ML20107C413
| ML20107C413 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 03/04/1984 |
| From: | Dunham F, Kusher M TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC) |
| To: | |
| Shared Package | |
| ML20106F959 | List: |
| References | |
| QI-QP-11.4-1, NUDOCS 8502210305 | |
| Download: ML20107C413 (14) | |
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' ' TEXAS UTIUTIES GENERATING CO. y REVISION PAGE O
i MAR 0 5 1984
, Q I-QP-11.4-1 20 l 1 of la PREPARED BY: M j
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INSPECTION OF STEEL DATE ,
A 0 PRIMER APPLICATION APPROVED BY:
3-V-M l DATE I APPROVED BY: o w g jV ;
7 /DATE
1.0 REFERENCES
'l-A CCP-30, " Coating Steel Substrates Inside Reactor Buildings !
and Radiation Areas" ,
1-B CCP-30A, " Coating Steel Substrates Inside Reactor Buildings
, and Radiation Areas" !
- l. ~ 1-C QI-QP-11.4-22, "QC Verification of Protective Coatings Unique Identification Number Transfer" l l
1-0 CP-QP-18.0, " Inspection Reports" 1-E CP-QP-15.0, " Tagging System" glh ,
1-F CP-QP-16.0, "Nonconfonnanc "
6 2.0 GENERAL '
2.1 PURPOSE AND SCOPE This Instruction shall describe methods utilized by Quality Control inspection of steel substrate surface preparation '
and prime coat applications in the safety related areas of !
Unit 2 and the paint shop. i 3.0 INSTRUCTION i i
Visual inspection of su rfaces 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 j by a two (2) 0-cell battery flashlight. Flashlight shall be held perpendicular to the surface during visual inspection. !
For definitions, refer to Attachment 4.
8502210305 850213 PDR ADOCK 05000445 S PDR
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IN RUCTION ISSUE UMBER REVISION PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES QI-Q P-11.4-1 20 MAR 0 51984 2 of 14 3.1 PRE-BLAST CLEANING OPERATIONS 3.1.1 Ambient Conditions The inspector shall detennine air temperatu re, surface tempera ture, relative humidity and dew-point of substrate s tructu res. A calibrated non-me rcury filled dr bul b thennometer or a calibrated temperature recorder (yBristol 4069 TH or equivalent) shall be used for air temperature detennination. A calibrated non-mercury wet bul b thennometer or a calibrated humidity recorder (Bristel 4069 TH or equivalent) shall be used to determine relative humidi ty. The dew point shall be detennined by the difference in the dry and wet bulb temperatures using the U.S. Department of Commerce Weather Bureau Psychrometric Tables, W.B. No. 235. When dry bulb readings are greater than 100*F, the dew point and relative humidity should be detennined using the 100*F reading (note in remarks). The surface tenperature shall be detennined by placing a calibrated surfacg temperature thermometer (0mega - Anprove Fastemp, Range 10-250 F) in contact with the substrate surface to be blast cleaned. The thermometer probe shall remain in contact with I the surface until the temperature reading stabilizes.
Final surface preparation shall not begin unless temperature of the surface is a minimum of 5'F above the dew po int.
3.1.2 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.
Verify that acceptable blast abrasive is used.
3.1.3 Blast Equipment Acceptability The inspector shall perform the following inspections / tests to detennine acceptability of blast cleaning equipment prior to use:
- a. Verify that wa ter separators are installed in air supply system and that the separators have been drained of accinulated water and drains lef t partially open.
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', INSTRUCTION REVISION ISSUE BER DATE PAGE TEXAS UTILITIES GENERATING CO.
CPSF.S QI-QP-11.4-1 20 MAR 0 51984 3 of 14 l
- b. Air supply shall be checked at the nozzle prior to use by exposing a white cloth to the blast of air (no sand) for approxima tely 30 seconds. The cloth shall be examined for evidence of contamination (oil, water, foreign matter, etc.). No evidence of contamination is acceptable.
3.1.4 Solvent Cleaning (If Contamination Is Present)
If oil, grease, or other contamination is present, verify that solvent cleaning (in accordance with SSPC-SP-1) is perfonned and that all contamination is removed prior to blast cleaning steel surfaces.
3.2 POST BLAST CLEANING OPERATIONS 3.2.1 Blast Cleanup The inspector shall visually check the blasted substrate su rface.
The surface shall be brushed or vacuumed 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.
