StandardRecommended Practice

Recommendations for Training and Qualifying Personnel as Railcar Coating and

Lining Inspectors

This NACE International standard represents a consensus of those individual members who havereviewed this document, its scope, and provisions. Its acceptance does not in any respectpreclude anyone, whether he has adopted the standard or not, from manufacturing, marketing,purchasing, or using products, processes, or procedures not in conformance with this standard.Nothing contained in this NACE International standard is to be construed as granting any right, byimplication or otherwise, to manufacture, sell, or use in connection with any method, apparatus,or product covered by Letters Patent, or as indemnifying or protecting anyone against liability forinfringement of Letters Patent. This standard represents minimum requirements and should in noway be interpreted as a restriction on the use of better procedures or materials. Neither is thisstandard intended to apply in all cases relating to the subject. Unpredictable circumstances maynegate the usefulness of this standard in specific instances. NACE International assumes noresponsibility for the interpretation or use of this standard by other parties and acceptsresponsibility for only those official NACE International interpretations issued by NACEInternational in accordance with its governing procedures and policies which preclude theissuance of interpretations by individual volunteers.

Users of this NACE International standard are responsible for reviewing appropriate health,safety, environmental, and regulatory documents and for determining their applicability in relationto this standard prior to its use. This NACE International standard may not necessarily addressall potential health and safety problems or environmental hazards associated with the use ofmaterials, equipment, and/or operations detailed or referred to within this standard. Users of thisNACE International standard are also responsible for establishing appropriate health, safety, andenvironmental protection practices, in consultation with appropriate regulatory authorities ifnecessary, to achieve compliance with any existing applicable regulatory requirements prior to theuse of this standard.

CAUTIONARY NOTICE: NACE International standards are subject to periodic review, and maybe revised or withdrawn at any time without prior notice. NACE International requires that actionbe taken to reaffirm, revise, or withdraw this standard no later than five years from the date ofinitial publication. The user is cautioned to obtain the latest edition. Purchasers of NACEInternational standards may receive current information on all standards and other NACEInternational publications by contacting the NACE International Membership ServicesDepartment, P.O. Box 218340, Houston, Texas 77218-8340 (telephone +1 [281]228-6200).

Approved 1998-10-26NACE InternationalP.O. Box 218340

Houston, Texas 77218-8340+1 (281) 228-6200

ISBN 1-57590-071-8 1999, NACE International

NACE Standard RP0398-98Item No. 21086

RP0398-98

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Foreword

The successful use of coating and/or lining systems for the protection of railcars and transportedcommodities depends on several factors. These include material quality, substrate compatibility,surface preparation, application techniques, process specifications, lining compatibility, andenvironmental conditions. Inspection of any or all of these elements by properly qualifiedpersonnel may be necessary to ensure that performance expectations, contracts, and regulatoryrequirements are met.

This standard recommended practice is intended for use by any corporate, public, or private entityin the railcar industry that employs personnel to inspect railcar coatings and linings. Thisstandard provides recommendations that assist employers in identifying the basic requirementsfor the in-house training, testing, and qualification of personnel who perform coating and/or lininginspections for a specific application or project. The qualification procedures recommended inthis standard are not, and should not be interpreted to be, a substitute or alternative to the NACEInternational Coating Inspector Training and Certification Program (NICITCP). An employer mayelect to incorporate NICITCP into its coating inspector qualification program or to use NICITCP asa partial or complete substitute for an in-house program.

This standard was prepared by NACE Task Group T-14C-11, a component of Unit Committee T-14C on Rail Equipment Corrosion, and is issued by NACE under the auspices of GroupCommittee T-14 on Corrosion in the Transportation Industry.

In NACE standards, the terms shall, must, should, and may are used in accordance with thedefinitions of these terms in the NACE Publications Style Manual, 3rd ed., Paragraph 8.4.1.8.Shall and must are used to state mandatory requirements. Should is used to state that which isconsidered good and is recommended but is not absolutely mandatory. May is used to state thatwhich is considered optional.

