12.1 All inspections required by this procedure shall be recorded in the inspection attributes on the back of the travelers (Attachment 4). Preparation and processing of the traveler shall be per QI-QP-11.4-28.

2.12.2 When the inspections required by Sections 2.1 through 2.2.3 have been satisfactorily completed Step 1 shall be signed and dated by the inspector.

2.12.3 When the inspections required by Sections 2.3 through 2.6.5 have been satisfactorily completed, Step ,2 shall be signed and dated by the inspector.

2.12.4 When the inspections required by Sections 2.7 through 2.8.4 have been satisfactorily completed Step 3 shall be signed and dated by the inspector. -

2.12.5 When the inspections required by Sections 2.9 through 2.10.7 have been satisfactorily completed, Step 4 shall be signed and dated by the inspector.

2.13 SPECIAL (DATINGS PROCEDURES Special coatings procedures and instructions set forth in CCP-30-M1 through CCP-30-M9, as applicable under the scope of this procedure, shall be inspected as per the guidelines of this procedure using the criteria established in the special coatings procedures.

. pwm eas. , TUGCC QA

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i INST 14UCTION REVISION ISSUE pggg TEtAS UT1uTIES GENERATING CO.

  • CPSES QI-QP-11.4-26 f3 MAR 0 5 584 l20 of 34 I

3.0 CLARIFICATION 3.1 SHOP C0ATED 1T095 3.1.1 - Items reoved from the butiJing for coating at the paint shop shall be the responsibility of the craft department.

3.1.1.1 The craft shall be resporstole for identifying each piece  !

by work package number.

3.1.1.2 The craft shall be responsible fbr returning and installing '

the shop coated its in tne same area it was removed from.

.' 3.1.2 The shop QC Inspector shall inspect the ite(s) in accontance with QI-QP-11.4-1 and QI-QP-11.4-5, as applicable, and I docuent his inspections on an Inspection Report (IR) in accordance with those procrAures.

3.1.2.1 In addition to the information required by 11.4-1 or 11.4-5, the shop inspection shall reference the work package number j identified on the ite(s) on the Inspection Report (IR). .

3.1.2.2 The IR, upon completion, shall be transmitted to the Paper Flow Group (PFG) for inclusion in the work package.

3.1.3 The QC Inspector (in the field) shall verify that itms prepared / coated in the shop, which are included in the scope of the traveler, have the applicable inspection reports (IR)

. from the shop included in the work

< with the identification on the item (s) package and correspond

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3.1.4 Itas which have *been finaled in the shop but incur mechanical damage during reinstallation shall be repaired in acconiance with QI-QP-r1.4-26 and documented on the traveler accordingly.

3.2 REPA!R OF ECHANICAL DAMAGE TO COMPLETED ITEMS 3.2.1 Areas that have been 'c apleted, inspected, accepted and traveler date package closed dich incur major pge at a later repair 51, may be inspected and documented on

  • Attachment 9 " Steel protective Coating Inspection Repair Traveler". Otherwise. :he minor areas of mechanical damage, which occur after czoletion of an area, will be repaired during the final protective coatings walkdown.

penn am , NGCCCA 4

INSTRUCT!CN ISSUE 74gg REVISION TEXAS UTIUTIES GENERATING CO.

DAM CPSES l QI-QP-11.4-26 3 21 of 34 MAR 0 51984 3.3 EXCLUSION AREAS 3.3.1 Clarification / Definition 3.3.1.1 Areas dich are scheduled to be painted but due to limited or no access are not possible to be painted at the present time and are beyond the control of protective coatings craft or quality control .

3.3.1.2 Building Management and/or the Paper Flow Group (PFG) shall detamine the legitimacy of excluding an area.

3.3.2 Areas which are detemined as exclusions shall be so noted on the original traveler and a new traveler will be generated by PFG to encompass the exclusion (s).

3.4 INACCESSIBLE / LIMITED ACCESS AREAS 3.4.1 Clarification / Definition 3.4.1.1 Areas dere, due to pemanent installation configuration, a dry film thickness (OFT) gauge cannot be properly engaged.

3.4.2 These areas shall be visually inspected to verify that the primer is applied and the finish coat is applied over the primer. No other inspection is required.

4.0 ATTACHMENTS 4.1 Attachment 1. " Ambient Conditions" 4.2 -

Attachment 18. " Air Supply Acceptability" 4.3 Attachment 2. " Preparation of Coating Materials"

, 4.4 Attachment 3. " Paint Mix Slip" 4.5 Attachment 4. " Steel Protective Coating Inspection Traveler" 4.6 Attachment 5 " Total Number of Allowable Points of Discontinui ty" 4.7 Attachment 6. " Environmental Log Sheet" 4.8 Attachment 7. " Definitions" 4.9 Attachment 8. " Pot Life Reference Sheet" 4.10 Attachment 9. " Steel Protective Coating Inspection Repair i Traveler" e

pm, TUGCC CA

. TEXh8 UTIUTIEE GENERATING CO.

emE QI-QP-11.4-26 3 ER 0 5 1984 22 of 34 ATTACHMENT 1A

~ '

Ambient Conditions The inspector shall detemine against the Enviromental Sheet (Attachment 6) air temperature, surface taperature, relative humidity and dew point of substrate structures.

A calibrated non-mercury filled bulb themometer or calibrated taperature recorder dry (Bristol 4069TH or equivalent) shall be used for air taperature detemination. A calihratad non-mereury wet bulb themometer or a calibrated humidity recorder (Bristol 4069TH or equivalent) shall be used to detemine '

relative huidity. The dew point shall be detamined

  • by the difference in dry and wet bulb taperatures using the U.S. Department of Commerce Weather Bureau Psychometric Tables, iS No. 235. When dry bulb readings are greater than 100*F. the dew point should be detamined using the 100*F dry bulb reading, and relative humidity shall be determined by subtracting wet bulb from the surface taperature or abient temperature, whichever is greater. If the dry bulb themometer exceeds 100*F. the instrument shall be returned to the calibration lab for recalibration.

The surface temperature shall be detamined by placing a calibrated surface taperature thermometer (0mega-Amprobe fast tag. range of 10*-250*F) in contact wi th the substrate surface until the taperature reading stabilizes.

Final surface preparation shall not begin unless the taperature of the surface is a minimum of 5'F above the dew pon.!,

Nomel condi:1ons of ambient and surface taperature fbr applicathn of primer shall be as follows:

Ambient Tenn. (*F) Surface Temo. (*F)

Dimetcote 6 40-120 40-130 Carbo Zinc 11 40-95 40-110 *

  • Carboline 191 50-120 50-120 Phenoline 305 50-120 50-120
  • Incrpnic zinc primer may be applied within an ambient range of 0 F to 130*F and surface taperature range of 0*F to 200*F.

Humidity values may vary fra 01 to 95% for inorganic primer; however, primer shall not be applied to a wet or damp surface.

pesus sea, , TUSCO CA

INSTRUCTION ISSUE NUMBER MISION DATE PAGE TEXAS UTIUTIES GENERATING CO.

CPSES QI-QP-11.4-26 3 fAAR0 5 sg4 23 of 34 ATTAQiMENT 1A (Cont.)

Minimum and maximun values of relative humidity for Phenoline 305 and Cartoline 191 shall be 01 anc M1 respectively.

l

% *** 1 TUGCC CA

INSTRUCTION ISSUE NUMSE.4r REVISICN PA DATE TEXAS UTluTIES GENERATING CO.

CPSES 11-QP-11.4-26 3 MAR 0 5 $84{4 of 34 ATTA099ENT 18 Air Sucoly Acceptability An inspector shall inspect the air supply systen of blast and spray equipment for suitable filters / traps / separators and that they are lef t cracked open. The effectiveness of these items shall be verified by exposing a piece of white cloth to the air outlet for approximately 30 seconds. The white cloth shall be examined for evidence of contamination (oil, water, foreign metter, etc.). No evidence of contamination is acceptable.

l

%%, TUGCC CA

. _ __._ . = - - _. .- - - - ---

r INSTRUCTION ISSUE NUMER REVISION PAGE TEXAS UTILITIES GENERATING CO. DATE QI-QP-11.4-26 3 Vap o 5 M24 25 of 34 i

! ATTAO# TENT 2 ,

PREPARATION OF COATING MATERIAL.S .

Primer - The primer, Carbo Zinc 11, is packaged in a two component kit consisting of a base and a zinc filler. First the base shall be thoroughly mixed. Zinc filler shall then '

4 he added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in a i proportion of 10 parts base to 22 parts zinc filler using a suitable scale to achieve a plus or minus 12 percent

accuracy. The mixture shall then be strained through ,a 1 30-mesh screen. <

i Viscosity shall be controlled by adding thinner, as required, I but shall not exceed two quarts of thinner per gallon of Carbo Zinc.11.

I Primer - The primer, Dimetcote 6, is packaged in a two component kit consisting of a base and zine filler. The l base - shall be thoroughly mixed first. Zinc filler shall

then be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in a proportion of 6.4 parts base to 15 parts zine filler using '

! a suitable scale to achieve a plus or minus 2 percent i accuracy. The mixture shall then be strained through a >

a' 30-mesh screen. Viscosity shall be controlled by adding thinner as required up to the maximum allowed by the latest i revision of Dimetcote 6 application instructions. Primer l coat shall be reddish gray. '

Primer Coat - The primer coat, Carboline 191, is packaged in

! a two caponent kit consisting of Carboline 191 base, Part A,

! and a catalyst, Part 8. Mixes are made by combining and ,

l thoroughly mixing the base and catalyst. Partial mixes may J be made by cambining, in a ration by volume, two parts base to one part catalyst. Viscosity shall be controlled by j adding thinner as required, but shall not exceed two quarts of thinner per gallon of Carboline 191. i 4

, Finish Coat - The finish coat, Phenoline 305, is packaged in 4

a two component kit consisting of Phenoline 305 base, Part A,

! and a Phenoline catalys t, Part B. Mixes are made by 4

combining and thoroughly mixing the base and catalyst.

I Partial mixes may be made by cabining, in a ration by

! volume, four parts base to one part catalyst. Vi scosi ty j shall be controlled by adding thinner as required, but i

shall not exceed two quarts of thinner per gallon of Phenoline 305.

4 e

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{ NH4 800. I

~

I NUM8 REVISIC N PAGE TEXAS UTIUTIES GENERATING CO.

CPSES QI-QP-11.4-26 3 E O 5 58f 26 of 34 l

ATTACHMENT 3 ,

PAINT MII $ LIP

  • deport No.

Bldg.

' GATE POT LIFE $HIFT TIME l MII NUSMER ELEVATIC1 MATERIAL GAL. MDED

$M LF LIFE ACCEPAT8LE: YES No mit #'s OAft & TIME M!IED __ RA$t 1

CURINE AGENT FILLER THINNE?.

ACCEPTED 17 DATE PCT LIFE $NIF* ,_

TIME MII MungER r. ELEVt :* .1 MTERIAL GAL. !:ID

$HELF LIFE ACCEPTASL( YES NO Mit d'; .

DATE & TIME MIIED Bast CURING AGENT FILLER THIMMER ACCEPTED BY DATE POT LIFE $HITT TIME MII NUMER ELEVATION MTERIAL GAL. M!IED SHELF LIFE ACCEPTABLE: TES NO MSTE f'$

DATE & TIME M!IED 8ASE CURING AGENT FILLER *HINNER ACCEPTED 87 ,

.. .A - _

QC REVIEW & ACCEPTANCE sIgneture da te pgsssi ma a T1JGCC OA

TEXAS UT1UTIES GENERATING CO.

QI-QP-11.4-26 3 ' MAR 0 51984 ]27of34 ATTACHMENT 4 STEEL PROTECTIVE COATING DsSPECTION TRAVELER wons;Pissa Pct T*AvtLan a ELEVATIG8 17 3s astesscRIPT1oes set owes..

PatPAnso eYt DATE STEP sunPACs ensPARATion ussPectro Amo PouNo acesPfaaLE Pin MacPIL4=24 aNo nsLEAsso Post Pnasen APPUCATioN.

lasPECrost Dart I

coasascots STEP Panasen APPucaricas sospeciso Amo Poumo acczPrAsts Pen og-opiL4-se Ano Pe raena Pon Puesa coat ArrucATloN.

se OArt 1

commesNTs

' STEP man coat APrucAtion insescTto Ase FouNo AcesPTAsLE ..

Pen et-opts.4-se sosperfest am 3

coisase Ts STEP Puesa coat sesPacTso Post masAL accgPTANCE Amo Pouseo AcesPTAala Ptn og-oPIL4-RS 4

consaacsT3 STEP consMATIoII oP sesPECT1oM YnAvtLEn Vin Mso.

SC ltEvitir oare coastse T3 N 11 occuase occuasest TATion sesPelmoM smarrts: ATTalSUTE1ols ATTAmtto sUPPostTING -

O T at oocunserT nsPAstes Asso ATTRt3UTES.tF manulaCD.oss ATTACMED suPPORTime occunsesTATiose SHsETts)

E at Pon envinownsenTAL cono:Tions martnesesTuc S F"vinommanTAL. Los.

Pes = = a TUGCO OA

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PROCEDURE I REVISION ISSUE PAGE NUMBER l OATE TEXAS UTIUTIES GENERATING ~

CO.

. CPSES QI-0P-11.4-26 3 4AR 0 51984 28 of 34 ATTAOiMENT 4 (Cont.).

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- I INSTRUCTICN REVISICN ISSUE ,3 g *. i )

NUMBER DATE l I TEXAS UTILITIES GENERATING CO.

CPSES QI-QP-11.4-26 3 MAR O 5 1984 j29 . of 34 ATTACHMENT 5 I

TOTAL NUMBER OF 4.LOWABLE POINTS OF DISCONTINUITY SURFACE AREA COND. "C" i BEING C0 ATE COMMERCIALLY (50. FT.) CONTINUOUS 10 5 10-50 10

-- 50-100 20 _____

100-500 30 - - -

500-1000 50 - - --

1000-5000 75 Gross Discantinuities - None Allowed.

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.,y PROCEDURE REVISION ISSUE NUMBER DATE PAGE TEXAS UTIUTIES GENERATING.CO, CPSES QI-0P-11.4-26 3 MAR 0 5 584 30 of 34 ATTACHMENT 6 h

Report No.

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ENVIRomoITAL LOG SHEET

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Shife Unlt TM MY GUL8 WET SULS RFACE T HUMIDITY DEW POINT G

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.s j INSTRUCTION mfSwN IS3UE pAGE

. TEXAS UTIUTIES GENERATING CO.

CPSES Q I-QP-11.4-26 3 MAR 0 51984 , 31 of 34 ATTACHMENT 7 DEFINITIONS Color and Gloss Nonunifomity: A milky haze 'or mist in the finish of a recently applied coating.

Contaminant: A foreign substance, inadvertently added to a coating or found on the substrate that adversely affects the application, adhesion, curing and/or subsequent perfomance of the applied coating. -

l Dry Soray: A dry powdery primer or finish coat readily renoved by light sanding with either sandpaper or a wire screen. A minor amount of adherent dry spray is acceptable on the final finish coat.

4 Feathering: An area that is roughened and tapered to obtain a smooth and continuous surface with an existing coating.

Fisheyes: Small openings (" fisheyes") in wet film exposing old

. surface or prtraious coat.

Full Hiding:. The coating provides suffici ent coverage so that the preceding coat is not readily visible with an unaided eya.

Holiday: A pinhole, ski p, di scontinuity or void in coating film.

Major Defect: Defined as an area, either circular or linear, in which a 1/2" diameter circle could be inscribed at any point or a-long the entire length.

Minor Defect: Defined as an area. either circular or linear, in which a 1/2" diameter circle could not be canpletely inscribed at any point along the entire length. I Monitor: Confomance verification by physically observing a task being perfomed on a periodic or random basis. I 1

u Muderacking: Irregular cracking as in a dried mud puddle (applicable to inorganic zinc primers). a  !

Orange Peel: Dents in the surface resembling orange skin. A moderate amount is acceptable. j Verify: Confim or make certain. l I

Visual: To examine with an unaided eye (correctional eye glasses or  ;

I contact lens are acceptable).

I l

1 1

Perm NG61 . ,,

^

e TEXAS UTILITIES GENERATING CO.

QI-QP-11.4-26 3 MAR O 5 1984 31 of 34 ATTACHMENT 8 POT LIFE REFERENCE SHEET Normal Pot Life - CZ 11 8 Hours Pot Life B s- -

7 a m. - .

I w.-L- .

o ., I. . .l. 1. .,q. - g.,l v isir We los** sar's 135 Pot life stated above for unthinned coatings are the .arrenended times and should be utilized as a guideline for cotir. .; sage time, however, actural pot life may be longer. For unthinr -:catings or coatings thinned 50% or less, acutal pot life is det: ;'ted by applicability of the coating.

POT LIFE PHENOLINE 305 & CARBOLINE 191 TEMPERATURE (OF) UNTHINNED THINNED 50%

50-54 10 hrs. 24 hrs.

55-59 7 hrs. 24 hrs.

60-64 4 hrs. 24 hrs.

65-69 3 hrs. 24 hrs..

70-74 2 hrs. 24 hrs.

75-79 1 hrs. 24 hrs.

80-84 '

1 hrs. 24 hrs.

85-89 I hrs. 24 hrs.

90-95 1 hrs. 24 hrs.

Pot life stated above for unthinned coatings are tne recomended times and should be utilized as a guideline for coating usage time,-

however, actual pot life may be longer. For unthinned coatings or-coatings thinned 50% or less, actual pot life is determined by the applicability of the coating.

i l

p.,. m a TUGCO OA

m .

PROCEDURE ISSUE NUMBER REVISION DATE PAGE' TEXAS UT1UTIES GENERATING CO.

CPSES QI-QP-11.4-26 3 gap g g g, 33 of 34 ATTACHMENT 9 STEIL PROTECTNE CQATING INSPECTION REPMt T1UWELER won Pine ED2 ~

N  ! TIM as /ogstasPfices netOwete resPansD evt cATT sHT OF ,

STEP sunraCs P9&AAAT1030 IMSPECTED AW Pi3#6 MlCEPTA4LE PWI Qt-CPtL4-25 Ase AELEASED Ptzt PRiaset APPUCAT Cat.