3.2.2 Blasted Surface Acceptability The inspector shall perfonn the following inspections to detennine acceptability of the blast cleaned surface:
- a. Absence of Foreign Matter --
A visual inspection shall be perfomed to detemine that all oil and grease, di rt, millscale, rus t, corrosion products, oxides, paint or other foreign matter have been completely renoved from the surface except for light shadows, very slight streaks or slight discolorations caused by rus t stains, mill scal e ,
oxides, or slight, tight residues of paint or coating that may rena in. At least 95 percent of each square inch of surface area shall be free of all residues, and the remainder shall be limi ted to light discolorations as mentioned above.
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INSTRUCTION ISSUE N NUMBER E8U PAGE i
TEXAS UTILITIES GENERATING CO. DATE CPSES QI,-Q P-11. 4-1 20 MAR 0 - icg4 4 of 14
- b. Removal of Sharp Projections --
A reinspection for sharp projections that were not blended (rounded) during blast cleaning shall be perfonned.
Weld splatter on structural steel shall be removed by either grinding or sand bla s ting . Howeve r, if the weld splatter should remain after the above operation, the weld splatter will be acceptable.
Sharp projections are not acceptable.
Protrusions and peaks shall be groun'd to a rounded
- contour.
- c. Anchor Pattern Oepth -- The anchor pattern depth of the blasted surface shall be inspec.ted at random locations using a Keane-Tator Surface Profile Comparator (model 373) or approved equal. l The anchor pa ttern depth for a surface shall be a minimum of 1.0 mils.
- d. For repairs of blasted surfaces, power tooling my be i utilized as required.
3.2.3 Unique Number Identification Af ter blasting and prior to prime coat application, QC shall verify that construction has identified each peice with a unique number in accordance with References 1-A and 1-8.
The QC Inspector shall maintain a Protective Coatings Unique Identification Number Log, Attachment 1 for all protective coatings application on all steel designated for use in the Reactor Building. Subsequent subdivision of coated steel in the field or shop shall be witnessed by QC in accordance with Reference 1-C.
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NOTE: ,
A. Unique number may be assigned to a lot of material to be prime coated at the same time. For example, six pieces steel to be coated at :..ne time may all have same unique number.
B. Liner plate is excluded from QP numbers. .
Equipmt +
which is identified with a permanent plant ,
identift ation numbe r need not be identified wi th a Protecthe Coatings unique Identification Number, p.,,, m , ,
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INSTRUCTION ISSUE NUMBER REVISION PAGe TEXAS UTILITIES GENERATING CO. DATE CPSES QI-QP-11.4-1 20 ggR0 5 $2a 5 of 14 3.3 PRIMER PRE-APPLICATION INSPECTIONS 3.3.1 Ambient Conditions Immediately prior to primer application, the QC Inspector shall detennine air tempera ture, surface tempera ture, relative humdity. The primer application shall not begin unless the surface temperature is a minimum of 5' above the dew point.
When dry bulb readings are greater than 100*F, the dew point and relative humidity should be determined using the 100*F reading (note in remarks).
Nonnal conditions of ambient and surface temperatures shall be as follows:
Ambient Temp. (*F) Surface Temp. ('F)
Dimetcote 6 40-120 40-130 CarboZinc II 40-95 40-110 Carboline 191 50-120 50-120 Inonjanic zine primer may be applied within an ambient range of 0*F to 130*F and surface temperature range of 0*F to 200*F.
Coating materials (if thinned) shall be thinned in accordance with Reference 1-A or 1-B.
Humidity values may vary from 0 to 95%; however, primer shall not be applied to a wet or damp surface.
3.3.2 Substrate Surface Acceptability The Inspector shall visually reinspect the sandblasted surface l of the substrate just prior to primer application for evidence of contamination (oil, grease, markings, rust, etc.) All contamination must be renoved prior to priming.
If rust fonns after Blasting, the surface shall be " Shower Blasted" or "Re-furbished" before priming.
3.3.3 Air Supply Acceptability The Inspector shall inspect the air supply sys ten for suitable .fil ters/ traps /separa tors. A trap, filter, or separator shall be installed in air system to pressure pot and spray gun. The effectiveness
- of these items shall be .
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INSTRUCTION BER " ISSUE OATE N TEXAS UTILITIES GENERATING CO.
CPSES QI-QP-11.4-1 20 MAR 0 51984 6 of 14 verified by exposing a white cloth to the blast of air for approximately 30 seconds. The cloth shall be examined for evidence of contamination (oil, water, foreign matter, etc.).
No evidence of contamination is acceptable.
3.3.4 Qualification of Applicator (s)
The Inspector shall verify (by Qualification Record or list of qualified applicators frcrn QA file) that the coating applicators on each shift are qualified for safety-related coating work.
3.3.5 Mixing Operations I
3.3.5.1 Coating Materials Identification The inspector shall inspect the coating material containers prior to mixing contents for product identification and veri fy that all materials are correct for coating application.
