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AMPP-Nuclear test Format | AMPP-Nuclear Course Contents | AMPP-Nuclear Course Outline | AMPP-Nuclear test Syllabus | AMPP-Nuclear test Objectives

Exam Code: AMPP NCIS

Exam Name: Nuclear Coatings Inspection Specialty (NCIS)

Number of Questions: 75 multiple-choice questions

Time Allotted: 2 hours.

Passing Marks: Pass/Fail (no numerical score provided; candidates receive a post-exam chart of strengths and weaknesses by domain).



Topic 1: Nuclear Power Plant (NPP) Operations- Work Procedures- and Industry Terminology

- NPP Operational Cycles: Reactor startup- normal power operation- shutdown- and refueling outages; role of coatings in maintaining structural integrity during thermal cycling and steam exposure.

- Work Procedures: Lockout/tagout (LOTO) procedures- confined space entry- hot work permits- and radiological work permits (RWPs); integration of coatings inspection into outage schedules.

- Safety and Administrative Controls: Personnel training- access controls- dosimetry monitoring- and decontamination processes; emphasis on verbatim compliance with procedures in safety-related areas.

- Industry Terminology Overview: Basic terms related to coatings in nuclear contexts- including exposure conditions like ionizing radiation- chemical sprays- and abrasion.



- Pressurized Water Reactor (PWR): A nuclear reactor type where water is kept under pressure to prevent boiling- used in ~60% of U.S. NPPs; coatings must withstand high-temperature steam.

- Boiling Water Reactor (BWR): A reactor where water boils in the core to produce steam; coatings face direct steam and suppression pool immersion.

- Radiation-Controlled Area (RCA): Designated zones in NPPs with potential radiation exposure; all work requires dosimetry and contamination surveys.

- Radiological Work Permit (RWP): Authorization document specifying dose limits- protective equipment- and decontamination requirements for work in RCAs.

- Lockout/Tagout (LOTO): Safety procedure to isolate energy sources before maintenance; critical for coatings work near electrical or steam systems.

- Decontamination Factor (DF): Measure of coating removability of radioactive contaminants; higher DF indicates easier cleanup.

- Qualified/Unqualified Coatings Inventory (QUCI): Plant-wide database tracking all coatings as qualified (meeting DBA criteria) or unqualified (non-safety-related).



Topic 2: Recognition of Industry Regulatory Organizations Worldwide

- U.S.-Focused Regulators: NRC's oversight of licensing- inspections- and enforcement; integration with ASTM/ANSI standards for coatings.

- International Organizations: IAEA's global safety standards; OECD/NEA's technical cooperation; regional groups like ENSREG for EU harmonization.

- National Regulators: Examples from major nuclear-operating countries- including their coatings-specific guidelines.

- Standards Bodies: Role of ASTM and ANSI in developing nuclear-specific coating qualification tests.



- U.S. Nuclear Regulatory Commission (NRC): U.S. federal agency regulating commercial nuclear power; enforces 10 CFR 50 Appendix B for QA in coatings.

- International Atomic Energy Agency (IAEA): UN-affiliated body promoting peaceful nuclear use; issues Safety Standards Series (SSR-2/1) for coatings in containment.

- Nuclear Energy Agency (NEA): OECD agency for advanced nuclear countries; develops guidelines via Committee on Nuclear Regulatory Activities (CNRA).

- European Nuclear Safety Regulators Group (ENSREG): EU forum for harmonizing nuclear safety; reviews coatings in stress tests post-Fukushima.

- ANSI N5.12: American National Standard for protective coatings in water-cooled NPPs; replaced by ASTM equivalents for qualification.Regulatory Guide 1.54 (RG 1.54)NRC guide on QA for protective coatings; requires DBA qualification for CSL I areas.



Topic 3: Performing Inspections in Various Areas of an NPP

- Inspection Areas: Containment (CSL I)- RCA outside containment (CSL II)- and non-RCA (CSL III); wet vs. dry areas.

- Methods and Tools: Visual examination (VT-1/VT-3 per ASME Section XI)- holiday detection- adhesion pull-off tests- and dry film thickness (DFT) measurements.

- Documentation and Reporting: Use of inspection checklists- defect classification (e.g.- blisters- cracks)- and integration with plant QA programs.

- Challenges: Working under RWPs- in high-radiation fields- or during outages; post-DBA debris exam.



- Visual Testing (VT-1/VT-3): ASME-qualified surface examination; VT-1 for general surfaces- VT-3 for accessibility in nuclear inspections.

- Holiday Detection: Non-destructive test using low/high-voltage to detect pinholes or voids in coatings.

- Dry Film Thickness (DFT): Measured coating layer depth post-cure; must meet spec (e.g.- 5-10 mils for epoxies).

- Adhesion Pull-Off Test (ASTM D4541): Measures bond strength between coating and substrate; minimum 200 psi for nuclear apps.

- Blistering (ASTM D714): Coating defect rated by size/frequency; critical in DBA-exposed areas.

- Degraded Coating: Failure mode (e.g.- chalking- cracking) requiring condition test per ASTM D5163.



Topic 4: Purpose- Criteria- and Types of Qualified NPP Coatings

- Purpose: Protect against corrosion- radiation- chemicals; ensure no debris in emergency core cooling systems (ECCS).