POSPECTest GAft I

ccan eers I

STEP Pnnset APruCAT Cse sesPs:TED Ase Pause ACCzPfasts PWI et-4PIL4-38 Aaso MELEASED POft P9eSN C af APPUCATION.

BINECT" OAT' 2

ccamorfs STEP Possu c=ar APPLCAT:Cm iseSPEC712 ano Paume ACCarTAaLE PWI 41-CPit.4-te mIEPE: tut "N 3

consaserfs STEP PINT 3M CCAT asSPEC"ZD PCR PIMA 4. ACC3FTANCE AMG PQune ACCEPfam.E Pet Q1-CPIL4-38 sesPEC7"  : ATE 4

consanerfs STEP c=ambrrion or sesre: som TRAvstan vet:PtsD.

Se newtsw sarr ccastsesf3 g I) CCC:.48CfT rMg AT="ttSuT23 CM AT"'A..;i1D SUP*:3- 's

  • I CC.astsTA;".CM 3;tsE- 33 ka 23 ccC:sses7 Agrasas anc AT M!suTts.:P sgCuutgg, x 27 ;c;3gg SUP*C3ET N4 GCC: asetTAT".CN 3 MEET;31 i E 33 PC84 CivtfelpeasCITAL "MCIT: CMS REFrtcectT*Ag '

S D'vinemassmTA4. i:4.

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Perm Ne6 3 TUGCC CA 6

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PROCEDURE ISSUE NUMBER REVISION PAGE DATE TEXAS UTILITIES GENERATING CO.

CPSES QI-QP-11.4-26 3 MAR 0 51984 34 of 34 i ATTACHMENT 9  !

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' I TEY S UTTU ES GENERATING ud. REVISICN '

, BER C PAGE CPSES QI-QP-11.4-26 2 1 1 of 34 I

FEB 2 41984 l

SU F PREPARED BY: M ~

.* //

PREPARATION, PRIMER APPLICATION, PRIMER g k i 1-2Z-k ^

REPAIR, SEAL AND APPROVED BY: -

. MA A1 2-se av

-- f FINISH COAT APPLICATI0fl

^" gg/g APPROVED BY:

/

  1. 8f 0 ATE 1.0 GENERAL

{ %,"N3@l ff 1.1 PURPOSE AND SCOPE Itbr7 =

l The purpose of this instruction is to outline methods utilized by Quality Control personnel in inspection of steel substrate surface preparation, primer application, primer repai r, seal and finish coat application and repair for Unit 1 Reactor Building. i

- -- 1 7 1 mt 2.0 INSTRUCTION 7d1$1i.U " ' N 8 i t

Visual inspection of surfaces as addressed by this instruction shall be made at approximately an ams length from the surface being inspected. Tne area of inspection shall be adequately lighted during the inspection activity.

! Adequate lighting is defined as the minimum light produced by a two (2) 0-cell battery flashlight. Flashlight shall be held perpendicular to the surface during visual inspection.

Visual aids fabricated on site and approved b'y Quality Assurance and Engineering may be used by Inspectors as an aid in the perfomance of their inspections. j For definitions, refer to Attachment 7.

f 2.1 PRE-BLAST HAND AND/0R POWER TOOL CLEANING OPERATIONS 2.1.1 Abrasive Acceptability The Inspector shall obtain a sample of the abrasive to be used from each work area. The abrasive shall be verified to be dry by feel . All grease, oil and deleterious material is unacceptable.

I

% ,= 4 WGCC CA l

3 .

- r INSTRUCTION ISSUE NUM2ER REVISION PAGE TEXAS UTIUTIES GENERATING )'. DATE CPSES QI-QP-11.4-26 FEB 2 41984 2 of 34 2

Particle size must be sufficient to* achieve 1 mil surface profile minimum.

2.1.2 ' Blast Equipment Acceptability '

The inspector shall perfonn the following inspections / tests to determine acceptability of blast cleaning equipment prior to use:

a. Air supply (refer to Attachment 18). ,
b. Ambient conditions (reference Attachment 1A and 6).

2.1.3 Solvent Cleaning (If Chemical Contamination Present)

If oil, grease, or other chemical contamination is present, verify that solvent cleaning is perfonned and that chemical contamination is removed prior to blast / power tool cleaning steel surfaces.

2.2 POST BLAST CLEANING OPERATIONS 2.2.1 Blast Cleanup The inspector shall visually check the blasted substrate surface.

The surface shall be air blasted or solvent wiped to the extent required for final surface inspection. The adjacent areas shall be cleaned to the extent necessary to avoid contamination during subsequent coating applications.

2.2.2 Blasted or Power Tooled Surface Acceptability I

The inspector shall perfonn the following inspections to determine acceptability of the blast cleaned or power tooled surface:

a. Absence of Foreign Matter --

A vi sual inspection shall be perfonned to detennine that all oil and grease, di rt, millscale, rust, corrosion products, oxides, paint or other foreign matter have been canplately renoved fran the surface except for light shadows, very slight streaks or slight di scolorations caused by rust stains, mill scale, oxides, or slight, tight residues of paint - or coating that may renain. At least 95 percent of each square inch of surface area shall be free of all residues, and the renainder shall be limited to light discolorations as mentioned a5 ave.

f

- , - - -,, ,m., - . - - - . . , , - . _ , , , , . - . . . - - . , , , , _ _ _-- -_.._.,.,r - . - _ . , - - - -

l

. g m REVISION TEXAS UTluTIES GENERATINC J.

kCTION h PAGE QI-QP-11.4-26 , FEB 2 41984 3 ofg: -

NOTE: In addition to the 5 percent of tight residue of

  • paint or coating which is permissible, shadows or tightly adhering residues of primer my renain (without limit) in 'the profile of the previously prepared substrate. However, areas with residues of Carboline 191 primer shall be recoated with Cartoline 191 primer. Areas with residues of inorganic zinc may be coated with either inorganic zinc or Cartoline 191 primer. It is not required that such areas meet the criteria of SSPC-SP10 or SSPC-SP6. ,
b. Removal of Shan Projections --

An inspection for sharp projections that were not blended (rounded) during blast cleaning, or power tooling shall be perfomed.

Weld spatter on structural steel which renains after grinding or sand blasting will be acceptable.

Shan projections are not acceptable.

~,

Protrusions and peaks shall be ground to a rounded Contour.

NOTE: Any e chanical 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.

c. 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 surface shall be a minimum of 1.0 mils.

Surfaces that have been power tooled with "3M Clean-N-l Strip", 80 grit and coarser " flapper wheels", sanding di scs , " Roto-Peen" or equivalent, provide acceptable surface profile.

No eximum profile will be specified, providing that correct millage and surface uniformity requirements can be obtained after primer application.

. 8 l

, __ _ - _ . _ _ . _ _ _ _ _ . . - _ . . . . , - _ _ _ . - ~ . . . _ _ _ . _ . , _ . , ._.m. . _ _ _ _ _ _ . . . .

._ . _ . _ _ _ _ ~

% I CTION I8 g REVISION PAGE TEXAS UTIUTIES GENERATINC. J. DA Q I-QP-11.4-26 FEB 2 4 1984 2' 4 of'34 l

2.2.3 Unique Number Identification After blasting, power tool and prior to prime coat application (if applicable), QC shall ve'ri fy that construction has identified each piece with a unique number.

2.3, PRIMER PRE-APPLICATION INSPECTIONS 2.'3.1 Ambient conditions The inspector at the " paint di stribution point" in Reactor 'l shall verify ambient conditions in accordance Attachment 1-A.

with 2.3.1.1 The inspector shall monitor the ambient conditions being recorded on the Environmental Log (Attachment 6) at the

" paint distribution point" in the building. 1 2.3.1.2 Documentation of Environmental Conditions

a. The inspector assigned to the " paint di stribution poi nt" in the Reactor building shall, as a minimum, take a complete set of readings (air temperature, relative humidity, dew point and surface temperature) on each floor elevation at least three (3) times each shift (preferably, the beginning, mid point and just  ;

prior to the end of each shift). More readings may be .

taken when necessary (i.e., noticeable change in air '

temperature, request by field inspector to take readings in a specific area, etc.).

b. The inspector at the " paint distribution point"'shall document these readings on Attachrent 6 as follows: ,
1. One (1) Envi rornental Log SNet (Attachment 6) shall be completed for all readings taken on one (1) floor elevation or specific area in a given shift.
2. The inspector shall fill in the applicable infonnation as delineated on the fo m , except for the " Report No. ". (The Report No.

will be filled in by the Paper Flow Group when j they assign numbers, prior to transmitting to the i QA Vault.

3. Upon completion of the shift, the inspector shall turn all of the environmental log sheets for that shift into the lead inspectors.

ammi em , maco cA

"~ -~~ '

I

. , INSTRUCTION l lSSUE' REVISION PAGE TEXAS UT1UTIES GENERATINC ).

QI-QP-11.4-26 2 5 of 34 FEB 2 41934 _

i

c. The lead inspector (s) shall review the log sheets for completeness and correctness, sign and date the "QC Review" block, obtain copies for QC reference and transmit the originals to 'the Paper Flow Group.
d. If at any time the inspector determines readings which do not comply with the parameters set forth in this procedure, he shall proceed in the following nenner:
1. Innediately take an additional set of readings in the immediate area of the first set of unacceptable readings and record them on the environmental log.
2. If the additional set of readings are acceptable, take a third set of readings for referee purposes and record them. If the referee set of readings i

are acceptable, then the area in question is acceptable but should be closely monitored with readings as necessary.

j~

3. If the additional set of readings is unacceptable and/or the referee set of readings is unacceptable, the inspector is to notify the coatings inspectors in the areas affected so that coating work may be stopped at that time. Coating work shall not continue acceptable status.

until the ambient conditions resume an

4. When unacceptable ambient conditions occur ar.d are verified by step 3 above, the inspector shall document it on a Nonconformance Report (NCR) in accordance with CP-QP-16.0 and adequately identify the affected areas / elevations.

2.3.2 Substrate Surface Acceptability The Inspector shall visually reinspect the sandblasted or powertooled surface of the substrate just prior to primer application for evidence of contamination (oil, grease, markings, rust, etc.). Contamination must be removed prior to priming. '

If rust fanns after Blasting or Power Tooling, the surface shall be recleaned before priming. Under no case will a prepared surface be exposed for more than 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> before

! priming.

l 2.3.3 Air Supply Acceptability The Inspector shall inspect the air per Attachment IB.

i.-

, , TUGCC CA

@T g o,6 esp 6e eum tha h @@e 6e- 6 @ &* *O

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I

{gTION REVISION PAGE TEXAS UTILITIES GENERATING J.

CPSES QI-QP-11.4-26 2 6 of 34 FEB 2.s veu 2.3.4 Qualification of Applicator (s)

The Inspector shall verify (by. Qualification Record or list of quali fied applicators fram QA file) that the coating applicators are qualified for safety-related coating work.

The applicator (s) badge nunber shall be listed on the back of the traveler.

2.3.5 Mixing Operations 2.3.5.1 Coating Materials Identification -

An inspector shall inspect the coating material containers

prior to mixing contents for product identification and verify that all materials are correct for coating application.

Approved materials are:

CZ-11 i

Carbo Zinc 11 base (gray or green)

Carbo Zinc filler Cartoline #21 or 33 Thinner DIMETCOTE Dimetcote 6 base Dimetcote filler i Amercoat #65 or 101 Thinner CARBOLINE 191 Cartoline 191 Primer (Red Brick)

Carboline 191 Catalyst Cartoline #15 Thinner PHENOLINE 305 Phenoline 305 base Phenoline 305 catalyst '

Phenoline thinner An inspector shall also verify that each camponent container is identified by batch nunber and that the shelf life has not expired. Carbo Zinc 11 base and Cartoline 191 has a shelf life of 12 months. Carbo Zinc filler, Dimetcote 6 base and filler, and Phenoline 305 all have a shelf life of 24 months. Pot life shall be monitored in accordance l with Attachment 8.

%, TUGCQ CA

~'~

INSTRUCTION ISSUE REVISION 8 AGE

. TEXAS UT1UTIES GENERATIN( D.

CPSES QI-QP-11.4-26 2 U #

FEB 2 41984 2.3.5.2- Mixing Operations An inspector shall witness each mixing / thinning operation.

The inspector shall verify ' that mixing operations are -

performed in accordance with Attachment 2.

2.3.5.3 Thinning Operation Coating materials (if thinned) viscosity control shall be accomplished by adding thinner as required, but shall not exceed two quarts of thinner per gallon of material .

2.3.5.4 When coating materials are mixed / thinned, the inspector verifying the mixing operation shall fill out the Paint Mix Sli p, Attachment 3. The inspector perfoming the pre-application inspection shall record the mix sheet number on the travelers. The Mix Slip shall be returned to the Paper Flow Group at the end of each shift to be sent to the vault.

4 2.4 PRIMER APPLICATION INSPECTION 2.4.1 Monitoring of Primer Acolication During application operations of CZ-11, the QC Inspector shall monitor that the pressure pot is continuously agitated. The QC Inspector shall also monitor that the hose length does not exceed 75 feet. CZ-11 shall not be brush applied to areas larger than 1 sq. ft.

. 2.4.2 During application of Carboline 191, the inspector will sonitor to assure that no fisheyes appear in the applied coating. If detected, the inspector shall infom the paint foreman of their presence and that they should be renoved while coating is still wet, surface cleaned with solvent and coating reapplied. ,

2.4.3 The inspector shall monitor the pot life in accordance with Attachment 8..

2.5 INSPECTION OF PRIMER 2.5.1 Primer Inspection Prior to Acolication of Seal or Finish Coat

a. Verify the primer has cured sufficiently for the top coatin CZ-11)g (as

. Cure determined to top coat byofthe use of a nickel Carboline testbe 191 shall on the same as Phenoline 305, stated in Section 2.9.1.

b. Perforin a visual inspection of the primed surface in accordance with the following:

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REVISION l TEXAS UTIUTIES GENERATINC.

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hCTION '

O PAGE CPSES QI-QP-11.4-26 8 of 34 i

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1. Runs / sags which do not exceed the neximum dry I film thickness for each coating applied and show no evidence of mud cracking or loss of adhesion are acceptable. Repairs for runs / sags other than the aforementioned shall be as per Sections 2.6.2 or 2.6.3, as applicable.
2. Dry Spray - Must be reno'ved before overcoating as per Section 2.6.3.
3. Contamination - unacceptable; repair as pair Section 2.6.2 or 2.6.3, as applicable.

Oil and crease - unacceptable; repair as per Section 2.6.3. *

4. Skips / damaged areas / holidays or voids -

unacceptable; repair as per 2.6.2 or 2.6.3, as applicable.

5. Orange peel - Moderate amounts are acceptable.

Excessive amounts unacceptable; repair as per Section 2.6.3.

6. Bubbling - unacceptable; repair as per Section 2.6.2 or 2.6.3, as applicable (does not apply to CZ11).
c. The inspector shall perfonn a DFT inspection of the cured primer film. A calibrated 0-25 E1cometer 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, measurenents less than 1 inch from the edge or a hole shall be avoided (See Note 3).

Dry Film Thickness shall be as follows (See Note 4):

Min. (mils)

Max. (mils)

Cartoline 191 spot test 1.6 8.5

.CZ-II spot test 1.5 7.0 D6 spot test 1.5 5.5 D6 average DFT 2.0 5.0 CZ-II' average DFT 2.0 6.0 Carboline 191 average DFT 2.0 7.0 l m, Tuoco c4 l

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. , INSTRUCTION ISSUE REVISION PAGE TEXAS UTILITICS GENERATIN( 3.  !

U QI-QP-11.4-26 9 f ~

2 24 9 34 1

NOTE 1: A spot measurenent is a series of three measurements in the same general area. The probe should be noved 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 measurenent.

NOTE 2: Five spot tests shall be taken for every 100 square feet of coated surface. For areas less than 100 square feet, the following shall apply:

Area Sq. Ft. No. Spots 100-80 5 80-50 4 FJ-10 3 10-3 2 3-0 1 NOTE 3: Itens with appreciable surface curvature and other geometrical di scontinuiti es, such as handrails, gratings, stairs, sway struts, checker plate, etc., shall be exempt from dry film thickness measurenent.

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 fran the failing spot and spaced radially at approximately 120 degree intervals to detennine the extent of the unacceptable area.

In the event that the average of the area is unacceptable due to unacceptable spot readings, the unacceptable spots shall be isolated as described above. Additional spot readings shall be taken equal to the nunber of unacceptable spot readings and the average recalculated.

NOTE 5: Unacceptable areas shall be repaired as per Section 2.6.3. [

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INSTRUCTION ISSUE NUMBER REVISION PAGE TEXAS UT1UTIES GENERATINt3'. DATE CPSES QI-QP-11.4-26 2 10 of 34, 24 M I

i 2.6 PRIMER REPAIRS 2.6.1 Saqs and Runs Runs / sags: Ref. Sec. 2.5.1.b if surface is unacceptable.

Repair per Sec. 2.6.2 or 2.6.3.

2.6.2 Primer Touch-up Repair (Primer Damaged to Steel Surface)

The coating inspector shall conduct' the following inspections to doctanent primer touch-up repair operations when the damage is to the steel surface and spot sandblasting, hand sanding or power tool abrading is perfonned for surface preparation,

a. Surface preparation Ref. Sec. 2.2.2.

~

. b. Verify that the blasted o: power tooled surface has-been high pressure air blowdown, and/or solvent wiped to the extent required for final surface inspection.

The adjacent areas shall be cleaned to the extent <

necessary to avoid contamination during subsequent coating applications,

c. Ambient Conditions: Ref. Attachment 1A and 6.

Air Supply Acceptability: Ref. Attachment 18.

The surface temperature shall be a minimum of 5' above the dew point.

d. Verify applicator qualifications per Section 2.3.4.
e. Verify air supply acceptability per Attachment 18.
f. Verify ambient condition per Attachment 1A.
1. Coating Materials Identification

! Verify per Sec. 2.3.5.1.