Approved materials are:
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, CZ-11 Carbo Zinc 11 base Carbo Zinc filler Cartoline #21 or 33 Thinner OIMETCOTE Dimetcote 6 base Dimetcote filler Amercoat #65 or 101 Thinner CARBOLINE 191 Carboline 191 Primer Carboline 191 Catalyst Carboline #15 Thinner He 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 and Dimetcote 6 base and filler have a shelf life of 24 months.
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INSTRUCTION ISSUE 1 BER "# N TEXAS UTILITIES GENERATING CO. DATE cPSES QI-QP-11.4-1 20 7 Of 14 MAR 0 51984 3.3.5.2 Mixing Operations An inspector shall witness each mixing / thinning operation.
The inspector shall verify that mixing operations are perfonned in accordance with Reference 1-A and 1-B.
3.3.5.3 Thinning Operation An inspector shall verify that primer thinning conplies with thinning requirements established in References 1-A and 1-B.
3.3.5.4 When coating materials are mixed / thinned in locations other than the field, the inspector verifying the mixing operation shall fill out the Paint Mixing Slip Attachment 3. The inspector performing the pre-application inspection shall record the information from the Paint Mixing Slip on the.
Inspection Report, Attachment 2. The Paint Mixing Slip need not be retained.
3.4 PRIMER APPLICATION INSPECTION l' 3.4.1 Monitoring of Primer Application During application operations of CZ-11 and 0-6, the QC Inspec- l tor shall monitor that the pressure pot is continuously agi-ta ted. The QC Inspector shall also monitor that the hose length does not exceed 75 feet, and that the coating has not exceeded pot life per Reference 1-A or 1-B.
- 3.5 INSPECTION REPORTS All inspections required by Sections 3.1 through 3.4 shall 4
be documented on an . IR, Attachment 2, in accordance with
! Reference 1-0. '
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. e NOTE: A reject tag will be applied to any unsat area, with the inspection report, inspector's name, and phone extension listed per Reference 1-E.
3.6 NONCONFORMANCES Nonconfonning conditions such as coating failure due to loss of adhesion or indeterminate / unacceptable conditions which cannot be repaired or corrected as per existing procedures shall be documented on a Nonconfomance Report (NCR) in accordance wi th CP-Q P-16. 0. The NCR nLabor shall be referenced on the inspection traveler, if appl,1 cable. ,
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INSTRUCTION NUMBER WSION ISSUE PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES QI-QP-11.4-1 20 MAR 0 5 ;cg4 8 of 14 4.0 SPECI AL C0ATINGS 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.
5.0 CLARIFICATION 5.1 SHOP C0ATED ITEMS 5.1.1 Items removed from the building for coating at the paint shop shall be the responsibility of the craft department.
5.1.1.1 The craf t shall be responsiole for identifying each piece by work package number.
5.1.1.2 The craft shall be responsible for returning and installing the shop coated item in the same area it was removed from.
5.1.2 The shop QC Inspector shall inspect the item (s) in accordance a 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.
5.1.2.1 In addition to the infomation required by QI-QP-11.4-1 or QI-QP-11.4-5, the shop inspector shall reference the work package neber identified on the item (s) on the Inspection Report (IR).
5.1.2.2 The IR, upon completion, shall be transmitted to the Paper Flow Group (PFG) for Unit 1 and/or the Interim Records Vault (IRV) for Unit 2 for inclusion in the work package.
5.1.3 The QC inspector (in the field) shall verify that items prepared / coated in the shop, which are included in the scope of the traveler, have the applicable Inspection Report (IR) from the shop included in the work package and correspond with the identification on the item, 5.1.' Items which have been finaled in the shop but incur mechanical damage during reinstallation shall be repaired in accordance with QI-Q P-11. 4-26 and docmented on the traveler accordingly.
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'.. INSTRUCTION ISSUE NUMBER REVISION PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES QI-QP-11.4-1 20 9 Of 14 MAR 0 51984 I
5.2 INACCESSIBLE / LIMITED ACCESS AREAS 5.2.1 Defined as areas where, due to pe rmanent installation configuration, a dry film thickness (DFT) gauge cannot be properly engaged.
5.2.2 These areas shall be visual.ly 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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INSTRUCTION ISSUE NUMBER REVISION PAGE TEXAS UTILITIES GENERATING CO. DATE CPSES y QI-QP-11.4-1 20 ] MAR 0 5192/ lo of 14 ATTACHMENT 1 PROTECTIVE COATINGS UN!QUE !0ENTIFICATION NUMER LOG i'
LOG NUWER ITEM OESC2!PT!01 iOATE CCP*ENTS l
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INSTRUCTION ISSUE W DATE N TEXAS UTILITIES GENERATING CO.