- Qualification Criteria: Testing per ASTM D5144 for radiation (ASTM D4082)- chemicals (ASTM D3912)- and fire (ASTM E84).

- Types: Safety-related (qualified) vs. non-safety (acceptable); shop-applied vs. field-applied.

- Evaluation: Physical properties (abrasion per ASTM D4060)- fire resistance- and post-exposure integrity.



- Qualified Coating: Meets DBA- radiation- and chemical tests per ASTM D5144; used in CSL I areas.

- Acceptable Coating: Non-safety-related; no formal DBA qualification but evaluated for RCA use.

- Epoxy Coating: Common nuclear type; provides chemical resistance and adhesion to steel/concrete.

- Phenolic Lining: High-temperature resistant for containment liners; withstands steam at 300°F+.

- Gamma Radiation Resistance: Ability to endure 10^7-10^8 rads without embrittlement (ASTM D4082).

- Decontamination (ASTM D4256): Test for removable contamination; coatings must achieve >90% efficiency.



Topic 5: Developing and Managing a Safety-Related Coatings Program

- Program Development: Align with RG 1.54; include training- procurement- and auditing.

- Management: Q UCI tracking- non-conformance handling (ASTM D7491)- and condition exams (ASTM D5163).

- Maintenance: Periodic inspections- repair strategies- and vendor qualification.

- QA Integration: Audits- records retention- and compliance with NQA-1.



- Safety-Related Coating: Applied to structures/systems/components (SSCs) vital to accident mitigation.

- Non-Conforming Coating: Degraded- unqualified- or unknown; managed via disposition (remove/repair) per ASTM D7491.

- Condition Assessment Program: Scheduled monitoring of CSL I coatings; uses visual and adhesion tests (ASTM D5163).

- NQA-1: ASME QA standard for nuclear facilities; covers coatings procurement and application.

- EPRI Report 1019157: Guideline for nuclear coatings selection- application- and maintenance.



Topic 6: Classifying Surface Preparation and Coating Application for Different Coating Service Level (CSL) Areas

- CSL Classification: I (DBA-qualified)- II (radiation-resistant)- III (general industrial).

- Surface Preparation: Abrasive blasting (SSPC-SP 10)- power tool cleaning (SSPC-SP 3); profile measurement (ASTM D4417).

- Application Techniques: Brush/roller for touch-up- spray for full coats; environmental controls (dew point- temp).

- Differences by CSL: Stricter QA for CSL I (e.g.- qualified applicators per ASTM D4228).



- Coating Service Level I (CSL I): Safety-related in containment; requires DBA qualification and strict prep (Sa 2.5 blast).

- Coating Service Level II (CSL II): RCA outside containment; no DBA test but radiation/chemical resistance needed.

- Coating Service Level III (CSL III): Non-RCA; general coatings like service water linings; minimal qualification.

- Surface Profile: Anchor pattern roughness (e.g.- 2-3 mils) for adhesion; measured via replica tape (ASTM D4417).

- SSPC-SP 10: Near-white blast cleaning; standard for CSL I steel prep.

- Qualified Applicator: Certified per ASTM D4228; demonstrates proficiency on test panels.



Topic 7: Matching Coating System Type and DBA Qualification Requirements

- System Types: Multi-coat systems for steel/concrete; immersion vs. atmospheric service.

- DBA Requirements: Simulate loss-of-coolant accident (LOCA) per ASTM D3911; no debris >0.125 in. post-test.

- Matching Process: Evaluate substrate (ferritic steel- stainless)- environment (pH 2-12 sprays)- and performance data.

- Requalification: When to retest (e.g.- formulation changes) per ASTM D8104.



- Design Basis Accident (DBA): Worst-case event (e.g.- LOCA); coatings must survive without debris impacting ECCS.

- Loss-of-Coolant Accident (LOCA): Pipe break releasing steam/chemicals; DBA test simulates 340°F/150 psig for 100 days.

- Debris Limit: Post-DBA- <1% weight loss and no chunks >0.125 in. diameter (ASTM D3911).

- Coating System: Multi-layer (primer- intermediate- topcoat); e.g.- inorganic zinc + epoxy for containment.

- Simulated DBA Test: Environmental chamber exposure to steam- radiation- and borated water sprays.



Topic 8: Determining and Applying Required Qualifications to Meet Industry and Plant-Specific ANSI and ASTM Standards

- ANSI/ASTM Framework: Use D5144 as umbrella; sub-standards for tests (D4082 radiation- D3912 chemicals).

- Qualification Process: demo prep (ASTM D5139)- testing- and data applicability (ASTM D8104).

- Plant-Specific Application: Customize for licensing basis; inspector certification (ASTM D4537).

- Compliance Verification: Audits- records- and peer reviews for CIP Level 3 Nuclear Specialty.



- ASTM D5144: Guide for protective coating standards in NPPs; covers qualification for CSL I/II/III.

- ANSI N101.2: Legacy standard for containment coatings; superseded by ASTM but referenced in licenses.

- Coating Qualification Test Document: Plant-specific plan outlining tests (radiation- DBA- fire) per RG 1.54.

- Inspector Certification (ASTM D4537): Procedures for qualifying personnel; requires training- exams- and experience for nuclear work.

- 10 CFR 50.49: NRC rule for environmental qualification of safety-related equipment- including coatings.

- Fire Resistance (ASTM E84): Class A rating required for CSL I; measures flame spread/smoke development.

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