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m INSTRUCTION AEVISION l ISSUE TEXAS UTIUTIES GENERATIN( O.

NUMSER DATE PAGE CPSES -

QI-QP-11.4-26 i

  • 2 FEB 2 41984 11ofg'
2. Mixing Operations i Verify per Sec. 2.3.5.2.
3. Thinning Operation  !

Verify per Sec. 2.3.5.3.

g. Verify that primer is appli ed in accordance wi th Sec. 2.4.1.

NOTE: (If applicable) Coating interface - at coating interface for finish and/or primer coat, the exit, ting coating shall be " feathered back" a sufficient distance to ensure a smooth final coating system. When inspecting coating interface 'the interface of the coating or systes shall be a eximum of 14 inch in width. Within the interface area, overlapping of any materials or systens is acceptable.

2.6.3 Primer Touch-up Repair (Primr '

Damace Does Not Extend to Stuel Surface '

The coating inspector shall conduct the following inspections for primer touch-up repair operations when the damage is within the primer coat and sandblasting to the steel substrate is not required.

a. Verify surface is abraded lightly then wiped clean. *
b. Verify primer is appli ed in accordance with Section 2A.1.
c. Visually verify acceptability of repaired area par Section 2.5.1.b.

2.6.4 Repair of Primer by Recoatinq The coating inspector shall conduct the following inspections for primer recoating repair. Only two (2) overcoats may be applied of inorganic zine primer.

a. Verify that the surface has been solvent cleaned or blown down with high air pressure. Contamination is unacceptable and requires further cleaning.

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P INSTRUCTION ISSUE NUMBER REVISION PAGE TEXAS UTILITIES GENERATIN(. J. CATE QI-QP-11.4-26 2 12 of 34 FEB % + 1984

b. Perfonn inspections in Section 2.6.2.

NOTE: After application of, primer to the spot primed area, the only additional feathering required is at the outer edge of the primed area. Sanding of the primed area is not required.

2.6.5 Complete Primer Repair (Primer Damage to Steel Surface 4

Extends Over Entire Iten)

The coating inspector shall conduct the following inspections to document primer repair when the damage is to the steel surface and requires surface preparation to steel substrate over entire item:

a. Verify ambient conditions per Attachment 1A to surface preparation. See Attachment 6.
b. Perfonn inspections (a) through (g) in Section 2.6.2.

2.6.6 In-process renai rs shall be documented on the Traveler *

(Attachment 4) showing their status and/or canpletion.

2.7 FINISH COAT PRE-APPLICATION INSPECTIONS The QC inspector shall verify the following itens prior to i applying coatings:

2.7.1 Coatina Applicator Qualifications The Inspector shall verify (by Qualification Record or list of quali fication reconis in QA File) that the coating I applicators on each shift are qualified for safety-related co'iting work.

2.7.2 Anbient Conditions (Refer Attachment 1A and 6)

The pennissible range of surface and ambient temperature for application of finish coat shall be 50-120*F.

The maximum humidity shall be 85% for Phenoline 305, and

)

95% for inorganic zine and Carboline 191.

The surface temperature shall be a minimum of 5*F above the dew point.

TUGCQ CA

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INSTRUCTION l ISSUE

- -  % NUMBER REVISION PAGE TEXAS UTILITIES GENERATING ). OATE QI-QP-11.4-26 2 FEB 2 41984 13 of 34 2.7.3 Coated Surface Acceptability The Inspector shall visually reinspect the previously coated surface just prior to finish coat application for evidence of contamination (oil, grease, forei The defective areas shall be repaired per Sec.(gn matter).s) 2.6.2, 2.6.3, 2.6.4 and 2.6.5, as applicable.

2.7.4 Air Supply Acceptability (Per Attachment 1B) 2.7.5 Finish Coat Mixing Operations 2.7.5.1 Prior to mixing, the mixing inspector shall verify that each i

camponent is identified by batch nunbers and that the 24 month shelf life has not been exceeded. Pot life shall be monitored in accordance with Attachment 8.

2.7.5.2 The mixing inspector shall veri fy that mixing / thinner

. operations are perfomed in accordance with Sec. 2.3.5.2.

Thinning may be done up to two quarts of Phenoline Thinner per gallon of Phenoline 305.

2.7.5.3 Mixing operation shall be documented on the traveler per Sec. 2.3.5.4.

2.8 MNITORING OF SEAL OR FINISH COAT APPLICATION 2.8.1 The Inspector shall monitor that hose length does not exceed 75 feet.

2.8.2 The inspector shall also verify that the seal coat (if present) is solvent wiped prior to finish coat application.

2.8.3 The inspector shall moni tor to assure that no fisheyes appear in the applied coating. If detected, the inspector shall infonn the paint forenan of their presence and that they should be removed while coating is still wet, surface cleaned with solvent and coating reapplied.

2.8.4 The inspector shall monitor the pot 11fe in accordance with Attachment 8. '

2.9 FINISH COAT FINAL ACCEPTANCE INSPECTION The inspector shall perfonn a final acceptance inspection of each finish coated itan(s) in accordance with Paragraphs 2.9.1 through 2.9.5.

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-% I CTION g REVISION >

PAGE TEXAS UTIUTIES GENERATING s.

CMES -

QI-QP-11.4-26 14 of f

NOTE:

(If applicable) ~ Coating interface - at coating interface for finish and/or primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smooth final coating syste. When inspecting coating interface the interface of the systens shall be a maximum of lh inch in widt h. Within the interface. area, overlapping of any materials or systems is acceptable.

NOTE:

The tie in interface between concrete coating's and steel coatings shall be visually inspected during the finish coat final acceptance of both systems.

2.9.1 Finish Coat Cure Final QC inspection nay be perfonned 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 /> and cure .to recoat time has been met.

Curing and time to recoat Phenoline 305 shall be as shown '

below:

Between Coats Tenperature 'F 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> 50 - 59 36 hours4.166667e-4 days <br />0.01 hours <br />5.952381e-5 weeks <br />1.3698e-5 months <br /> 60 - 74 18 hours2.083333e-4 days <br />0.005 hours <br />2.97619e-5 weeks <br />6.849e-6 months <br /> 75 - 89 .

12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> 90 and above Phenoline thin'ned at 50% and applied as a seal coat may be recoated after 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> of cure at or above 75'F.

, 2.9.2 Visual Defects Inspection j

The Inspector shall perfonn 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 15.0 mils or less, which show no evidence of mudcracking , are acceptable. Those '

1 greater than 15.0 mils shall be repaired as per l Section 2.10.1.

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b) Ski ps, damaged a reas, holidays, voids, bubbles, j blisters and excessive orange peel are not acceptable and shall be repaired as per Section 2.10, as  ;

applicable. ~ ,

l c) Pinholes - acceptable to the extent allowed by i Attachment 5; areas not acceptable -shall be repaired I as per Section 2.10.5. '

d) Contamination - unacceptable; areas shall be repaired as per Section 2.10.4. ~

e) Dry spray - unacceptable; shall be repaired as per Section 2.10.6. A minor amount of adherent dry spray is acceptable on the final finish coat.

f) color and gloss non aiformity - unacceptable; shall be repaired as per Section 2.10.8.

Top coated areas which have been abraded for various reasons (i.e., runs, sags, high millage, etc.) and are within acceptable procedural thickness following repairs, do not require recoating for gloss enhancing. i For' small repair areas such as pir. holes, gloss and gloss unifonnity is not required, provided the coating is smooth and continuous.

2.9.3 Dry 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. Separate spot measurements (See Note 1) spaced evenly over the structure (See Note 2) shall be taken. Since the nagnetic gage is sensitive to geometric di scontinuities in the steel, measurenents less than 1 inch from an edge or a hole shall be avoided. (See Note 3).

The average DFT of the total coating systen shall be a minimum of 6.0 mils and a maxinun of 13.0 mils. The spot 4

test DFT of the total coatino systen shall be a minimum of 6.0 mils and a maxinun of 15.0 mils (See Note 4).

The finish coated systen shall exhibi t full "hidi ng" properties of the primecoat.

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.- INSTRUCTION REVISION l '

NUMIER PAGE TEXAS UTIUTIES GENERATINL 3.

CPSES QI-QP-11.4-26 2 16 of 24 l FEB 2 41984 -

i 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 measurement.

NOTE 2: Five spot tests shall 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 I

100-80 5 80-50 4 5&.10 3 l

10-3 2 -

. b0 1 NOTE 3: Items with appreciable surface curvature and othqr geometrical di scontinuities such as handrails, I gratings, stairs, sway struts, etc. shall be exempt from 0FT measurement.

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 radi ally at approximately 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.

In the event that the average of the area is I unacceptable due to unacceptable spot readi ngs, 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 recalculated. If the recalculated average is acceptable, the traveler shall be so narked wi th an explanation in

" Remarks" stating that " average recalculated -

now acceptable", or wording to that effect. If the recalculated average is unacceptable, the unacceptable spots shall be isolated and repaired ,

per Sec. 2.IO. -

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INSTRUCTION ISSUE

, REVISION PAGE TEXAS UTluT1ES GENERATINC. J.

CPSES QI-QP-11.4-26 2 FEB 2 41584 17 of 34 2.9.4 Continuity Inspection The Inspector shall test the continuity of the cured finish coat on liner plate using a Tinker and Rasor Model M1 (67.5 volt) holiday detector. 100% of the finish coated surface area shall be tested.

The applied film should contain on1y a minor number of points of di scontinuity. 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 scontinuity (pinholes). No more than 40% of the total nunber of I

allowable points of discontinuity should occur within any one area equal to 25% of the total area being coated. The i total number of pinhole discontinuities allowed is defined in Attachment 5. No gross discontinutties are allowed.

2.10 REPAIRS OF FINISH COAT 2.10.1 Repairs of Runs and Saas The QC inspector shall verify that the area is abraded until the DFT of the total coating systen is within 6.0 to 15.0 mils, and examined for nuderacking. Muderacking shall be repaired in accordance with Sec. 2.10.2 or 2.10.3.

2.10.2 Repair of Minor Defects The QC 1nspector shall perfonn the following inspection when repairing minor defects:

a) Verify ambient conditions per Attachment 1A prior to surface preparation.

b) Verify that the damaged area is blasted or abraded until all loosely adherent particles are removed.

c)- Verify damaged area is solvent wiped.

d) Perfonn inspections described in Sec. 2.7, 2.8 and 2.9.

e) Minor defects may be repaired at the time of final inspection without later reinspection of, the repair.

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' INSTRUCTION REVISION L ISSUE TEXAS UTIUTIES GENERATIN(,. J. NUMBER DATE MGE 88 QI-QP-11.4-26 18 of 3 4 2.10.3 Repair of Ma.ior Defects a

The QC inspector shall perfonn the following inspection when repairing major defects: -

l a) Verify ambi ent conditions per Attachment 1A and 6.

b) Verify area is abraded or spot blasted until all loosely adherent particles are reoved.

c) Verify area is solvent wiped.

d) Perfonn inspections in Section 2.7. 2.8 and 2.9.

2.10.A Repair of Contamination The QC inspector shall verify that contamination is reoved by abrading and the surface recoated. The inspector shall perfonn inspections delineated in Sections 2.7, 2.8 and 2.9.

2.10.5 Repair of Pinholes and Small Discontinuities f.

a) Verify all loose particles are renoved and area is solvent wiped.

b) Pinholes and small discontinuities may be repaired at the time of- final inspection without a later 4 reinspection of the repair. The inspections in Section 2.7, 2.8 and 2.9 still apply.

2.10.6 Repair of Dry Snray Repair of dry spray identifiable by vi sual inspection defined within thi; procedure shall be removed.

a) Verify all loose particles are removed.

b) Verify coating film thickness is still within

allowable range.

c) If film thickness is not within allowable range perfonn inspections in Sec. 2.7. 2.8 and 2.9.

, NOTE: A minor amount of adherent dry spray is acceptable on the final finish coat.

i

, 2.10.7 Renair of Excessive Orange Peel a) Verify the affected area is abraded and solvent wiped.

b) Verify the affected area is refinished and perfonn the 2

inspections delineated in Section 2.7, 2.8 and 2.9.

M%I

I INSTRUCTION ISSUE

% REVISION PAGE TEXAS UTILITIES GENERATIN(, 3.

NUMBER MTE ES QI-QP-11.4-26 2 19 of 24 )

FEB 2 419g4 1

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, 2.10.8 - Repair of Gloss and Color Nonunifomity i a) Verify the affected area is solvent wiped.

b) Verify the affected area is recoated without exceeding the maxiam - film thickness and perfom inspections in Sections 2.7, 2.8 and 2.9. .

c) Top coated areas which have been abraded for various j reasons (i.e., runs, sags, high millage, etc.) and are

, within acceptable procedural thickness, following

repairs, do not require recoating for gloss enhancing.

t

, d) For small repair areas such as pinholes, gloss and gloss s uni famity is not requi red , provided the coating is i ,. smooth and continuous.

} 2.10.9 Documentation of In-Process Repairs i

In-process repai rs shall be documented on the traveler

. (Attachment 4) showing their completion and/or status.

2.11 NONCONFORMANCES 2.11.1 Unacceptable _ conditions dich are not readily repaired or corrected per the approved procedures shall be documented as unsatisfactory on the inspection traveler.

l' 2.11.2 Monconforming conditions such as coating failure due to loss

of adhesion or indeteminate/ unacceptable conditions which

, cannot be repaired or corrected as per existing procedures shall be docaented on a Nonconfomance Report (NCR) in

' accordance with CP-QP-16.0. The NCR number shall be referenced on the inspection traveler, if applicable.

2.12 00CUENTATION (REFER TO ATTACHENT 4) 2.12.1 All inspections required by this procedure shall be recorded )

in the inspection attributes on the back of the travelers (Attachment 4). Preparation and processing of the traveler shall be per QI-QP-11.4-28. l t

i 2.12.2 When the inspections required by Sections 2.1 through 2.2.3 4

' have been satisfactorily completed, Step 1 shall be signed {

and dated by the inspector.

4 2.'12.3 When the inspections required by Sections 2.3 through 2.6.5 have been satisfactorily canpleted, Step 2 shall be signed and dated by the inspector. .

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1 2.12.4 - When the inspections required by Sections 2.7 through 2.8.4 have been satisfactorily completed, Step 3 shall be signed and dated by the inspector. .

2.12.5 When the inspections required by Sections 2.9 through 2.10.7 have been satisfactorily completed. Step 4 shall be signed and dated by the inspector.

2.13 SPECIAL COATINGS PROCEDURES Special coatings procedures and instructions set forth in CCP-30-M1 through CCP-30-M9, as applicable under the scope of this procedure, shall be inspected as per the guidelines of this procedure using the criteria established in the special coatings procedures.

3.0 CLARIFICATION 3,1 SHOP C0ATED ITEMS 3.1.1 Itans reoved from the building for coating at the paint

, shop shall be the responsibility of the craft department.

1 3.1.1.1 The craft shall be responsible for identifying each piece by work package number.

3.1.1.2 The craft shall be responsible for returning and installing the shop coated item in the same area it was removed from.

3.1.2 The shop QC Inspector shall inspect the item (s) in accordance with QI-QP-11.4-1 and QI-QP-11.4-5, as applicable, and

  • doctment his inspections on an Inspection Report (IR) in accordance with those procedures.

3.1.2.1 In addition to the infonnation required by 11.4-1 or 11.4-5, the shop inspection shall reference the work package number identified on the itan(s) on the Inspection Report (IR).

3.1.2.2 ' The IR, upon completion, shall be transmitted to the Paper Flow Group (PFG) for inclusion in the work package.

3.1.3 The QC Inspector (in the field) shall verify .that items prepared / coated in the shop, dich are included in the scope of the traveler, have the applicable inspection reports (IR) from the shop included in the work with the identification on the item (s) package and correspond .

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INSTRUCTION ISSUE NUMBER REVISION PAGE DATE TEXAS UTluTIES GENERATINC' J '.

CPSES QI-QP-11.4-26 2 FG24 g 21 of 34 4

3.1.4 -

Itans dich have been finaled in the shop but incur mechanical damage during reinstallation shall be repaired in accordance with QI-QP-11.4-26 and docunented en the traveler accordingly.

3.2 REPAIR OF ECHANICAL DAMAGE TO COMPLETED ITEMS 3.2.1 Areas that have been completed, inspected, accepted and traveler package closed which incur major darhage at a later date may be repaired, inspected and docuinented on Attachment 9 " Steel -Protective Coating Inspection Repair Traveler". Otherwise, the minor areas of mechanical damage, which occur after completion of an area, will be repaired during the final protective coatings walkdown.

3.3 EXCLUSION AREAS 3.3.1 Clarification / Definition 3.3.1.1 Areas dich are scheduled to be painted but due to limited or no access are not possible to be painted at the present time and are beyond the control of protective coatings craft or quality control.

3.3.1.2 Building Management and/or the Paper Flow Group (PFG) shall determine the legitimacy of excluding an area.

3.3.2 Areas which are detennined as exclusions shall be so noted on the original traveler and a new traveler will be generated by PFG to encampass the exclusion (s).

3.4 INACCESSIBLE / LIMITED ACCESS AREAS 3.4.1 Clarification / Definition 3.4.1.1 Areas dere, due to pennanent installation configuration, a dry film thickness (DFT) gauge cannot be properly engaged.

3.4.2 These areas shall be visually inspected to verify that the primer is applied and the finish coat is applied over the primer. No other inspection is required. '

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PAGE TEXAS UTIUTIES GENERATINC J. DATE >

I QI-QP-11.4-26 2 22 of FES 2 4 g 34 1

4.0 . ATTACHMENTS 4.1 Attachment 1. " Ambient Conditions" 4.2 Attachment 18 " Air Supply Acceptability" 4.3 Attachment 2, " Preparation of Coating Materials" 4.4 Attachment 3. " Paint Mix Slip" 4.5 Attachment 4, " Steel Protective Coating Inspection Traveler"'

4.6 Attachment 5 " Total Number of Allowable Points of Di scontinui ty" 4.7 Attachment 6, " Environmental Log Sheet" 4.8 Attachment 7. " Definitions" 4.9 Attachment 8. " Pot Life Reference Sheet" 4.10 Attachment 9, " Steel Protective Coating Inspection Repair Traveler" l

, Tuoco CA

INSTRUCTION TEXAS UTIUTIES GENERATIN.