CPSES QI-QP-11.4-1 20
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ATTACHMENT 2 CCM AN CME 7(AX STDM ELECTRIC S TATICN w 1 e 2 INSPECTICN REPCRT jaa.
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- 1. lA=e' eat ceeditieas cheebed eer Para 3.1.1 and recorded I l I l I lbelow: CATE: l ll l ; ,
ITINE: WET BULB TUP: CRY BULS TENP: l l ( !
, lRELATIVE HUMIDITY: CEir POINT: $URF. TEMP: l l i i 2, I Abrasive acceptable per Para. 3.1.2. ll l !
- 3. lSeearators festalled. drained. and drains left i I l partially open. . l l j 4 I Air su=oly free of contamination. l l l 1 ;
- 5. lyerify that solvent cleaning eerformed criar to l i 1 l (
I Stastico in accordance with ears. 3.1.4 1 i i i .
4_ IR1atted turface and erefile? l l l l 3 i n ata< ren tur*ue and tueem eA4ns arent eieaand eer l l l I I l Para. 3.2.1 I l l l
- b. Surface free of foreign matter including grease and l l l l l oli. 3.2.2.a l li i i
- e. $har9 fren-ro.imded) pro f ections removed. 3.2.2.b l 'i l i la Archar ant +een death 1 6 11_ min!w 1.2 2.e lI i t i
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7 ! !?nta ne qu-*er tramned nn efer, fee-ard "afaue % Mow in I l l l l
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- 8. 1 Ambient conditions checked per Para. 31.1. prior to 1i l l l primer application and record below. CATE: l l l l l ITfur. uit sta9 TEu8? *8v BUtB TEup; I l 1 i l o ri Af f yr we_'u f 0 f ty . Dry pofqT. t0AF. Trup- II l l-
- 9. 15ubstrate surface free of contaminants and less than ll [ j 124 hours0.00144 days <br />0.0344 hours <br />2.050265e-4 weeks <br />4.7182e-5 months <br /> elapsed since blasting. l l l l
- 10. ITrap filter or separator installed per Para. 3.3.3. 1 I l j !
- 11. lAtr sucoly free of contamination, l Ii l i l ll} l l (CONTf9tfD 01 Sw!Et 2 of 21 i fI e
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INSTRUCTION ISSUE NUMBER REVISION MGE TEXAS UT1UTIES GENERATING CO. DATE CPSES o QI-QP-11.4-1 20 W 0 5 Mgr , 12 of 14 ATTACHNENT 2 (CONTINUED) 01 0P 11.4-1. new.
Sheet 2 of 2 CCM ANCME PEM STEAM ELECTalc stATICN INSPECTION REPORT (scalh.Ev!N n t) l irt w l . .- **
.: 3 sarc so.a re no. I INS;EC?iCN ATTaisuTES
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- 12. Qualification of neoffei*a*_ ftfe* a--itente.e5 - '
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- i 13. I Veri f- Mf v f ee er.en* f rat re,p,e,. 115 i i I i i i i 14 ' Coating Material Pecduct Identification; I e i
'a. Base lot No. PART A.* I 8 I i
- b. Filler lot No.' 3 1 3 i
- t. Catafvit 8 ' '
W. Ininner L0t N0! t i 1 i
- k. Time Mixed: 1 1 : I f
8 6 i f
- 15. Pressure pot agitated. i e i 16- 1 Pat life net o u r sede d I 4 i
- 17. I Wete lett tht- 75 feet _ i : #
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y-INSTRUCTION ISSUE NUMBER REVISION AGE TEXAS UTILITIES GENERATING CO. DATE CPSES QI-QP-11.4.1 20 ; MAR 0 ? 198e 13 of 14 ATTACRMENT 3 PAINT MIXING SLIP DATE: >
BLDG. ELEV.
COATING: COLOR.
TIME MIXED: TEMP.
BATCH # BASE (A)
CAT./FLR (B)
THINNER (C)
CAL.
M&TE #'s INSP DATE:
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ATTACHMENT 4 I 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.
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 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 a
preceding coat is not readily visible with an unaided eye, Holiday: A pinhole, ski p, discontinuity or void in coating fil m.
Major Defect: Defined as an area, aither 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.
Moni tor: Confomance verification by physically observing a task being performed on a periodic or random ~ basis.
Muderacking: Irregular cracking as in a dried mud puddle (applicable to inorganic zine primers).
Orange Peel: Dents in the surface resembling orange skin. A moderate amount is acceptable.
Veri fy: Confim or make certain, i Vi sual : To examine with an unaided eye (correctional eye glasses or contact lens are acceptable).
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