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NACE InternationalStandard

Recommended Practice

Recommendations for Training and Qualifying Personnel as Railcar Coating and

Lining Inspectors

Contents

1. General ..................................................................................................................... 12. Definitions ................................................................................................................. 13. Written Practice......................................................................................................... 24. Education, Training, and Experience ......................................................................... 25. Qualification .............................................................................................................. 36. Documentation and Requalification ........................................................................... 37. Code Of Ethics .......................................................................................................... 4References..................................................................................................................... 4Bibliography ................................................................................................................... 5Appendix A–Recommended Training Topics .................................................................. 6Appendix B–Recommended Form for a Visual Acuity Examination ................................ 7

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Section 1: General

1.1 This standard provides guidelines specific to therailcar industry for the in-house training and employer-administered qualification of one level of coating-inspection qualification. An employee who has passedthis level of qualification is called an Employer-QualifiedCoating Inspector (EQCI). Included are recommendedcriteria for employers recognizing this qualification, aswell as a list of suggested training topics and referencesto publications useful to such a training program.

1.2 There is one basic level of qualification defined in thisstandard. It is the EQCI qualification. Otherlevels/classes may be added to a training program asneeded in accordance with the employer’s writtenpractice.(1)

1.3 The factors and conditions judged to be significant tothe quality and performance of a coating and/or liningsystem to be inspected should be reviewed and agreedon at a prejob conference.

1.4 The recommendations in this standard are intendedto assist employers in training and qualifying personnel toinspect coatings and linings only in the railcar industry.

1.5 If permitted in the written practice, a NACE CertifiedCoating Inspector may perform the duties of an EQCIwithout separate qualification or certification.

1.6 Although an employer may elect to incorporateNICITCP as part of its coating inspector qualificationprogram, examination and certification by NACE is not arequirement for EQCI qualification.

1.7 While EQCI qualification is an established credential,employer qualification alone may not legally qualify aninspector to provide inspection services to the public.Contract documents, codes, and standards may requireinspections to be performed under the direction ofpersonnel with qualifications such as a NACE CoatingInspector certification or a professional engineer license.

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Section 2: Definitions

Coating, Interior: Any paint-type protective coveringapplied in one or more layers to the interior of a railcarand/or its components that acts as a barrier between thesubstrate and the lading.

Documentation of Qualification: A written statement ordocument signed by the qualifying official attesting thatan individual has met the standards of the writtenpractice.

Employer-Qualified Coating Inspector (EQCI): Anindividual who has been documented by the employer asmeeting the training, experience, and examinationrequirements of the written practice.

Lining: Any type of rubber or elastomeric material(s)applied in sheet or strip form in one or more layers to theinterior surfaces of a railcar and/or its components to actas a barrier between the substrate and the lading.

Qualification: Demonstrated skill, training, knowledge,and experience deemed necessary for personnel to

properly perform the duties of a specific job as describedin a code, standard, or written practice.

Employer: The corporate, public, or private entity thatemploys the individual being qualified. An employer maybe any entity in the railcar industry that employs railcarcoating and lining inspectors including railcar owners,coating applicators, shippers, and consultants.

Qualifying Official: The employee designated to qualifyinspectors and, if necessary, to revoke EQCIqualification.

Quality Assurance: All of the planned and systematicactions necessary to provide specified documentationand adequate confidence that the coating and/or liningsystem meets established performance expectations aswell as contract and regulatory requirements.

Quality Control: Those quality assurance actionsrelated to the verification of specific characteristics orevents as a means of providing documentation ofcompliance with contract and regulatory requirements.

____________________________(1) Classes that may supplement EQCI qualification include the NACE Protective Coatings and Linings Courses and the NACE Basic CorrosionCourse.

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Training: The program developed to impart theknowledge and skills necessary for qualification and workperformance.

Written Practice: A document prepared by the employerthat specifies methods, requirements, examinations,records, qualifying officials, etc., for the administration ofan EQCI program.

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Section 3: Written Practice

3.1 The employer shall establish a written practice for theadministration of coating and/or lining inspection,personnel training, qualification, and the specificfunctions to be carried out by an EQCI.

3.2 In order to develop a written practice, the employershall review the detailed recommendations presented inthis standard and modify them as necessary to meetspecific needs. The recommended training topics listedin Appendix A should be incorporated, as applicable, intothe written practice and/or training materials used.

3.3 The written practice shall identify the level ofresponsibility and authority of the EQCI, the qualifyingofficial, and those individuals performing training, as wellas the means for accomplishing each allocated duty.