CPSES

'. O NUMBER REVISION k '

ISSUE DATE PAGE i

1 l

QI-QP-11.4-26 2 23 ' Of'-34a ~

, FEB 2 4 ;gg4 ATTAOIMEhT 1_A_

Ambient Conditions The inspector shall detennine against the Environnental Sheet (Attachment 6) air temperature, surface tenperature, relative humidity and dew point of substrate structures.

A calibrated non-mercury filled dry bulb thennometer or calibrated tenperature recorder (Bristol 4069TH or equivalent) shall be used for air tenperature detennination. A calibrated non-mercury wet bulb thennometer or a calibrated humidity recorder (Bristol 4069TH or equivalent) shall be used to detennine relative humidi ty. The dew point shall be determined by the di fference in dry and wet bulb tenperatu res 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 should be detennined using the 100*F dry bulb reading , and relative humidity shall be determined by subtracting wet bulb from the surface tenperature or ambi ent temperature, whichever is greater. If the dry bulb thennometer exceeds 100* F, the instrunent shall be returned to the calibration lab for recalibration.

The surface tenperature shall be detennined by placing '

a calibrated surface temperature thermometer (Omega-Amprobe fast tenp. range of 10*-250*F) in contact wi th the substrate surface until the tenperature reading stabilizes.

Final surface preparation shall not begin unless the temperature of the surface is a minimum of 5'F above the dew point.

l Nonnal conditions of anbi ent and surface tenperature l for application of primer shall be as follows:

Ambient Temo. ('F) Surface Temo. ('F)

Dimetcote 6 40-120 40-130 l

Carbo Zinc 11 40-95 40-110 i

Carboline 191 50-120 50-120 Phenoline 305 50-120 50-120 l

Humidity values may vary from 0% to 95% for inorganic primer; however, primer shall not De applied to a wet or damp surface.

Miniaan and maximun values of relative humidity for Phenoline 305 and Carboline 191 shall be 0% and 85%

respectively.

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INSTRUCTION l ISSUE NUM ER REVISION PAGE

, TEXAS UTiUTIES GENERATIN  ;

'O. DATE QI-QP-11.4-26 1 '

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~

FEB247gg4 24  : 34; 1

ATTACHMENT 1B '

Air Supply Acceptability -

An inspector shall inspect the air supply system of blast and spray equipment for suitable filters / traps / separators and that they are left cracked open. The effectiveness of these items shall be verified by exposing a piece of white cloth to the air outlet for approximately 30 seconds. The white cloth shall be examined for evidence of contaminatio'n (oil, water, foreign atter, etc.). No evidence of contamination is acceptable.

s

INSTRUCTION ISSUE

- NUM8ER REVISION .'

PAGE TEXAS UTluTIES GENERATIN(. h. OATE CPSES QI-QP-11.4-26 2 FEB 2 4 g 25'of 34{

l l

ATTACHMENT 2 i PREPARATIONOFCOATINGMATERIA(S Primer - The primer, Cartio Zinc 11, is packaged in a two component kit consisting of a base and a zinc filler. First the base shall be thoroughly mixed. Zinc filler shall then be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in .a proportion of 10 parts base to 22 parts zine filler using a suitable scale to achieve a plus or minus 2 percent accuracy. The mixture shall then be strained through a 30-mesh screen.

Viscosity shall be controlled by adding thinner, as required, but. shall not exceed two quarts of thinner per gallon of 4

Camo Zinc 11.

Primer - The. primer, Dimetcote 6, is packaged in a two component kit consisting of a base and zine filler. The base shall be thoroughly mixed first. Zinc filler shall then be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in a proportion of 6.4 parts base to 15 parts zinc filler using a

suitable scale - to achieve a plus or minus 2 percent accuracy. The mixture shall then be strained through a 30-mesh screen. Vi scosity shall be controlled by adding thinner as reoutred up to the maxima allowed by the latest revision of Dimetcote 6 application instructions. Primer coat shall be reddish gray.

Primer Coat - The primer coat, Ca6oline 191, is packaged in a two component kit consisting of Carboline 191 base, Part A, and a catalyst, Part B. Mixes are made by cambining and ^

thoroughly mixing the base and catalyst. Partial mixes may i be made by canbining, in a ration by volume, two parts base to one part catalyst. Viscosity shall be controlled by adding thinner as required, but shall not exceed two qearts of thinner per gallon of Carboline 191. -

Finish Coat - The finish coat, Phenoline 305, is packaged in a two component kit consisting of Phenoline 305 base, Part A, and a Phenoline catalyst, Part 8. Mixes are made by combining and thoroughly mixing the base and catalyst.

Partial mixes say be made by combining, in a ration by volume, four parts base to one part catalyst. Viscosity shall be controlled by adding thinner as required, but '

shall not exceed two quarts of thinner per gallon of Phenoline 305.

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m .s PROCEDURE ISSUE NUMBER REVISICN PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES QI-QP-11.4-26 2 FEB 2 4 gg4 26 of .34-ATTACliMENT 3 PAINT MIX 5 LIP

  • Report No.

Bldg.

DATE POT LIFE SHIFT TIME l MIX NUOMER ELEVATION MATERIAL GAL. MIXED SHELF LIFE ACCEPATELE: YES NO MSTE 8'S DATE & TIME MIXED BASE CURING AGENT FILLER THINNER ACCEPTED SY DATE POT LIFE SHIFT T!!E MIX NLMBER

-- --- -- . ELEVATION MATERIAL GAL. ft!IED SHELF LIFE ACCEPTABLE: TES NO MATE #'s DATE & TIME MIXED BASE CURING AGENT FILLER THINNER ACCEPTED BY

-m DATE POT LIFE SHIFT TIME MIX NUMBER ELEVATION MATERIAL GAL. MIXED SHELF LIFE ACCEPTA8LE: YES NO MATE l's DATE & TIME MIXED BASE CURING AGENT FILLER THINNER ACCEPTED 8Y QC REVIEW & ACCEPTANCE sIpietore da te Pam na a TUGCO OA

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. PR I N REVISION PAGE D

TEXAS UTIUTIES GENERATING CO.

CPSES .  ;

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QI-QP-11.4-26 2 . FEB 2 41934 27.ofi 34" ATTACHMENT 4 STEE. PROTECTIVE COATING INSPECTION TRAVELER WoRet Pte,e> PCI TRAVELE3t a

! miops' iTed astoEscRsPflast PER owes.s PetEPARto Syr DATE STEP sustPAct PREPARATION WesPEcTEo Aado FouNo AcCEPTA8LE Pet E-QPIL4*24 ANo stELEAsEo FoR PRaadER APPucAftoN.

INsPtsfost DATE I

commeerfs STEP PReassit APrucarloss isespeCTEo A8eo Pousso AccEPTASLE PER et-QPit.4=18 Aato RELEAsEn FoR FINESN coat APPUCATloN.

BENEcT" OATE 2

commesmTs f

3TO man coat ArrucATlose asesPEcfta ANo rouno AccEPTAsts PER et-epil.4-as sospecfon a *TE 3 .

t consuests _

3TEP msn coat BespecTro fast PiseAL ACCEPTANCE ANo Fo4No  !

AccePTASLE Pet 08-4PlL4-2s '

INsPECTgn DATE 4

consessers STEP coastsTIoss oP BlsPEcTloN TRAVELER VERIPIEo.

sc Review OAT

  • 3 l coenserfs '

I N in oomaseer msPamon Amisursson ArrAcuso sur,onTuss oocumarrATion susETts: -

O al occuuerf RsPA Rs Ano ArTRouTus.iP siscuistsp. ass ATrAcaco T suPPontuse occuuerTArion snEErts:

E 31 Pon emRomisesTAs. conomons Ramancarus 3 savinomusmTAs. Loe.

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  • ~

I O' REVISION I N[MS PAGE

p. TEXAS UT1UTIES GENERATING CO.

CPSES t OI-OP-11.4-26 2 FEB 2 41984,28 nf i y - .

ATTACHMENT 4 '

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, . . . . j INSTRUCTION 388U REVISION PAGE TkKAS UT1UTIES GENERATING CC.

NUM8ER l CATE '

( QI-QP-11.4-25 2 FEB 2 4.198% 29 of,p

. ATTACHMENT 5 TOTAL NUMBER OF ALLOWABLE POINTS OF DISCONTINUITY SURFACE AREA COND. "C".

SEING COATED COMMERCIALLY (S0. FT.) CONTINUOUS 10 . 5 10-50 10 50-100 20 100-500 30 500-1CPA -

50

(- 1000-5000 75 Gross Discontinuities - None Allowed.

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PROCEDURE ISSUE NUMBER REVISION PAGE DATE TEXAS UTluTIES GENERATING CO.

CPSES , -

QI-QP-11.4-26 ~2 FEB 2 41984 30 of 34

. ATTACHMENT 6 Report No.

'= NL of sneet a

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ENVIRONMENTAL LOG SHEET W E #'s Elevation Bldg.

Date Shift Unft

! W EC W TIME DAY SULS WET SUL8 I '

SunFACE TEMP.

OEW POINT l STEEL l CONCRETE HUMIDITY l e em o e, e

i 1

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Ignature Date I

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INSTRUCTION '88UE

<N-NUM':ER REVISION ^ DATE PAGE TEXAS UTIUTIES GENERATIN O.

. CPSES QI-QP-11.4-26 2 FEB 2 41984 .31 of 34 ATTACHMENT 7 DEFINITIONS Color and Gloss Nonunifomity: A milky haze or mist in the finish of a recently applied coating.

Contaminant: A foreign substance, inadvertently added to a coating or found on the substrate that adversely affects the application, adhesion, curing and/or subsequent performance of the applied coating.

  • Dry Soray: A dry powdery primer or finish coat readily renoved by light sanding with either sandpaper or a wire screen. A minor amount of adherent dry spray is acceptable on the final finish coat.

Feathering: An area that is roughened and tapered to obtain a smooth 1

and continuous surface with an existing coating.

Fisheyes: Small openings (" fisheyes") in wet film exposing old 4

surface or previous coat.

Full Hiding: The coating provides sufficient coverage so that the t preceding coat is not readily visible with an unaided eye.

Holiday: A pinhole, ski p, discontinuity or void in coating film.

Major Defect: Defined as an area, either circular or linear, in which a 1/2" diameter circle could be inscribed at any point or along i

the entire length.

Minor Defect: Defined as an area, either circular or linear, in which a 1/2" diameter circle could not be completely inscribed at any point along the entire length.

Monitor: Confomance verification by physically observing a task being perfomed on a periodic or random basis.

Muderacking: Irregular cracking as in a dried mud puddle (applicable

, to inorganic zinc primers).

Orance Peel: Dents in the surface resembling orange skin. A moderate amount is acceptable.

Verify: Confim or make certain.

Visual: To examine with an unaided eye (correctional eye glasses or contact lens are acceptable).

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PR URE TEXAS UTIUTIES GENERATING CO.

NUMBEq REVISION h PAGE CPSES ~~

QI-QP-11.4-26 FEB 2 4' 1984 3#

2 32 of ATTACHMENT 8 P0T LIFE REFERENCE SHEET Normal Pot Life - CZ 11 8 Hours Pot Life Sk -

gun. .

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de 5'a 99

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  • toS*! sida i15 Pot life stated above for unthinned coatings are the reconsnended times and should be utilized as a guideline for cotins usage time, however, actural pot life may be longer. For unthinned coatings or coatings thinned 50% or less, acutal pot life is determined by applicability of the coating.

POT LIFE PHENOLINE 305 & CARB0LINE 191 TEMPERATURE (OF) UNTHINNED THINNED 50%

50-54 10 hrs. 24 hrs.

55-59 7 hrs. 24 hrs.

'60-64 4 hrs. 24 hrs.

65-69 3 hrs. 24 hrs.

70-74 2 hrs. 24 hrs.

75-79 1h hrs. 24 hrs.

80-84 lh hrs. 24 hrs.

85-89 1h hrs. 24 hrs.

90-95 1 hrs. 24 hrs.

Pot life stated above for unthinned coatings are the recommended times and should be utilized as a ' guideline for coating usage time, however, actual pot life may be longer. For unthinned coatings or coatings thinned 50% or less, actual pot life is determined by the applicability of the coating.

~ .

TEXAS UUUDES GENERATING CO.

CPSES QI-QP-11.4-26 2 IES 2 4 igg 4 ' 33 of 34 ATTACHMENT 9 SM PROTECTNE COATING MCTIWIMEPM TRafELEN N

sensman ME ITEM se /CEEnePfleet IERswe&s perpenED evt SATT 94T OF STEP sunraCa pnsmutaticas inanc7En ase pause acczPfAaLE PER 3 W E4=36 ase NELEASED POR MesuEll am%BCAT1oss, uespecTan cart I

assancers STEP M8MER APrucAfices suspeTun Ano poumo acczpfAstr .

PM oE41PIL4-as Asso itsLEAaED POR Pensas Cear Appucarlem.

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2 ccuuerfu STEP resan casr AppucA71cm lasPECTES afe fcW88 ACCOTAaLE i PER et-4PIL4-38 sere:et ==w

. 3 eaauerrs STEP meman coat septCTun m mass, accartasecs Aase roumo acespraaLE Psa es-er:L4-as separM= cart 4

coamserts 3TEP cuestsTien op maperrion Taavaksa vanema.

sa naview nar*

. . M N II CCc:.aser7 Nse AT tesuT33 cm A7 t. ass supaen .:ss CCC astafAT.Cm Si4EIT;31 O al coensert apnes ano ar atsuits.:P RsCuinc.cx 471.Cass 7 Sap *carTDet cccuasetT.".. cts skEITial l T. 3) pgst ENvefelDeesse7AL C:DeCIT:Cass ftEFetceCITHE g avisemmanTAs Lee, i

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O N TEXA8 UBUDES GENERADNG CO.

CPSES QI-QP-11.4-26 2 FEB 2 41984 34 34 of ATTACHMENT 9

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7 .

l i INSTRUCTICN i ISSUE l  !

TEXAS UTfuT185 GENERATING.CO. NUM8ER REVISICN CATE j PAGE i

, CPsEs ,

QI-QP-11.4-25 1 l f 29 M28 I

INSPECTION OF STEEL PREPARED BY: X.r % /M , '

/-P9-59 SUBSTRATE SURFACE p- gg7g PREPARATION, PRIE R APPROVED BY:

64jy-j as t-2e- / , # # ^ /[. j l

APPLICATION, PRIMER -w - /-M -W REPAIR, SEAL AND - CATE FINISH CDAT APPLICATION -s AND REPAIR APPROVED BY:WA _' bM

'0 ATE 1.0 GENERAL f'[ , ,,..,........

1.1 PURPOSE AND SCOPE The purpose of this instruction is to outline m thods utilized by Quality Control personnel in inspection of steel substrate surface preparation, primer application, primer repai r, seal and finish coat application and repair for .

Unit 1 Reactor Building.

2.0 INSTRUCTION Vi sual inspection of su rfaces as addressed 'by this  ;

instruction shall be made at approximately an ams length '

i fran the surface being inspected. The area of inspection

! , shall be adequately lighted during the inspection activity.

l Adequate lighting is defined as the minimum light produced l by a two (2) cell battery flashlight. Flashlight shall be ,

held perpendicular to the surface during visual inspection. I

! Visual surface preparation standards fabricated on site and approved by Quality Assurance and Engineering my be used

. j by Inspectors as an aid in the performance of their i ins pections. .

i For definitions, refer to Attachment 7.

l 2.1 PRE-BLAST HAND AND/OR POWER TOOL CLEANING OPERATI0NS ,

l 2.1.1 Abrasive Acceotability The Inspector shall obtain a sample of the abrasive to be  ;

used from each work area. The abrasive shall be verifici .

to be dry by feel . All grease, oil and deleterica material is unacceptable.

t

'o l

lilSTORICAL FILE T'.;GCC oA

INSTRUCTION ISSUE pggg REVISION

3 QI-QP-11.4-26 1 2 e 29 M 2 S 19H

/ .

Particle size must be sufficient to achieve 1 mil surface profile ' minimum. '

2.1.2 Blast Eouipment Acceptability The inspector shall perfonn the following inspections / tests to determine acceptability of blast cleaning equipment prior to use:

a. Air supply (refer to Attachment 1B).
b. Ambient conditions (reference Attachment 1A and 6).

2.1.3 Solvent' Cleanino (If Chenical Contaminati Present)

If oil, grease, or other chemical coht mination is present, verify that. solvent cleaning is perfonned and that chemical l contamination is removed prior to blast / power tool cleaning steel surfaces.

2.2 POST BLAST CLEANING OPERATIONS 2.2.1 Blast Cleanuo The inspector shall visually check the blasted substrate surface.

The surface shall be air blasted or solvent wipea to the extent required for final surface inspection. The adjacent areas shall be cleaned to the extent necessary to avoid

, cont *.mination during subsequent coating applications.

2.2.2 Blasted or Power Tooled Surface Acceptability The inspector shall perfonn the following inspectials to detennine acceptability of the blast cleaned or power tooled surface: .

a. Absence of Foreign Matter --

A vi sual inspection shall be performed to detennine that all oil and grease, di rt, m111 scale, rust, corrosion products, oxides, paint or other foreign matter have been coupletely renoved from the surface except for light shadows, very slight streaks or slight di scolorations caused by rust stains, mill scale, oxides, or slight, tight residues of paint or coating that_may renain. At least 95 percent of each square inch of surface area shall be free of all residues, and the renainder shall be limi ted to light discolorations as mentioned a6ove.

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TEXAS UtutES GENGIADNG CQ.

QI-QP-11.4-26 1 3 of 29:

3 g, NOTE: In addition to the 5 percent of tight residue of N' paint or coating which is permissible, shadows or tightly - adhering residues of primer nay renain (without limit) .in the profile of the previously prepared substrate. However, areas with residues of Carboline 191 primer shall be recoated with ,

Cartoline 191 primer. Areas wi th residues of inorganic zine may be coated with either inorganic zinc or Cartoline 191 primer. It is not required that such areas meet the criteria of SSPC-SP10,or SSPC-SP6.

b. Removal of Shan Projections -- An inspection for sharp projections that were not blended (rounded) during blast cleaning, or power tooling shall be perforsned.

Weld spatter on structural steel which renains after grinding or sand blasting 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 sham edges or weld spatter will require a visual welding inspector's acceptance of the work perfonned.

c. 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 surface shall be a mininun of 1.0 mils.

Surfaces that have been power tooled with "3M Clean-N-Strip", 80 grit and coarser " flapper wheels", sanding di scs , " Roto-Peen" or equivalent, provide acceptable surface profile.

No maximum profile will be specified, providing that correct millage and surface uni forinity requirements can be obtained after primer application.

pen. i WM CA

INSMUCUCN REVISION ISSUE DAGE

. TEXAS UTil.JTIES GENERATING CC.  !

ES Q I-Q P-11.4-26 1 4 of 29 2.2.3 Unioue Number Identification After blasting, power tool and prior to prime coat application (if applicable). QC shall verify that construction has identified each piece with a unique number.

2.3 PRIMER PRE-APPLICATION INSPECTIONS

~

2.3.1 Ambient tonditions The inspector at the " paint di stribution point" in Reactor 'l shall verify ambient conditions in accordance with Attachment 1-A.

2.3.1.1 The inspector shal1 nonitor the ambient conditions being recorded on the Environmental Log (Attachment 6) at the

" paint distribution point" in the building.

2.3.1.2 Occumentation of Environmental Conditions

a. The inspector assigned to the " paint di stribution point" in the Reactor building shall, as a minimum, take a complete set of readings (air temperature, relative humidity, dew point and surface temperature) on each floor elevation at least three (3) times each shift (preferably, the beginning, mid point and just prior to the end of each shift). More readings may be taken when necessary (i.e., noticeable change in air tanperature, request by field inspector to take readings in a specific area, etc.).

/ b. The inspector at the " paint distribution point" shall document these readings on Attachmert 6 as follows:

1. One (1) Envi ronmental Log Sheet (Attachment 6) shall be completed for all readings taken on one (1) floor elevation or specific area in a given shift.
2. The inspector shall fill in the applicable information as delineated on the fonn, exceot for the " Report No. "

. (The Report No.

will be filled in by the Paper Flow Group when they assign numbers, prior to transmitting to the QA Vault.

3. Upon completion of the shift, the inspector shall turn all of the environmental log sheets for that shift into the lead inspectors.

,  %, Tuoco c4 *

. i 1 6 CMON REVISION IIIUE PAGE

. TEXA8 UTluTIES GENERATING CO.  ! j cnEs QI-QP-11.4-26 1 Jg; o 8 icg4 > 5 of 29 l

~

l i

c. The lead inspector (s) shall review the log sheets for completeness and correctness, sign and date the "QC Review" block, obtain copies for QC reference and transmit the originals to the Paper Flow Group.
d. If at any time the inspector determines readings which i

do not comply with the parameters set forth in this procedure, he shall proceed in the following nenner:

I -

1. Innediately take an additional set of readings in the immediate area of the first set of unacceptable readings and record them on the environmental log.
2. If the additional set of readings are acceptable, take a third set of readings for referee purposes and record then. If the referee set of *eadings are acceptable, then the area in question is acceptable but should be closely monitored with readings as necessary.
3. If the additional set of readings is acceptable and/or the referee set of readings is unacceptable, the inspector is to notify the coatings inspectors in the areas affected so that coating work may be stopped at that time. Coating work shall not continue until the ambient conditions resume an acceptable status.
4. men unacceptable ambient conditions occur and are veri fied by step 3 above, the inspector shall i

doctanent it on a Nonconfonnance Report (NCR) in i

accordance with CP-QP-16.0 and adequstely identify the affected areas / elevations, t

2.3.2 Substrate Surface Accepta5ility

! The Inspector shall visually reinspect the sandblasted or powertooled surface of the substrate just prior to primer application for evidence of contamination (oil, grease, markings, rust, etc.) Contamination must be removed prior

,i to priming.

i If rust fanns after Blasting or Power Tooling, the surface shall be recleaned before priming. Under no case will a prepared surface be exposed for more than 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> before priming.

2.3.3 Air Supply Acceptability i

The Inspector shall inspect the air per Attachment 18.

neu, == i N CA I

2

. _ . - .. _ .,. . _ , _ ~ . _ _ _ _ . _ , . . - , . . , . _ _ , - _ , , _ _ _ _ .,_,_ ,_ _ ..,_.,_,_ ,_.., _ , _,_ _

INSTRUCTION ISSUE REVISION DATE N TEXAS UTIOTIES GENERATING CO.

QI-QP-11.4-26 1 g 3 3 3cga 6 of 29 2.3.4 Qualification of Applicator (s)

The Inspector shall verify (bf Qualification Record or list of quali fied applicators fran QA file) that the coating applicators are qualified for safety-related coating work.

The applicator (s) badge number shall be listed on the back of the traveler.

2.3.5 Mixino Operations 3' 2.3.5.1 Coating Materials Identification ~

An inspector shall inspect the coating sterial containers prior to mixing contents for product identification and verify that all materials are correct for coating application.

Approved sterials are:

CZ-11 Carto Zinc 11 base (gray or green)

Carbo Zinc filler Cartoline #21 or 33 Thinner DIMETCOTE i

Dimetcote 6 base Dimetcote filler Amercoat #65 or 101 Thinner CARBOLINE 191

  • Cartoline 191 Primer (Red Brick)

Carboline 191 Catalyst Cartoline #15 Thinner PHENOLINE 305 Phenoline 305 base Phenoline 305 catalyst Phenoline thinner An inspector shall also verify that each component container is identified by batch number and that the shelf life has not expired. Carto Zinc 11 base and Cartoline 191 has a shelf life of 12 months. Carbo Zinc filler Dimetcote 6 base and filler, and Phenoline 305 all have a shelf 11fe of 24 months.

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IMCTICN REVl!!CN I88UI

^ TAGE TEXAS UTIUTIES GENERATING CC.

88 QI-QP-11.4-26 1 g 3 s iga 7 of 29 d

2.3.5.2 Mixing Operations An inspector shall witness each mixing / thinning operation.

The inspector shall verify that mixing operations are perfonned in accordance with Attachment 2.

2.3.5.3 Thinning Operation Coating naterials (if thinned) viscosity control shall be accomplished by adding thinner as required, but shall not exceed two quarts of thinner per gallon of naterial .

2.3.5.4 When coating materials are mixed / thinned, the inspector verifying the mixing operation shall fill out the Paint Mix Sli p, Attachment 3. The inspector perfonning the pre-application inspection shall record the mix. sheet number on the travelers. The Mix Slip shall be returned to the Paper Flow Group at the end of each shift to be sent to the vault.

2.4 PRIMER APPLICATION INSPECTION 2.4.1 Surveillance of Primer ADDlication During application operations of CZ-l'., the QC Inspector shall monitor that the pressure pot is continuously agitated. The QC Inspector shall also verify that the hose length does not exceed 75 feet. CZ-11 shall not be brush appiled to areas larger than 1 sq. ft.

2.4.2 During app'ication of Carboline 191, the inspector will

/

monitor to assure that no fisheyes appear in the applied coating. If detected, the inspector shall inform the paint forenan of their presence and that they should be renoved while coating is still wet, surface cleaned with solvent and coating reapplied.

2.5 INSPECTION OF PRIMER 2.5.1 Primer Insoection Prior to Application of Seal or Finish Coat

a. Verify the primer has cured sufficiently for the top coatin CZ-11)g (as

. Curedetennined to top coatby of the Carbouse11neof a 191 nickel testbeon shall the same as Phenoline 305.

b. Perfonn a visual inspection of the primed surface in accordance with the following:

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INSTRUCTION I88UE REVISION DAGE TEXAS UTIUTIES GENERATING CC. DAM )

QI-Qp-11.4-26 1 8 of 29 333 9 3 cg4

1. Runs / sags dich do not exceed the maximum dry film thickness for each coating applied and show no evidence of mud ' cracking or loss of adhesion

, are acceptable. Repairs for runs / sags other than the aforementioned shall be as per Sections 2.6.2 or 2.6.3, as applicable.

2. Dry Spray - Must be removed before overcoating as per Section 2.6.3.
3. Contamination - unacceptable; repair as pair Section 2.6.2 or 2.6.3, as applicable.

Oil and crease - unacceptable; repair as per Section 2.6.3.

4. Ski ps/ damaged areas / holidays or voids -

unacceptable; repair as per 2.6.2 or 2.6.3, as applicable.

5. Orange peel - Moderate amounts are acceptable.

Excessive amounts unacceptable; repair as per I.

M ion 2.6.3.

6. Subbling - unacceptable; repair as per Section 2.6.2 or 2.6.3, as applicable (does not apply to CZ11).
c. The inspector shall perfonn a DFT inspection of the cured primer film. A calibrated 0-25 Elcometer 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 geametric discontinuities in the steel, measurenents less than 1 inch from the edge or a hole shall be avoided (See Note 3).

Dry Film Thickness shall be as follows (See Note 4):

Min. (mils) Max.(mils)

Cartoline 191 spot test 1.6 8.5

.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 Carboline 191 average DFT 2.0 7.0

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INSMUCTION REVISION ISSUE p4gg

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QI-QF-11.4-26 1 M; ,e ,c,4 9 of 29 ',

NOTE 1: A spot masurment 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 measurment.

NOTE 2: Five spot tests shall be taken for every 100 square feet of coated surface. 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: Itans with appreciable surface curvatare and other geo.aetrictl di scontinuities, such as handrail s, gratings, stairs, sway struts, checker plate, etc., shall be exempt fran dry film thickness measurenent.

NOTE 4: In the event that any spot is found to be outside of the acceptable thickness range, three additional spots shall De taken at

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approximately 6 inches fran the failing spot and spaced radially at approximately 120 degree intervals to de,tennine the extent of the unacceptable area.

In the event that the average of the area is unacceptable due to unacceptable spot readings, the unacceptable spots shall be isolated as described above. Additional spot readings shall be taken equal to the nunber of unacceptable spot readings and the average recalculated.

NOTE 5: Unacceptable areas shall be repaired as per Section 2.6.3. l l

INSTRUCTION 388UE S REVISION PAGE TEXAS UT!UTIES GENERATING CO. j DAM CN QI-QP-11.4-26 1 JAN 2 3 $2a 10 of 29

d. Inaccessible and/or limited access areas dere DFT gauge cannot be properly engaged shall be vi sually inspected to veri fy that primer is applied to the substrate. No other inspection is required.

, 2.6 PRIMER REPAIRS 2.6.1 Saas and Runs Runs / sags : Ref. Sec. 2.5.1.b if surface is unacceptable.

Repair per Sec. 2.6.2 or 2.6.3.

  • 2.6.2 Primer Touch-up Repair (Primer Damaced to Steel Surface)

The coating inspector shall conduct the following inspections to doctanent primer touch-up repair operations when the damage is to the steel surface and spot-sandblasting, hand sar.di ng or power tool abradi ng ' is perfonned for surface preparation.

4

a. Surface preparation Ref. Sec. 2.2.2.
b. berify that the blasted or power tooled surface has been high pressure air blowdown, and/or solvent wiped to the extent required for final surface inspection.

The adjacent areas shall be cleaned to the extent necessary to avoid contamination during subsequent coating applications.

c. Ambient Conditions: Ref. Attachment'1A and 6.

i

." Air Supply Acceptability: Ref. Attachment 18.

The surface temperature shall. be a minimum of 5' above the dew point.

d. Verify applicator quali fications per Section 2.3.4.
e. Verify air supply acceptability per Attachment 18.
f. Ver1fy amoiont condition per Attachment 1A.
1. Coating Materials Identification j Verify per Sec. 2.3.5.1.

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  • l CPSES QI-QP-11.4-26 1 Jgg o g ;cg4 11 of' 29l
2. Mixing Oper*.tions Verify per Sec. 2.3.5.2.
3. Thinning Operation Veri fy per Sec. 2.3.5.3.
g. Verify that primer is appli ed in accordance wi th Sec. 2.4.1. .

NOTE: (If applicable) Coating interface - at coating interface for finish ind/or primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smooth final coating system. When inspecting coating interface the interface of the coating or systens shall be a eximum of 115 inch in wi dth. Within the interface area, overlapping of any materials or systems is acceptable.

2.6.3 Primer Touch-up Rorair (Primer Damaae Does Not Extend to Steel Surface The coating inspector shall conduct the following inspections for primer touch-up repair operations when the damage is within the primer ccat and sandblasting to the steel substrate is not required.

a. Verify surface is abraded lightly then wiped clean.
b. Verify primer is applied in accordance with Section 2.4.1.
c. Vi sually veri fy acceptability of repaired area per Section 2.5.1.b.

2.6.4 Repair of Primer by Recoatino The coating inspector shall conduct the following inspections for primer recoating repair. Only two (2) overcoats may be applied of inorganic zinc primer.

a. Verify that the surface has been solvent cleaned or blown down with high air pressure. Contamination is unacceptable and requires further cleaning.

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INSTRUCTION ISSUE TEXAS UTluTIES GENERATING CO. l UAM '

m ES QI-QP-11.4-26 1 I2 of 29,:

JAN

  • 3 tc84 --

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b. Perfom inspections in Section 2.6.2.

NOTE: After application of primer to the spot primed area, the oniy additional feathering required is at the outer edge of the primed area. Sanding of the primed area is not required.

2.6.5 Comolete Primer Repair (Primer Damaos to Steel Surface Extends Over Entire Itan)

The coating inspector shall conduct the following inspections to document priner repair when the damage is to the steel 1 surface and requires surface preparation to steel substrate

, over entire item:

a. Verify ambient conditions per Attachment 1A to surface

, preparation. See Attachment 6.

b. Perfom inspections (a) through (g) in Section 2.6.2.

2.7 FINISH C0AT PRE-APPLICATION INSPECTIONS The QC inspector shall verify the following items prior to applying coatings:

2.7.1 Coatina Applicator Qualifications The Inspector shall verify (by Qualification Record or list of quali fication records in QA File) that the coating applicators on each shift are qualified for safety-related coating erk.

, 2.7.2 Ambient Conditions (Refer Attachment 1A and 6)

The pennissible range- of surface and ambient temperature for application of finish coat shall be 50-120*F.

, The maximum humidity shall be 85% for Phenolina 305, and 95% for inorganic zine and Cartoline 191.

, The surface temperature shall be a minimun of 5'F above the dew point.

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INSTRUCTION I NUMSER RNSION O p4gg TEXAS UTIUTIEs GENERATING CO. I CPSEs QI-QP-11.,4-26 1 13 0# 29 JAN ? 3 :cg4 t

2.7.3 Coated Surface Acceptability .

The Inspector shall visually reinspect 'the previously coated surface just prior to finish coat application for evidence of contamination (oil, grease, forei The defective areas shall be repaired per Sec.(gn matter).s) 2.6.2, 2.6.3, 2.6.4 and 2.6.5, as applicable.

2.7.4 Air Supply Accootability (per Attachment IB) 2.7.5 Finish Coat Mixino Operations

  • 2.7.5.1 Prior to mixing, the mixing inspector shall verify that each caponent is identified by batch msnbers and that the 2A month shelf life has not been exceeded.

2.7.5.2 The mixing inspector shall

  • veri fy that mixing / thinner operations are perfonned in accordance with Sec. 2.3.5.2.

Thinning my be done up to two quarts of Phenotine Thinner per gallon of Phenoline 305.

2.7.5.3 Mixing operation shall be documented on the traveler per

, Sec. 2.3.5.4.

2.8 SURVEILLANCE OF SEAL OR FINISH COAT APPLICATION 2.8.1 The Inspector shall monitor that hose length does not exceed 75 feet.

2.8.2 The inspector shall also verify that the seal coat (if present) is solvent wiped prior to finish coat application.

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2.8.3 The inspector shall nonitor to assure that no fisheyes appear in the applied coating. If detected, the inspector shall infonn the paint forenan of their presence and that they should be removed while coating is still wet, surface cleaned with solvent and coating reapplied.

2.9 FINISH C0AT FINAL ACCEPTANCE INSPECTION The inspector shall perfonn a final acceptance inspection of each finish coated item (s) in accordance with Paragraphs 2.9.1 through 2.9.5.

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. . i INSTRUCTION ISSUE pggg NUMSER REVCON OATE

. TEXAS UTIUTIES GENERATING CO. l CMES QI-QP-11.4-26 1 JAN ? 3 1924 14 of 29' NOTE: (If applicable) Coating interface - at coating interface for finish and/or primer coat, the existing coating shall be " feathered back" a sufficient distance to ensure a smooth final coating system. When inspecting coating interface the interface of the systens shall be a maximum of th inch in width. Within the interface area, overlapping of any materials or systems is acceptable.

NOTE: The tie in interface between concrete coating's and steel coatings shall be vi sually inspected during the finish coat final acceptance of both systems.

2.9.1 Finish Coat Cure Final QC inspection may be perfonned after a minimum topcost cure of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> and cure to recoat time has been met.

Curing and time to recoat Phenoline 305 shall be as shown below:

Between Coats Temperature 'F 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> 50 - 59 36 hours4.166667e-4 days <br />0.01 hours <br />5.952381e-5 weeks <br />1.3698e-5 months <br /> 60 - 74 18 hours2.083333e-4 days <br />0.005 hours <br />2.97619e-5 weeks <br />6.849e-6 months <br /> 75 - 89 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> 90 and above

' Phenoline thinned at 50% and applied as a seal coat may be recoated after 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> of cure at or above 75'F.

. 2.9.2 Visual Defects inspection The Inspector shall perfonn 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 15.0 mils or less, which show no evidence of nuderacki ng , are acceptable. Those

' greater than 15.0 mils shall be repaired as per l Section 2.10.1.