3.4 The written practice shall comply with applicablelaws, codes, and standards. No modification shall bemade that compromises the quality of the inspectionprocess or violates the provisions of an applicableregulation, code, or standard.

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Section 4: Education, Training, and Experience

4.1 Minimum Requirements: All EQCI candidates mustmeet the requirements of Paragraphs 4.1.1 and 4.1.2 inorder to be considered for EQCI qualification.

4.1.1 Education: A high school diploma or approvedgeneral equivalency diploma (GED) is required.

4.1.2 Training

4.1.2.1 Candidates for EQCI qualification shallcomplete sufficient organized training to becomethoroughly familiar with the principles andpractices of coating and/or lining inspection.Training programs must cover fundamentalinspection concepts and may also includeadvanced technology about which coursematerial has not yet been published.

4.1.2.2 Additionally, training topics shallencompass areas unique to the railcar industry.Topics should include applicable sections ofAAR(2) standards M-1001,2 M-1002, and M-1003,3 Field Manual of the AAR InterchangeRules,4 DOT(3) 49CFR1794 and 49CFR180,6

publications listed in the bibliography, andrecommendations and specifications supplied bycustomers and/or coating and liningmanufacturers.

4.1.2.3 Organized training programs for EQCIcandidates shall consist of at least 40 hours ofclassroom and on-the-job experience.

4.1.2.4 If permitted in the written practice, creditmay be awarded for documented training andexperience received in situations outside thoseprovided by the employer.

4.2 Experience: All candidates for EQCI qualificationshall meet one of the following criteria:

4.2.1 The EQCI candidate has been employed noless than one year by the employer in a functiondirectly involving the installation or inspection of newor existing coatings and/or linings in the railcarindustry. These functions shall have been performedin accordance with a written procedure, code,standard, or specification. The candidate shall havehad direct experience in one or more of the followingareas:

(a) Design: Includes the preparation of plans,procedures, and specifications for coating and/orlining selection, application, and inspection.

____________________________(2) Association of American Railroads (AAR), 50 F St. NW, Washington, DC 20001-1564.(3) U.S. Department of Transportation (DOT), 400 7th St. SW, Washington, DC 20590.

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(b) Production: Includes the planning and control ofcoating and/or lining operations, including the prejobconference, procurement, preparation, application,and supervision.

(c) Manufacturing: Includes participation in thedevelopment, formulation, and processing of coatingand/or lining materials.

(d) Inspection: Includes the verification andassessment of coating and/or lining applications.

(e) Repair: Includes the performance of coatingand/or lining repairs.

4.2.2 The EQCI candidate has been employed lessthan one year by the employer and has three years ofexperience in a function directly involving theinstallation or inspection of new or existing coatingsand/or linings in the railcar industry. These functionsshall have been performed in accordance with awritten procedure, code, standard, or specification.This experience shall be documented by transcriptsor letters of reference.

4.3 If permitted in the written practice, experience gainedin accordance with Paragraph 4.2.2 shall satisfy therequirements for EQCI qualification. However, theappropriate examinations shall be administered by theemployer in all cases.

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Section 5: Qualification

5.2 The employer shall create a measurement system toassess the EQCI candidate’s initial and finalcomprehension of training materials, facility practices,and applicable quality provisions. The measurementsystem shall consist of the following:

5.2.1 Practical Exam: A test of practical applicationsof coating and/or lining inspection principles andequipment employed in the railcar industry shall begiven to verify that the EQCI candidate possessesthe ability to perform specific inspections andinterpret results. A checklist of at least 10 items shallbe prepared, and the EQCI candidate mustdemonstrate proficiency in 70% of the principlesbeing tested in order to pass the examination. Thechecklist shall be a part of the EQCI candidate’spermanent employment record. The recommendedduration of the practical examination is two hours.

5.2.2 Written Exam: A written examination to verifythat the EQCI candidate comprehends procedures,codes, and specifications shall be given. At theoption of the employer, the examinee may be allowed

access to books and notes during the exam. Arecommended format is a two-hour long examinationcomposed of at least 50 questions. Therecommended minimum passing score is 70%. Thewritten examination shall be part of the candidate’spermanent employment record.

5.2.3 Physical Requirements: An EQCI must bephysically able to safely perform activities requiredby the employer. The activities to be performed byan EQCI shall be defined in the written practice.