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I CTION I REVISION , PAGE

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  • TEXAS UTluTIES GENERATING CO. l QI-QP-11.4-26 1 15 of 29

, JAN 2 3 1924 b) Ski ps, daar.ged areas, holidays, voids, bubbles, blisters and excessive orange peel are not acceptable and shall be repaired as per Section 2.10, as applicable.

c) Pinholes - acceptable to the extent allowed by

, Attachment 5; areas not acceptable shall be repaired as per Section 2.10.5.

d) Contamination - unacceptable; areas shall be repaired as per Section 2.10.4.

e) Dry spray - unacceptable; shall be repaired as per Section 2.10.6. A minor amount of adherent dry spray is acceptable on the final finish coe.t.

f) Color and gloss non-uniformity - unacceptable; shall be repaired as per Section 2.10.8.

Top coated areas which have been abraded for various reasons (i.e., runs, sags, high millage, etc.) and are within acceptable procedural thickness following repairs, do not require recoating for gloss enhancing.

For small repair areas such as pinholes, gloss and

, gloss unifonnity is not required, provided the coating 4

is smooth and continuous.

2.9.3 Dry Film Thickness (OFT)

The Inspector shall perform a DFT of the cured coating

/ system. A calibrated 0-25 E1cometer 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 nagnetic gage is sensitive to geometric di scontinuities in the steel,

. measurements less than 1 inch fran an edge or a hole shall be avoided. (See Note 3).

The average DFT of the total coating systen shall be a miniaan of 6.0 mils and a maximum of 13.0 mils. The spot test OFT of the total coating systen shall be a minicum of 6.0 mils and a maximum of 15.0 mils (See Note 4).

The finish coated systen shall exhibit full "hidi ng" properties of the primecoat.

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INSTRUCTION ISSUE hEVISION PAGE

. TEXAS UTluTIES GENERATING CO. I N E3 QI-QP-11.4-26 1

, 16 of 29 NOTE 1: A spot masurement is a series of three masure-ments in the same general area. The probe should be noved a short 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 measurment.

NOTE 2: Five spot tests shall be taken for every 100 square feet of coated surface. For areas less than 100 square feet, the following shall applyi Area Sq. Ft. No. Spots 100-80 5 80-E0 4 1 50-10 3 10-3 2 3-0 1 NOTE 3: Items with appreciable surface curvature and other gemetrical discontinuities such as handrails,

( gratings, stairs, sway struts, etc. shall be exempt from DFT measurment.

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 fra the failing spot and spaced radi ally at approximately 120 degree intervals to determine

/

the extent of the unacceptable area. Dimensions and locations of unacceptable areas and results of additional testing shall be docunented on the IR.

In the event that the average of the area is t unacceptable due to unacceptable spot readings, l the unacceptable spots shall be i solated as l

described above. Additional spot readings shall i be taken equal to the number of unacceptable spot t readings and the average recalculated. If the recalculated average is acceptable, the traveler shall be so marked with an explanation in

" Remarks" statin that " average recalculated -

now acceptable",g or wording to that effect. If the recalculated average is unacceptable, the unacceptable spots shall be isolated and repaired per Sec. 3.10.

INSTRUCTION ISSUE REVISION PAGE TEXAS UTIUTIES GENERATING CC. l DAM QI-QP-11.4-26 ,1 g.; ,,, 3 g 17 of 29 2.9.4 Continuity inspection The Inspector shall test the . continuity of the cured finish coat on liner plate using a Tinker and Rasor Model M1 (67.5 volt) holiday detector. 100% of the finish coated surface area shall be tested.

The applied film should contain only a minor number of points of di scontinuity. 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 scontinuity (pinholes). No more than 40% of the total nunber 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 5. No gross discontinuities are allowed.

2.9.5 Inaccessible and/or limited access areas, where a DFT gauge cannot be properly engaged, shall be visually inspected to verify that topcoat is applied. No other inspection is requi red. - -

2.10 ~ REPAIRS OF FINISH COAT .

2.10.1 Repairs of Runs and Sacs The QC inspector shall verify that the area is abraded until the DFT of the total coating system is within 6.0 to 15.0 mils, and examined for nudcracking. Mudcracking shall be repaired in accordance with Sec. 2.10.2 or 2.10.3.

2.10.2 Repair of Minor Defects The QC inspector shall perfom the following inspection when repairing minor defects:

a) Verify ambient conditions per Attachment 1A prior to surface preparation.

b). Verify that the damaged area is blasted or abraded until all loosely adherent particles are removed.

c) Verify damaged area is solvent wiped.

d) Perfom inspections described in Sec. 2.7, 2.8 and 2'.9.

Minor defects may be repaired at the time of final e) inspection without later reinspection of the repair, mm i m mco cA

g I CTICN I REVISION PAGE TEXAS UTluTIES GENERATING CO. l D

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E3 QI-QP-11.4-26 1 y; a g g 18 of 29 l

2.10.3 Repair of Maior Defects The QC inspector shall perfonn.the following inspection when repairing major defects:

a) Verify ambient conditions per Attachment 1A and 6.

b) Verify area is abraded or spot blasted until all loosely adherent particles are renoved.

c) Verify area is solvent wiped. '

d) Perfonn inspections in Section 2.7, 2.8 and 2.9.

2.10.4 Repair of Contamination The QC inspector shall verify that contamination is renoved by abrading and the surface recoated. The inspector shall perfonn inspections delineated in Sections 2.7, 2.8 and 2.9.

2.10.5 Repair of Pinholes and Small Discentinuities

( a) Verify all loose particles are renoved and area is s01 vent wiped.

b) Pinholes and small discontinuities may be repaired at the time of final inspection without a later

- reinspection of the repair. The inspections in Section 2.7, 2.8 and 2.9 still apply.

, 2.10.6 Repair of Dry Spray ,

Repair of dry spray identifiable by vi sual inspection defined within thn procedure shall be removed.

a) Verify all loose particles are renoved.

b) Verify coating film thickness is still within allowable range.

c) If film thickness is not within allowable range perfonn inspections in Sec. 2.7, 2.8 and 2.9.

NOTE: A minor amount of adherent dry spray is acceptable on the final finish coat.

2.10.7 Repair of Excessive Orance ' d a) Verify the affected area is abraded and solvent wiped.

b) Verify the affected area is refinished and perfonn the inspections delineated in Section 2.7 2.8 and 2.9.

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. TEXA8 UTluTIES GENEFIATING CO.

  • E3 QI-QP-11.4-26 1 g , g .cg4 19 of 29 2.10.8 Repair of Gloss and Color Nonunifonnity a) Verify the affected area is solvent wiped.

b) Verify the affected area is recoated without exceeding the maximum film thickness and perfonn inspections in Sections 2.7, 2.8 and 2.9.

c) Top coated areas which have been abraded for various reasons (i.e., runs, sags, high millage, etc.) and are within acceptable procedural thickness, following repairs, do not require recoating for gloss enhancing.

d) For small repair areas such as pinholes, gloss and gloss unifonaity i s not requi red, providad the coating is smooth and continuous.

2.10.9 Doctanentation of Repairs l Repairs shall be doctanented on the traveler (Attachment 4) showing their completion and/or status.

2.11 - NONCONFORMANCES 2.11.1 Unacceptable conditions dich are not readily repaired or corrected per the approved procedures shall be documented as unsatisfactory on the inspection traveler.

2.11.2 Nonconfonning conditions such as coating failure due to loss of adhesion or indetenninate/ unacceptable conditions. which

. cannot be repaired or corrected as per existing procedures shall be docisnented on a Nonconfonnance Repo rt (NCR) in accordance with CP-QP-16.0. The NCR number shall be referenced on the inspection traveler, if applicable.

2.12 00CUENTATION (REFER TO ATTACHENT 4) 2.12.1 All inspections required by this procedure shall be recceded in the inspection attributes on the back of the travelers (Attachment 4). Preparation and processing of the traveler shall be per QI-QP-11.4-28.

2.12.2 When the inspections required by Sections 2.1 through 2.2.3 have been satisfactorily completed. Step 1 shall be signed and dated by the inspector.

2.12.3 When the inspections required by Sections 2.3 through 2.6.5 have been satisfactorily canpleted, Step 2 shall be signed and dated by the inspector.

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INSTRUCTION 133ug MBE OATE PAGE TEXAS UTIUTIES GENERATING Co. l CPSES QI-Q P-11.4-26 1 JM 0 3 1924 20 of 29 2.12.4 When the inspections required by Sections 2.7 through 2.8.4 have been satisfactorily cmpleted, Step 3 shall be signed and dated by the inspector. -

2.12.5 When the inspections required by Sections 2.9 through 2.10.7 have been satisfactorily capleted, Step 4 shall be signed and dated by the inspector.

2.13 SPECIAL COATINGS PROCEDtJRES Special coatings procedures and instructions set forth in CCP-30-M1 through CCP-30-M9, as applicable under the scope of this procedure, shall be inspected as per the guidelines of this procedure using the criteria established in the special coatings procedures.

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INSTRUCTION ISSUE REVISION PAGE TEXAS UT1UTIES GENERATING CO.

CN QI-QP-11.4-26' 1 of 21 29;'

JANoS 94 . . -

ATTAOiMENT 1A Anbient Conditions .

The inspector shall determine against the Envi rorsnental Sheet (Attachment 6) air tenperature, surface taperature, relative humidity and dew point of substrate structures.

A calibrated non-narcury filled dry bulb thermometer or calibrated tenperature recorder (Bristol 4069TH or equivalent) shall be used for air tenperature determination. A calibrated non-mercury wet bulb thermometer or a calibrated humidi ty recorder (Bristol 4069TH or equivalent) shall be used to detennine relative humidi ty. The dew point shall be detennined by the di fference in dry and wet bulb tenperatures using the U.S. Department of Commerce Weather Bureau Psychometric Tables, W8 No. 235. When dry bulb readings are greater than 100*F, the dew point should be determined using the 100* F dry bulb reading , and relative humidity shall be determined by subtracting wet bulb fece the surface temperature or ambi ent tenperature, whichever is greater. If the dry bulb thennometer exceeds 100* F, the instrument shall be returned to the calibration lab for recalibration.

The surface tenperature shall be determined by placing a calibrated surface .tenperature thennometer (Omega-Anprobe fast tenp. range of 10*-250*F) in contact wi th the substrate surface until the tenperature reading stabilizes. .

, Final surface preparation shall not begin unless the temperature of the surface is a minimum of 5'F above the dew point.

Nonnal conditions of ambient and surface tenperature for application of primer shall be as follows:

Anbient Teno. (*F) Surface Teno. (*F) 01metcote 6 40-120 40-130 Carto Zinc 11 40-95 40-110 Carboline 191 50-120 50-120 Phenoline 305 50-120 50-120 l

Humidity values may vary from 0% to 95% for inorganic primer; however, primer shall not be applied to a wet or damp surface.

Minimiss and maximum values of relative humidity for Phenoline 305 and Cartoline 191 shall be 0% and 85%

respectively.

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INSTRUCTION ISSUE NUMIER WSION OATE PAGE TEXAS' UTIUTIES GENERATING CC. l CPSES -

QI-QP-11.4-26 1 f 29 JAN 9 8 1984 22 ATTACHMENT 18 Air Supply Acceptability An inspector shall inspect the air supply systen of blast and spray equipment for suitable filters / traps / separators and that they are left cracked open. The effectiveness of these itens shall be verified by exposing a piece of white cloth to the air outlet for approximately 30 seconds. The white cloth shall be examined for evidence of contaminatio~n *

(oil, water, foreign atter, etc.). No evidence of contamination is acceptable.

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l lNSTRUCTION ISSUE ER EN OAM N TEXAS UT1UTIES GENERATING CO. l CPSES .

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QI-QP-11.4-26 1 JAN 2 8 1984 2[ 29',

l ATTA04 MENT 2

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PREPAAATION OF COATING MATERIALS Primer - The primer, Carto Zinc 11, is packaged in a two i component kit consisting of a base and a zinc filler. First the base shall be thoroughly mixed. Zinc filler shall then be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by wight in .a proportion of 10 parts base to 22 parts zine filler using a suitable scale to achieve a plus or minus 2 percent accurscy. The mixture shall then be strained through a 30-mesh screen.

Viscosity shall be controlled by adding thinner, as required, but. shall not exceed two quarts of thinner per gallon of Carto Zinc 11.

Primer - The primer, Dimetcote 6, is packaged in a two component kit consisting of a base and zinc filler. The base shall be thoroughly mixed fi rst. Zinc filler shall then be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in a proportion of 6.4 parts base to 15 parts zinc filler using a suitable scale to achieve a plus or minus 2 percent accuracy. The mixture shall then .be strained thrpugh a 30-mesh screen. Viscosity shall be controlled by adding thinner as required up to the maximum allowed by the latest revi'sion of Dimetcote 6 application instructions. Primer

,. coat shall be reddish gray.

Primer Coat - The primer coat, Cartoline 191, is packaged in a two component kit consisting of Carboline 191 base, Part A, and a catalyst, Part B. Mixes are ade by combining and thoroughly mixing the base and catalyst. Partial mixes may be made by combining, in a ration by volume, two parts base to one part catalyst. Vi scosity shall be controlled by adding thinner as required, but shall not exceed two quarts of thinner per gallon of Carboline 191.

Finish Coat - The finish coat, Phenoline 305, is packaged in a two component kit consisting of Phenoline 305 base, Part A, and a Phenoline catalyst, Part B. Mixes are ade 1by es;;bining and thoroughly mixing the base and catalyst.

Partial mixes my be ade by combining, in a ration by volume, four parts base to one part catalyst. Vi scosi ty shall be controlled by adding thinner as required, but shall not exceed two quarts of thinner per gallon of Phenoline 305.

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REVISION -I N D PAGE TEXAS UTluTIES GENERATING CO.

CPSES J W93@

, QI-QP-11.4-26 1 24 of 29-ATTACHMENT 3 -

PAINT MIX SLIP

  • 4eport No. .

8149 DATE POT LIFE SHIFT TIME l MIX NUBMER ELEVATION MATERIAL GAL. MIXED SHELF LIFE ACCEPAT8LE: YES NO MATE t's DATE & TIME MIXED BASE CURING AGENT FILLER THINNER ACCEPTEDilf OATE POT LIFE SHIFT TIME MIX NUMBER ..... ELEVATION MATERIAL GAL. ft!XED SHELF LIFE ACCEPTABLE: YES NO M&TE #'S DATE & TIME MIXED BASE CURING AGENT FILLER THINNER ACCEPTED SY

-. .a OATE POT LIFE SHIFT TIME MIX NUMBER ELEVATION MATERIAL GAL. MIXED SHELF LIFE ACCEPTABLE: YES 4 M&TE #'S DATE & TIME MIXED BASE CURING AGENT FILLER THINNER ACCEPTED BY

- .,~.m-me QC REVIEW & ACCEPTANCE signetww aate Pome mm a N OA 4

e __ _, _ - - . , , , _- . . - _ _ _ , . . _ _ , . _ . _ , . _ _- . . , .

. s PROCEDURE REVISION ISSUE NUMBER DATE PAGE TEXAS UT:LITIES GENERATING CO. _

CPSES lI-QP-11.4-26 JAN S S 1984 1 25 of 29' ATTACHMENT,4 STEIL PROTECTIVE CCATING INSPECTION TRK/ELER wens piate. Per TRAveLEn s _ _ . . _ _ _ .

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STEP ' suaract enspanATiam INSPECTED Aho FoufG ACCEPTA4LE PGt QI-CP!L4*24 ANo nELEASED Pon PRluct APPucAT1oN.

tuspecton DATE .

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STEP Pnmet APPucATion isesPECTro Asso roumo acctPTAatt PGt Ol*QP IL4=26 ANo nELEASED Poll FWESM COAT APPucAfloN.

meSPtcT= OATE .

2

__ COMMENTS . . - - . . .

STEP Pissesu coat APPucATion isssPECTED ANo Fousso AcctPTASLE PER et-4 Pit.4-2s seSPEctost M _ . .

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STEP Pismsw coat seseccTrn con rusak accEPTAnct Ano rouno ACcEPTA8LE pen Ql-CPIL4-28 t

i WISPECT M DATE i 4 .

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2C #EVIEW DAT* ____

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I PROCECURE I REVISION ISUE PAGE NUMBER [ OATE TEXAS UTIUTIES GENERATING CO.

CPSES

_ QI-QP-11.4-26 1 JAN 2 8 1984 . 25 g. 29 -

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QI-QP-11.4-25 1 JAN 2 81984 l 27W 29 .

o ATTACHMENT 5

- TOTAL NUMBER OF ALLOWA8LE POINTS OF OISCONTINUITY SURFACF. AREA COND. 'C .

BEING COATED COMfERCIALLY

-- (S0. FT.) CONTINUOUS 10 5 10-50 10 50-100 20 100-500 30 500-1000 50

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1000-5000 75 l Gross Discontinuities - None Allowed.

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TEXAS UTIUTIES GENERATING.CO. l CPSES OI-QP-11.4-26 1 " 1 1984 .'28 of 29

_ 4 ATTACHMENT 6 eeoort No.

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E.WIRoletENTAL LOG SHEET

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INSTRUCTION I NUMSER REVISION PAGE texas uriuTIES G NERATING CC. ( D QI-Q P-il.4-26 I JAN 2 3 1984 29 of 29 1

l i

ATTACHMENT 7 OEFINITIONS Color and Gloss Nonunifonnity: A milky haze or mist in the finish of l a recently applied coating. I

" Contaminant: A foreign substance, inadvertently added to a coating or found on the substrate that adversely affects the application, adhesion, curing and/or subsequent perfonnance of the applied coating.

Dry Spray: A dry powdery primer or finish coat readily remceed by light sanding with either sandpaper or a wire screen. A minor amount of adherent dry spray is acceptable on the final finish coat.

Feathering: An area that is roughened and tapered to obtain a smooth and contintaus surface with an existing coating.

Fisheyes: Small openings (" fisheyes") in wec film exposing old surface or previous coat.