5.2.4 Visual Exam: An EQCI must possess visualacuity (with or without corrective lenses) equivalentto that required by a Jaeger J-2 or Snellen exam andcolor perception equivalent to that required in thewritten practice. The visual examination shall beadministered by an optometrist, medical doctor,registered nurse, or certified physician’s assistant noearlier than six months prior to the date ofqualification or requalification. A record of theexamination results shall be documented in thecandidate’s permanent employment record.

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Section 6: Documentation and Requalification

6.1 The employer is responsible for documenting thequalification of coating inspectors in accordance with theterms of this standard.

6.2 At the option of the employer, an outside agency mayprovide training, assessment, and qualification services.In such instances, the employer is responsible forassuring that training and qualification are carried out inaccordance with this standard and the written practice.

The qualifying official shall review and approve all suchoutside services.

6.3 The qualification of an EQCI must be reassessed atleast once every three years. Requalification iscontingent on satisfactory fulfillment of all of the followingcriteria:(a) Documentation of continued acceptable performance(b) Annual visual examination

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(c) Participation in annual training

6.3.1 The qualification of an EQCI may bereassessed for cause at the discretion of thequalifying official.

6.4 Qualification records shall be maintained by theemployer and shall include the following:

(a) Name of the EQCI(b) Accumulated experience and training(c) Examination results(d) Statement of qualification

(e) Qualifying official’s signature(f) Date(s) of qualification and requalification

6.5 The qualifying official has the authority to revoke thequalification of an EQCI for violation of this standard, thewritten practice, or the code of ethics. Reinstatement isallowed, provided the reason for revocation has beenrectified to the satisfaction of the qualifying official.

6.6 An EQCI qualification shall be terminatedautomatically when the EQCI’s employment with theemployer is terminated.

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Section 7: Code of Ethics

7.1 The employer shall develop a code of ethics andresponsibilities applicable to the scope of activitiesperformed by an EQCI. The code of ethics shall signify acommitment to comply with laws, codes, and standardsfor preserving the public health and wellbeing, avoidconflicts of interest, and disclose any businessassociation or circumstance that may be considered aconflict of interest.

7.2 An EQCI shall perform assignments only if he/she isproperly qualified. An EQCI shall be completelyobjective, thorough, and factual in making inspectionsand issuing reports. An EQCI shall only approve workabout which personal knowledge has been acquiredthrough direct observation.

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References

1. AAR Standard M-1002 (latest revision),“Specification for Tank Cars” (Washington, DC: AAR).

2. AAR Standard M-1001 (latest revision),“Specification for Freight Cars” (Washington, DC: AAR).

3. AAR Standard M-1003 (latest revision),“Specification for Quality Assurance” (Washington, DC:AAR).

4. Field Manual of the AAR Interchange Rules(Washington, DC: AAR, 1993).

5. U.S. Department of Transportation, Code of FederalRegulations Title 49: Hazardous Materials, Part 179“Specifications for Tank Cars” (1997), pp. 925-984.

6. U.S. Department of Transportation, Code of FederalRegulations Title 49: Hazardous Materials, Part 180“Continuing Qualification and Maintenance of Packaging”(1997), pp. 984-1011.

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Bibliography

ASTM(4)D 4285 (latest revision). “Standard Test Methodfor Indicating Oil or Water in Compressed Air.” WestConshohocken, PA: ASTM.

CAN/CGSB-43.147P (latest revision). “Construction andMaintenance of Tank Car Tanks and Selection andUse of Tank Car Tanks, Portable Tanks and RailCars for the Transportation of Dangerous Goods byRail.” Ottawa, Ontario: Canadian General StandardsBoard.(5)

Graver, D.L. Corrosion Data Survey. 6th ed. Houston,TX: NACE, 1985.

Guide to Qualification of Tradesman IndustrialMaintenance Painters. Houston, TX: NACE, 1988.

NACE No. 1/SSPC(6) - SP 5 (latest revision). “WhiteMetal Blast Cleaning.” Houston, TX: NACE andPittsburgh, PA: SSPC.

NACE Publication 6G186 (latest revision). “SurfacePreparation of Contaminated Steel Surfaces.”Houston, TX: NACE..

NACE Publication 6Q187 (latest revision). “CurrentPractices in Quality Control during Application ofProtective Coating Materials.” Houston, TX: NACE..

NACE Publication TPC 2 (latest revision). “Coatings andLinings for Immersion Service.” Houston, TX: NACE.

NACE Standard RP0178 (latest revision). “FabricationDetails, Surface Finish Requirements, and ProperDesign Considerations for Tanks and Vessels to beLined for Immersion Service.” Houston, TX: NACE.

NACE Standard RP0188 (latest revision). “Discontinuity(Holiday) Testing of Protective Coatings.” Houston,TX: NACE.

NACE Standard RP0287 (latest revision). “FieldMeasurement of Surface Profile of Abrasive BlastCleaned Steel Surfaces Using a Replica Tape.”Houston, TX: NACE.

NACE Standard RP0295 (latest revision). “Application ofa Coating System to Interior Surfaces of New andUsed Rail Tank Cars.” Houston, TX: NACE.

NACE Standard RP0386 (latest revision). “Application ofa Coating System to Interior Surfaces of CoveredRailroad Hopper Cars in Plastic, Food, and ChemicalService.” Houston, TX: NACE.

NACE Standard RP0495 (latest revision). “Guidelines forQualifying Personnel as Abrasive Blasters andCoating and Lining Applicators in the Rail Industries.”Houston, TX: NACE.

NACE Standard RP0592 (latest revision). “Application ofa Coating System to Interior Surfaces of New andUsed Rail Tank Cars in Concentrated (90 to 98%)Sulfuric Acid Service.” Houston, TX: NACE.

____________________________(4) American Society for Testing and Materials (ASTM), 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.(5) Canadian General Standards Board (CGSB), KIA 1G6, Ottawa, Canada.(6) The Society for Protective Coatings (SSPC), 40 24th Street, 6th Floor, Pittsburgh, PA 15222.

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Appendix A:Recommended Training Topics

A1 General and Administrative Requirements

A1.1 Quality System Elements

A1.2 Customer Specifications and RegulatoryRequirements

A1.3 Inspector Responsibility and Authority

A1.4 Prejob Conference

A1.5 Report Requirements

A2 Corrosion Basics

A2.1 Definitions

A2.2 Types and Causes of Corrosion

A2.3 Corrosive Commodities

A2.4 Corrosion Rate and Remaining Life

A2.5 Corrosion Prevention

A3 Coatings and Linings

A3.1 Definitions

A3.2 Types of Coatings and Linings

A3.3 Advantages and Limitations

A3.4 Manufacturer’s Recommendations

A3.5 Service Life

A4 Surface Preparation

A4.1 Definitions

A4.2 Types of Surface Preparation

A4.3 Methods of Surface Preparation

A4.4 Equipment for Surface Preparation

A4.5 Requirements

A5 Inspection

A5.1 Definitions

A5.2 Types of Inspection

A5.3 Methods of Inspection

A5.4 Points of Inspection

A5.5 Inspection Equipment

A5.6 Reporting Requirements

A6 Safety and Health

A6.1 Definitions

A6.2 Safety Regulations

A6.3 Personnel Monitoring

A6.4 Applicable Environmental Regulations

A6.5 Reporting Requirements

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Appendix B:Recommended Form for a Visual Acuity Examination

This form is included for informational purposes only.

• The eye exam shall not be given earlier than six months prior to the EQCI written examination or the EQCI practicalexamination.

• THE PRINTED TEST REQUIREMENTS SHALL NOT BE ALTERED. NO MEDICAL TERMINOLOGY SHALL BEADDED. ONLY ONE BOX SHALL BE CHECKED PER TEST.

___________________ ___________________ ___________________Applicant’s Name Employee Identification Social Security Number

TESTS: Meets without Meets with eye correction eye correction Does not meet

1. Far Vision 20/40 or better

2. Near Vision Snellen English or Jaeger J-2 @ 30 cm (12 in.)

3. Color Perception Pseudoisochromatic plates Color differentiation

I certify that I, __________________________, administered an eye exam on _______________ Printed Name of Eye Examiner MM/DD/YY

to __________________________, which demonstrated the vision capabilities indicated above. Printed Name of Applicant

Check one of the following:

Optometrist Medical Doctor Registered Nurse Certified Physician’s Asst.

__________________________ ____________ ________________________________ Signature of Eye Examiner State License # Professional Address

TEL. No. ______________ FAX No. ______________ E-mail ________________________