Full Hiding: The coating provices rM ".ci ent coverage so that the preceding coat is.not readily visible dth an unaided eye.

Holiday: A pinhole, ski p, discontinuity or void in coating film.

Major Defect: Defined as an trea, either circular or linear, in which a 1/2" diameter circle could be inscribed at any point or along the entire length.

Minor Defect: Defined as an area, either circular or linear, in which a 1/2" diameter circle could not be completely inscribed at any point along the entire length.

Monitor: To observe or check, especially for a special pu rpose.

Muderacking: Irregular cracking as. in a dried mud puddle (applicable to inorganic zinc primers).

Orange Peel: Dents in the surface resembling orange skin. A moderate amount is acceptable.

Surveillance: Close watch kept over someone or something.

Verify: Confinn or make certain. '

Vi sual: To examine with an unaided eye (correctional eye glasses or contact lens are acceptable).

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! INSTRUCBCN i l, lSSUE i l NUMBER  ;. REVISICN cA7g j PAGE l

l texas UnuBES GENERADNG CC.

CPsEs . .

l l QI-QP-11.4-26 0 1 of 24l l ,

l 0EC 2 9 I"88 l INSPECTION OF STEEL-  : PREPARED SYh W 23 ./. C - A-- 2-LO SUBSTRATE SURFACc  :- '

CA E PREP.ARATION, PRIMER l APPLICATION, PRIMER APPROVED SY: 7[Adom

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/ o -e CATE v.Ta !

i REPAIR, SEAL AND FINISH CDAT APPLICATION E/,, , ,

ANO REPAIR APPROVED BY:

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i, 1.1 PURPOSE AND SCOPE The purpose of thi s instruction is to outline methods utilized by Quality Control personnel in inspection of steel I i substrate surface preparation, primer application, primer l repai r, seal and finish coat application and repair for f

Unit 1 Reactor Building. ,

1.2 (If applicable) Backfit shall be performed per QI-QP-11.a-23. i

. Document in the comments section of the traveler Attacnment -

i 4.

I 2.0 INSTRUCTION Visual inspection of surfaces as addressed by this

instruction shall be cade at approximately an anns length .

I from the surface being inspected. The area of inspection i shall be adequately lighted during the inspection activity. '

l Adecuate lighting is defined as the minimum light produced by a tw (2) cell battery flashlight. Flashlight shall be l held perpendicular to the surface during visual inspection.

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. INSTRUCTION SICN ISSUE _

NUMSER CATE CAGE l TEXAS UTILT~fES GENERATING CO.

CPSES ,

QI-QP-11.4-26 0 1

DEC 2 9 E 2 of 24 li i

l l ,

2.1 PRE-BLAST HAND AND/OR POWER TOOL CLEANING OPERATIONS i 2.1.1 Abrasive Acceptability The Inspector shall obtain a sample of the abrasive to be

! used from each work area. The abrasive shall be verified to be dry by feel . All grease, oil and deleterious  !

material is unacceptable.

Particle size must be sufficient to achieve 1 mil surface i i profile minimum. i l 2.1.2 Blast Eouipment Acceptability i i i l The inspector shall perfonn the following inspections / tests  ;

l to detemine acceptability of blast cleaning equipment prior j j to use:

l

' a. Air supply (refer to Attachment 18).

b. Ambient conditions (reference Attachment IA and 6).  !

2.1.3 Solvent Cleanino (If Chemical Contamination Present) l If oil, grease, or other chemical contaminacion is present, i verify that solvent cleaning is perfomed and that chemical

! contamination is removed prior to blast cleaning steel .

surfaces. j 2.2 POST BLAST CLEANING OPERATIONS  !

2.2.1 Blast Cleanuo -

The inspector shall visually check the blasted substrate  ;

surface. l The surface shall be air blasted or solvent wiped to the extent reouired for final surface inspection. The adjacent areas shall be cleaned to the extent necessary to avoid '

j contamination during subsequent coating application::.

l 2.2.2 Bissted or Power Tooled Surface Acceptability The inspector shall perfonn the following inspections to j detennine acceptability of the blast cleaned or power tooled j ,

surface: .

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I INSTRUCTICN REMSIO.* I33 3 i

"

  • FAGE TEXAS UTILITIES GENERATING CO. I  !

CPSES QI-QP-11.4-26 0 DEC : 9 IS63 3 of 24 l

-.i I

a. Absence of Foreign Matter -- A visual inspection 4 I

shall be perfonned to' determine that all oil and I

grease, di rt, millscale, rust, corrosion products, oxides, paint or other foreign matter have been I com?letely removed fran the surface except for l light shadows, very slight streaks or slight  !

( di scolorations caused by rust stains, mill scale , ,

oxi des , or slight, tight residues of paint or coating that may renain . At least 95 percent of j each square inch of surface area shall be free of i all residues, and the renainder shall be limited to light discolorations as mentioned above. l l NOTE: In addition to the 5 percent of tight residue of .  !

paint or coating which is permissible (above),  !

I shadows or tightly adhering residues of primer

may remain (without limit) in the profile of the previously prepared substrate.

l

b. Removal of Sharp Projections -- A reinspection for l sharp projections that were not blended (rounded) i during blast cleaning or power tooling shall be i f perfomed. l 4 .

Weld splatter on structural steel which remains after j grinding or sand blasting will be acceptable. j I

Sharp projections are not acceptable.

Protrusions and peaks shall be ground to a rounded i

! Contour.  ;

NOTE: Any mechanical surface preparation other i than sandblasting or hand or power tooling -

of sharp edges or weld spatter will require ,

a visual welding inspector's acceptance of l

, the work perfomed. ,

I c. Anchor Pattern Depth -- The anchor pattern depth of the

' blasted surface shall be inspected at random locations '

i using a Keane-Tator Surface Profile Comparator (model 373) or equivalent.  ;

The anchor pattern depth for a blasted surface shall  :

i l be a minimum of 1.0 mils. >

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INSTRUCTICN ISSUE SG R PAGE

  • NUMBER CATE TEXAS UTILITIES GENERATING CO.

CPSES ,

QI-QP-11.4-26 0 DEC 2 9 :983 4 of 24 j Surfaces that have been power tooled with "3M Clean-N-Strip", 80 grit and coarser " flapper wheels", sanding j discs, " roto oeans" or equivalent, provide acceptable i surface profile. l No maximum profile will be specified, providing that  !

correct millage and surface uni formity requirements can be obtained after primer application.

2.2.3 Unique Number Identification i After blasting $),power (if applicab1 tool and QC shall prior veri fy to prime that coat application construction has I identified each peice with a unique number.

2.3 i PRIMER PRE-APPLICATION INSPECTIONS l

2.3.1 Ambient Conditions l

l The inspector shall verify ambient conditions in accordance with Attachment 1-A.

I 2.3.2 Substrate Surface Acceptability The Inspector shall visually reinspect the sandblasted or i' powertooled surface of the substrate just prior to primer application for evidence of contamination (oil, grease, l markings, rust, etc.) Contamination must be removed prior  ;

to priming. I i

! If rust foms after Blasting or Power Tooling, the surface l l shall be recleaned befnre priming. Under no case will a .

prepared surface be exposed for more than 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> before I priming. (This shall be verified on Step 1 of Traveler Attachment 4.)

2.3.3 Air Suoply Acceptability

  • The Inspector shall inspect the air per Attachment 18. ,

i 2.3.4 Oualification of Aeolicator(s) ,

The Inspector shall verify (by Qualification Record or list -

i of qualified applicators from QA file) that the coating '

i applicators are qualified for safety-related coating work. '

The applicator (s) badge number shall be listed on the back I

of the traveler.

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s t h8ER REVISION [U,,E PAGE TEXAS UT!UTIES GENERATING CC.

'" l CPSES '

QI-QP-11.4-26' 0 gg g 5 of 24 i

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2.3.5 Mixing Operations 2.3.5.1 Coating Materials !dentification  !

, An inspector shall inspect the coating sterial containers ,

} prior to mixing contents for product identification and i verify that all material s are correct for coating I application.

Approved materials are: l

. CZ-11 1

-Carto Zinc 11 base (gray or green) l '

Carbo Zinc filler i Cartoline #21 or 33 Thinner l DIMETCOTE

Dimetcote 6 base

! Dimetcote filler l Amercoat #65 or 101 Thinner I'

CARBOLINE 191

)

i Cartoline 191 Primer (Red Brick) i Carboline 191 Catalyst i Cartoline #15 Thinner An inspector shall also verify that each component container I is identified by batch number and that the shelf life has  !

i not expired. Carto Zinc 11 base and Cartoline 191 has a  !

! shelf life of 12 months. Carbo Zinc filler and Dimetcote 6 l 1 base and filler have a shelf life of 24 months. - -

l e 2.3.5.2 Mixing Operations An inspector shall witness each mixing / thinning o:eration.

i The i nspector shall verify that mixing operations are perfomed in accordance wittLAttachment 2. l

! 2.3.5.3 Thinning Operation

! I j Coating materials (if thinned) viscosity control shall be -

accomplished by adding thinner as required, but shall not l

- exceed two quarts of thinner per gallon of material .  :

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INSTRUCT!CN ISSUE

" REVISICN ^ PAGE TEXAS UTILITIES GENERATING CO.

CMES QI-QP-11.4-26 l 0 6 of 24 l

D E C ,,s -a .cJ3 I

. l 2.3.5.4 When coating naterials are mixed / thinned , the inspector verifying the mixing operation shall fill out the Paint Mix Sli p, Attachment 3. The inspector perfoming the pre-application inspection shall record the mix sheet msnber on the travelers. The Mix Slip shall be returned to the Paper Flow Group at the end of each shift to be sent i to the vault.

2.4 PRIMER APPLICATION INSPECTION 2.4.1 Surveillance of Primer Acolication

! During application operations of CZ-11, the QC Inspector l

shall monitor that the pressure pot is continuously

, agitated. The QC Inspector shall also veri fy that the

! hose length does not exceed 75 feet, i

I 2.5 INSPECTION OF PRIMER l

l 2.5.1 Primer Inspection Prior to Aoplication of Seal or Finish Coat

a. Verify the primer has cured sufficiently for the top coating (as detennined by the use of a nickel test). l Cure of Carboline 191 shall be the same as Phenoline' l 305, i
b. Perfonn a visual inspection of the primed surface in accordance with the following:
1. Runs / sags which are less than or equal to the maximum dry film thickness for each coating applied ,

and show no evidence of mud cracking or loss of '

! adhesion are acceptable. Repairs (if applicable) per Sec. 2.6.2 or 2.6.3.

NOTE: Pt.;dcracking is defined as irregular cracking as in a dried mud puddle.

2. Dry Spray - Must be renoved before overcoating. '
3. Over Spray - Must be removed before overcoating.

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INSTRUCT 1CN ISSUE REVISICN PAGE TEXAS UTit.! TIES GENERATING CC.

QI-QP-11.4-26 0 g,, ,c, g 1993 7 of 24

4. Contamination - unacceptable Oil and arease - unacceptable NOTE: Contaminant - a foreign sub stance, inadverte.ittly added to a coating or found on the substrate, that adversely affects the application, adhesion ,

curing , and/or subsequent perfonnance of the applied coating.

5. Skips / damaged areas / gross discontinuities such as holidays or voids - unacceptable.

4

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c. The inspector shall perfonn a DFT inspection of the cured primer film. A calibrated 0-25 E1cometer Inspector DFT gage Model III/1E, or equivalent, shall be used. Separate spot measurements (See Note 1)

! spaced evenly over the structure (See Note 2) shall I

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 (See Ngte 3).

,i Ory Film Thickness shall be as follows (See Note 4):

Min. (mils) Max. (mils)

, Carboline 191 spot test 1.6 8.5 I l CZ-II spot test 1.5 7.0 I"

. 06 spot test 1.5 5.5 I 06 average DFT 2.0 5.0 i CZ-II average DFT 2.0 6.0 Cartoline 191 average DFT 2.0 l l 7.0  :

NOTE 1: A spot measurenent is a series of three measurements in the same general area. The l probe should be moved a short distance for each gage reading. Discard any unusually high

, or low gage reading that cannot be repeateo .

consistently. Take an average of these three i gage readings as one spot measurement.  ;

NOTE 2: Five spot tests shall be taken for every  !

. j 100 square feet of coated surface. For areas j 4

less than 100 square feet, the following  ;

! shall apply: i l

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INSTRUCTION

" REVISIC. . I33^' *3 PAGE TEXAS UTILITIES GENERATING CO.  ;

CPSES  ;

QI-Q P-11.4-26 0 DEC '; 9 ;g33 8 of 24 1 Area Sq. Ft. No. Spots 100-80 5 80-50 4 50-10 3 10-3 2 l 3-0 1

  • 1 NOTE 3: Itens with appreciable surface cunature and other geometrica; di scontinuiti es , such as handrail s, gratings, stai rs , sway struts, checker plate, etc., shall be exempt from dry film thickness measurement.

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 i and spaced radially at approximately 120 j degree intervals to detennine the extent of the unacceptable area.

In the event that the average of the area is  ;

unacceptable due to unacceptable spot  !

readings, the unacceptable spots shall be l isolated as described above. Additional spot

' readings shall be taken equal to the number

  • of unacceptable spot readings and the average  ;

recalculated. -

2.6 PRIMER REPAIRS 2.6.1 Saos and Runs f

! Runs / sags: Ref. Sec. 2.8.b.1 if surface is unacceptable.

Repair per Sec. 2.9.2 or 2.9.3.

2.6.2 Primer Touch-up Recair (Primer Damaged to Steel Surface)

I i The coating inspector shall conduct the following E r inspections to document primer touch-up repair operations l 1 when the damage is to the steel surface and spot  ;

! sandblasting, hand sanding or power tool abradi ng. is  ;

} required for surface preparation.  ;

a. ' Surface preparation Ref. Sec. 2.2.2.

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b. Verify that the blasted or power tooled surface has been high pressure air blowdown, and/or solvent wiped to the extent :equired . for final surface inspection.

4 The adjacent areas shall be cleaned to the extent necessary to avoid contanination during subsequent coating applications.

c. Anbient Conditions: Raf. Attachment 1A and 6.

Air Supply Acceptability: Ref. Attachment 18.

The surfact. temperature shall be a minimum of 5' above l the dew point.

I i d. Veri fy applicator qualifications per Section 2.3.4.

e. Verify. air supply acceptability per Attachment 18.

! f. Verify ambient condition per Attachment 1A.

1. Coating Materials Identifi. cation Verify per Sec. 2.3.5.1.

! ' 2. Mixing Operations I Verify per Sec. 2.3.5.2.

f

3. Thinning Operation Verify per Sec. 2.3.5.3.

l

! g. Verify that primer is applied in accordance with {.

l Sec. 2.4.1. -

NOTE: (If applicable) Coating interface - at coating interface for finish and/or primer coat, the

existing coating shall be ' feathered back" a e
sufficient distance to ensure a smooth final *
coating system. When perfonning coating l

interface the interface of the coating or

. systems shall be approximately 14 inch in  !

l wi dth. Within the interface area,  !

! overlapping of any materials or systems is t acceptable. l

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, INSTRUCBCN ISSUE REVISICis PAGE TEXAS Uti.!BES GENERADNG CO. '

QI-QP-11.4-26 0 DEC99 g3 10 of 24 i

l 2.6.3 Primer Touch-up Repair (Primer Damage Does Not Extend to Steel surface -

The coating inspector shall conduct the following inspections for primer touch-up repair operations when the damage is wi thin the primer coat and sandblasting to the steel substrate is not required.

a. Verify surface is abraded lightly then wiped clean.
b. Vi sually veri fy acceptability of repaired area per Section 2.5.1.b.

2.6.4 Repair of Primer by Recoatinq l

The coating inspector shall conduct the following inspections for primer recoating repair. Only two (2) overcoats shall be applied of CZ11.

I

a. Verify that the surface has been solve-;t . cleaned or cleansed with high air pressure blow down. , ,

Contamination is unacceptable and requires fu rther  !

cleaning. l Perfonn inspections in Section 2.6.2.

~

b. i NOTE: After application of primer to the spot primed .

area, the only additional featuring required is at i the outer wge of the primed area. Sanding of the  !

primed area is not required. '

2.6.5 Complete Primer Repair (Primer Damace t3 Steel Surface .

Extends Over Entire Item) 1 The coating inspector shall conduct the following inspections  !

to document primer repair when the damage is to the steel  !

surface and requires surface preparation to steel substrate l

, over entire item: t i

a. Verify ambient conditions per Attachment 1A to starface l preparation. See Attachment 6.  !

f b. Perform inspections (a) through (g) in Section 2.9.2.

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l INSTRUCTICN REVISION ISSUE

" PAGE TEXAS UTILITIES GENERATING CC. '

CPSES QI-QP-11.4-26 l 0 11 of 24 lDEC 2 91983 ,

2.7 FINISH COAT PRE-APPLICATION INSPECTIONS The QC inspector shall verify the following items prior to applying coatings: 1 2.7.1 Coating Aoolicator Qualifications '

The Inspector shall verify (by Qualification Record or list of qualification records in QA File) that the coating applicators on each shift are qualified for safety-related coating work.

2.7.2 Ambient Conditions (Refer Attachment 1A and 6)

The permissible range of surface and ambient temperature for application of finish coat shall be 50-120*F.

The maximum humidity shall be 857. for Carboline 305, and j l 95% for inorganic zine and Cartoline 191. '

l The surface temperature shall be a minimum of 5'F above j

' the dew point.  !

, 2.7.3 Coated Surface Acceptability ~

l The Inspector shall visually reinspect the previously coated suf face just prior to finish coat application for evidence of i contamination (oil , grease, foreign matter). The defective i areas shall be repai red per Sec.(s) 2.9.6A and B and/or  !

Sec. 2.6.4.A and B. l 2.7.4 Air Supoly Acceptability (Per Attachment 1B) l 2.7.5 Finish Coat Mixina Operations 2.7.5.1 Prior to mixing, the mixing inspector shall verify that each component is identified by batch numbers ano that the l l 24 month shelf life has not been exceeded.  :

i 2.7.5.2

! The mixing inspector shall verify that mixing / thinner '

i operations are performed in accordance with Se:. 2.3.5.2.

, i Thinning may be done up to two quarts of Phenoline Thinner  ;

! l per gallon of Phenoline 305.

4 j 2.7.5.3 Mixing operation shall be documented on the traveler per i Sec. 2.3.5.4. '

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INSTRUCTION R EVISK.,. , 383U NUMBER CATE PAGE

. TEXAS UTILITIES GENERATING CO. '

CPSES QI-QP-11.4-25 0 DEC 2 9 2 12 of 24 i

2.8 SURVEILLANCE OF SEAL OR FINISH COAT APPLICATION

. I The Inspector shall verify that hose length is less than 75 feet. ,

\

l The inspector shall also verify that the seal coat (i f present) is solvent wiped with Phenoline 305 thinner or

. Xylol prior to finish coat application.

This shall be verified in Step 3 of Attachment 4.

2.9 FINISH CDAT FINAL ACCEPTANCE INSPECTION I The inspector shall perfonn a final acceptance inspection l' of each finish coated item (s) in accordance with Paragraphs [l 2.9.1 through 2.9.5.

NOTE: (If applicable) Coating interface - at coating j interface for finish and/or primer coat, the

,' t existing coating shall be " feathered back" a l

  • sufficient distance to ensure a smooth final I

coating systen. When perfonning coating interface the interface of the systems shall be approximately s

  • 1h inch in width. Within the interface area,  ;

l e

overlapping of any materials or systems is 8

acceptable.

t .

I NOTE: The tie in interface between concrete coatings and steel coatings shall be - vi sually inspected during the finish coat final acceptance of both '

systems.

g l 2.9.1 Finish Coat Cure  !

i Final QC inspection may be perfonned after a minimum topcoat )i cure of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />. s l

, 2.9.2 Visual Defects Inspection  !

The Inspector shall perfonn a visual inspection of the: cured .

finish coated substrate surface in accordance with the i I following, i , i Runs / sags - Runs or sags in which the DFT of the total l a) coating system is 15.0 mils or less thick, which show  ;

I no evidence of nuderacking , are acceptablo. Those j l greater than 15.0 mils shall be repaired, f

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, I CTICN REVISION PAGE TEXAS UTIUTIES GENERATING CO.

CPSES l i

QI-QP-11.4-26 0  !DEC 2 91983

~

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_' b) Skips / damaged areas / gross di scontinuities such as 4

t holidays, voids, and bubbles are not acceptable.

x

s. _ c) Pinholes - acceptable to the extent allowed by ,
g. Attachment 5. j k'- d) Contamination - unacceptable. l w l 2.9.3 Dry Film Thickness (DFT)

The Inspector shall perfonn a DFT of the cured coating system. A calibrated 0-25 Elcometer Inspector DFT Gage i Model III/IE, or equivalent, shall be used.- Separate spot  !

I measurements (See Note 1) spaced evenly over the st'ructure j

'(See Note 2) shall be taken. Since the magnetic gage is  !

sensitive to geometric di scontinuities in the steel , }

measurments less than 1 inch from an edge or a hole shall l be avoided. (See Note 3). l The average DFT of the total coating system shall be a f minimum of 6.0 mils and a maximun of 13.0 mils. The spot ,

test DFT of the total coating systen shall be a minimum of I 6.0 mils and a maximum of 15.0 mils (See Note 4). l l Th9 finish coated systen shall exhibi t full " hiding" properties of the primecoat. .  !

'- I NOTE 1: A spot measurenent is a series of three measure- l ments in the same general area. The probe should i be moved a short distance for each gage reading.  !

1 l Discard any unusually high or low gage reading I

, that cannot be repeated cons'stently. Take an  ;

average of these three gage readirigs as one spot '

measu rment. I i

NOTE 2: Five spot tests shall be taken for etery 100 i square feet of coated surface. For areas less l f

than 100 square feet, the following shall apoly: '

! Area Sq. Ft. No. Spots  :

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100-80 5 80-50 4 l.

! 50-10 3 i 10-3 2 j 3-0

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INSTRUCBCN REVISICN ISSUE NW CAM PAGE TEXAS UtuTES GENERADNG CO.

CPSES QI-QP-11.4-26 0 DEC 2 ? D 14 of 24

~l NOTE 3: Itens with appreciable surface cunature and other geometrical discontinuities such as handrails, gratings, stairs, sway struts, etc. shall be exempt from DFT measurement.

l 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 i approvimately 120 degree intenals to detennine l the extent of the unacceptable area. Dimensions i 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 readi ngs , '

the unacceptable spots shall be isolated as

described above. Additional spot readings shall i be taken equal to the neber of unacceptable spot readings and the average recalculated. If the recalculated averane is acceptable, the traveler i shall be so marked with an explanation in l

" Remarks" stating that " average recalculated -

l now acceptable", or wording to that effect. If .

the recalculated average is unacceptable, the l unacceptable spots shall be isolated and repaired per Sec. 3.10. j 2.9.4 Continuity Insoection  !

l The Inspector shall test the continuity of the cured finish l

! coat on liner plate using a Tinker and Rasor Model M1 (67.5  :

volt) holiday detector. 100% of the finish coated surface  !

area shall be tested.  ;

The applied film should contain oniy a minor number of .

i points of di scontinuity. No more than two points of i discontinuity should occur within an area having a radius of

! 6 inches as measured from a point of di scontinuity

(pinholes). No more than 40% of the total nuber of '

allowable points of discontinuity should occur within any l one a ea equal to 25% of the total area being coated. The -

total number of pinhole discontinuities allowed is defined '

l in Attachment 5. No gross discontinuities are allowed. '

i 2.9.5 Documentation of Finish Coat / Seal Coat Accectance Insoec.tions '

Results of inspections described in Sections 2. shall be documented on the traveler, Attachment 4. l t

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. l INSTRUCT 1CN REVISICr. ISSUE

^ PAGE TEXAS UT!UTIES GENERATING CC.

CPSES .

lQI-QP-11.4-25 O DEC 2 3 '.h l 15 of 24  !

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2.10 REPAIRS OF FINISH COAT 2.10.1 Repairs of Runs and Sacs l The QC inspector shall verify that the area is abraded until the DFT of the total coating system is within 6.0 to 15.0

mils, and examined for mudcracking. Mudcracking shall be i repaired in accordance with Sec. 2.10.2 or 2.10.3. ,

2.10.2 Repair of Minor Defects The QC inspector shall perfonn the follow!ng inspection when

{ repairing minor defects:

1

! a)' Verify ambi ent conditions per Attachment 1A prior to l 3

surface preparation.  ;

, b) Verify that the damaged area is blasted or abraded.

c) Verify damaged area is solvent wiped.

d) Perfonn inspections described in Sec. 2.7

? NOTE: Minor defects are defined as an area, either [

l ci rcular or li near, in which a 4' di ameter circle could not be completely inscribed at any point along the entire length.

2.10.3 Repair of Major Defects The QC inspector shall perfonn the following inspection when .

repairing major defects- I i a) Verify ambient conditions . per Attachment IA and 6. -

I b) Verify area is abraded or spot blasted. l l c) Perfonn inspections in Section 2.10.2(d).

g u .

NOTE
Major defects are defined as an area, either circular or linear, in which a V' di ameter ,

! circle could be inscribc3 at any point or along .

I the entire length. 8 i

2.10.4 Repair of Contamination  ! ,
; l l The QC inspector shall verify that can'tamination is renoved )
and the surface recoated per Section 2.9. l l

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!NSTRUCTICN REVISION ISSUE PAGE TEXAS UTILITIES GENERATING CO.

CPSES I QI-QP-11.4-26 0 DEC a 9 53 l16of24

I 2.10.5 ' Repair of Pinholes and Discontinuities a) Verify all loose partic es are removed and area is i solvent wiped.

b) Pinholes and minor dicontittuities may be repaired at r the time of final inspection without a later i reinspection of the repair.

2. M . 6 Repair of Excessive Over Sorny, and/or Overcoatino

! a) Verify all loose particles are renoved.

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l b) Verify coating film thickness is still within i i allowable range. -

l c) If film thickness it, not within allowable range perfom l

inspections in Sec. 2.7.

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' 2.10.7 Docunentation of Repairs I

i All repairs shall be docunented on the traveler, Attachment 4.

2.11 NONCONFORMANCES I

Unacceptable conditions shall be reported on the traveier except for coating failure due to loss of adhesion, which ,

shall be reported on an NCR in accordance with CP-QP-16.0.

{

2.12 TRAVELER CmPLETION I All inspections required by this procedurt 3 hall be recorded j on the Coating Traveler, Attachment 4. The traveler shall ,

be completed in accordance with QI-QP-11.4-28. .

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7 INSTRUCT!CN IOSUE REVISICN PAGE TEXAS UT!!JTIES GENERADNG CO.

CPSES-

  • 7 QI-QP-11.4-25 0 73 g3 17 of 24 ATTACHMENT 1A Anbient Conditions The inspector shall detennine against the Envi ronnental

. Sheet (Attachment 6) air temperature, surface temperature, relative humidity and dew point of substrate structures.

A calibrated non-mercury filled dry bulb themometer or calibrated triperature recorder (Bristol 4069TH or equivalent) shall be used for air temperature detennination. A calibrated non-mercury wet bulb i thennometer or a calibrated humidity recorder (Bristol l

, 4069TH or equivalent) shall be used to detennine j relative humi di ty. The dew poi nt shall be determined i by the difference in dry and wet bulb temperatures using the U.S. Depart:nent of Commerce Weather Bureau Psychometric Tables, WB No. 235. When dry bulb readings are greater than 100*F, the dew point should be I detennined using the 100*F dry bulb readi ng , and j relative humidity shall be determined by subtracting fran the surface temperature or ambi ent wet bulb temperature, whichever is greater. If the dry bulb i thennometer exceeds 100*F, the instrunent shall be . l returned to the calibration lab for recalibration. i The surface temperature shall be detennined by placing  !

a calibrated surface temperature thermometer (Omega-Anprobe fast temp. range of 10*-250*F) in contact wi th the substrate surface until the temperature reading .

stabilizes.  !

l l Final surface preparation shall not begin unless the i i temperature of the surface is a minimum of 5* above l

! the dew point.

Nonnal condi tions of ambient and surface temperature for application 'of primer shall be as follows:

l Anbient Temp. (*F) Surface Temo. (*F) a i

. ' ~0iinetcote 6 40-120 40-130  :

i Cartozinc 11 40-95 40-110 -

! Carboline 191 50-120 50-120 I

i Humidity values may vary from 0% to 95%; however, primer shall not be applied to a wet or damp surface. '

j j Minimum and maximum values of relative humidi ty for Phenoline 305 shall be 0% and 85% respectively.

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INSTRUCT!CN ISSUE REVISICN l PAGE TEXAS UTIUTIES GENERATING CC.

NUMBER -

CAM l CPSES 0

jDEC,a.ca)--

18 of 24 QI-Q P-11.4-26 ,  ;

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ATTACHMENT 18 l

l l Air Supply Acceptability An inspector shall inspect the air supply system of ' blast

  • and spray equipment for suitable filters / traps / separators  !

and that they are left crackad open. The effectiveness of i these items shall be verified by exposing a piece of white i cloth to the air outlet for approximately 30 seconds. The white cloth shall be examined for evidence of contamination (oil, water, foreign ratter, etc.). No evidence of contamination is -acceptable.

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INSTRUCTION REVISION ISSUE PAGE NUMBER CATE TEXAS UTILITIES GENERATING CO. _. -

QI-QP-11.4-26 0 -

DEC 2 3 D ATTACHMENT 2 PREPARATION OF COATING MATERIALS Primer - The primer, Carto Zinc 11, is packaged in a two component kit consisting of a base and a zine filler. First i the base shall be thoroughly mixed. Zinc filler shall then

! be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in a proportion of 10 parts base to 22 parts zinc filler using a suitable scale to achieve a plus or minus 2 percent accuracy. The mixture shall then be strained through a 30-mesh screen.

Viscosity shall be controlled by adding thinner, as required, but shall not exceed two quarts of thinner per gallon of Carto Zinc 11.

, Primer - The primer, Dimetcote 6, is packaged in a two component kit consisting of a base and zinc filler. The base shall be thoroughly - mixed fi rst. Zinc filler shall

, then be added under constant agitation and mixed until free of lumps. Partial mixes shall be mixed by weight in a proportion of 6.4 parts base to 15 parts zinc filler using l i-a suitable scale to achieve a plus or minus 2 percent l accuracy. The mixture shall then be strained through a l i

30-mesh screen. Viscosity shall be controlled by adding '

thinner as required up to the maximum allowed by the latest revision of Dimetcote 6 aoplication instructions. Primer coat shall be reddish gray.

Primer Coat - The primer coat, Carboline 191, is packaged in i

a two component kit consisting of Carboline 191 base, Part A, and a catalyst, Part B. Mixes are mde by combining and thoroughly mixing the base and catalyst. Partial mixes may .

i.

be mde by ccab1ning, in a ration by volume, two parts base to one part catalyst. Viscosity shall be controlled by adding thinne as tsquired, but shall not exceed two quarts *

, of thinner per gallon of Phenoline 305. j i

! Finish Coat - The finish coat, Phenoline 305, is packaged in  !

i a two component kit consisting of Phenoline 305 base, Part A, I j

i and a Phenoline catalyst, Part B. Mixes are made by j combining and thoroughly mixing tha base and catalyst. i l Partial mixes may be made by combining, in a ration by j volume, four parts base to one part catalyst. Vi scosity shall be controlled by adding thinner as required , but i

. 3 l.

shall not exceed two quarts of thinner per gallon of l 9henoline 305.

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PROCEDURE REVISION ISSUE NUMBER CATE PAGE TEXAS UT!UTIES GENERATING CO.

CPSES lDEC " 9 1983 QI-0P-11.4-26 0 l .

20of 24 ATTACHMENT,3

- PAINT MIX SLIP g Da te ___ .

Sh i f t . .,

His fiumeer _ _ _,,,,_,,,,

El eva t i on ,,_,,

.Matertal ,

Ga l . 't, m ed ,,__

Shelf Life AcceptaDie; fes N0 lla se,,,, , ,,,

Comments rioTE *

  • 5 Curing Agent Filter __ Thinner Accepted Gy:

Date Shift His tsummer Elevation Materfal Gal. Mixed Shelf tife Acceptacle: Y,es_,,,,5 Base Casuments M&TE d's Curing Agent Filler Thinner Accepted By:

Oate Shift _

Mit Number EIGvatton_

Material Gal. Filmed Shelf Life Acceptable: Yes rio Sase ,__ ,,,,. ,_

Cossents MATE 8's Curing Agent filler Thinner l Accepted sy: .

i

l Da te Shift _ ,,_,,,,,

i ni. uu 0, a e. n o.i . _ . _ . . . . _ . _ _ _ . _.

Material Gal. Mimed ,,,,

Shelf Life Acceptable: Yes _ No il4 % c _ , , _ , , ,, , , ,

i Conenen ts _ _,,_ , , ,,, M&TE **s. ,_ ,,,_ ,,_ , _ , _ _ , ,

Curtng Agent Filler .,_ ,,_ ,,thinnee , _

A c~da-r . _ - . _ .. ..

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TEXAS UTILITIES GENERATING CO.

CPSES UEC 2 90 QI-QP-11.4-26 0 21 g 24 ATTACHMENT 4 STEEL PROTECTIVE CDATING 94SPECT10N TRAVELER wensPlan PCI TRAvsLgn a ELEVAFlons - ITDIastassentPTloN MKowe&e_

pettpangD gy: cATt STEP sunPacs ensPAnation inspected Ano rouse AccsPTAaLE PtJI GEHFIL4*24 Ano nELEASED Fon PaluGI APPucATion, inspecton DATE

!,' l 3ygp Preusa APPucAfion inspecTro Ano rouno AcczPTAatz

. Pen St-QPIL4-18 Ano nELEASED Pon FBesu coat APPucAT1oN.

N PAT' ,m 2

comm esTs STEP rain caAT APPucArion insPacTED Ano rouno AcesPfaaLE Psn et-opit.4-te

sospecten wr 3

consuants -

i l 37gy PINISH COAT 50sPEcTED Pon PinAb Acc1PTAncE Ano Fougeo AccEPTA8LE PER o!-QPIL4-28 i

sePECTa' 0A73 4

comesENTS STEP coassLETion cP sospecTion TRAvsksn vanwiso.

I Sc MVIEW OAT * ,

S ij occuaser? IlesPP31ose ATTRISuTES o00 ATTAcMED suPPolrfuss N oocuaderTAT1oM SnEETtS1 -

i O 31 oocuuerf asPAmis Ano ATTnioutts. P neouinso,ces ATTAcHen i f T suppoemne occumanTATion susxTt:1 l E si ron ervaionum:TAL cewmons nsPunsuctTuc l 3 a vinonese:TAa. Loe. ,

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PROCEDURE REVISION ISSUE NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO. .

1 CPSES  !

G,Cs *,, ,, o~c3 lQI-QP-11.4-26 0 22 of 24 4 ATTACHMENT 4 (Cont.) ,

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INSTRUCTION REVISICN ISSUE NUMBER CATE PAGE TEXAS UT1UTIES GENERATING CO. ~

CPSES .

QI-QP-11.4-26 0 0E 2 9 '95' 23 I 24 !

l 4-ATTACHMENT 5 TOTAL NUMBER OF ALLOWABLE POINTS OF OISCONTINUITY l

SURFACE AREA COND. "C" BEING COATED COMMERCIALLY (50. FT.) CONTINUOUS 10 5 10-50 10 t

50-100 20 100-500 30 500-1000 50 1000-5000 75 l

l Gross Discontinuities - None Allowed. I t t e

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

CPSES 24 24 OI-OP-11.4-26 0 DEC ? 91983 ATTACHMENT 6 Sheet of sheet, Sheet fluseer E!N!ROMENTAL M&TE e's Elevation Dato Shift INSPECTOR TIME ORY BULS WET SUL" SURFACE TEMP. DEW POINT STEEL l CONCRETE HUMIDITY l l

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