ML17202L288
| ML17202L288 | |
| Person / Time | |
|---|---|
| Site: | Dresden  |
| Issue date: | 06/29/1990 |
| From: | Chapman T, Szombathy R GENERAL ELECTRIC CO. |
| To: | |
| Shared Package | |
| ML17202L287 | List: |
| References | |
| DRF#-A-3851, DRF#-A00-03851, NUDOCS 9007090041 | |
| Download: ML17202L288 (44) | |
Text
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'i DRESDEN II Transmittal 508-9006 ORF # A00-03851 UPPER VESSEL CONTRACT VARIATION REVIEW June 29, 1990 General Electric Nuclear Energy 175 Curtner Avenue San Jose, California 95125 Approved by:
~----
T.L. Chapman, Manager Reactor and Fuel Examination Technology
-9007090041 900702 PDR ADOCK 05000237 p
~.
5089006.wp
IMPORTANT NOTICE REGARDING CONTENTS OF THIS REPORT PLEASE READ CAREFULLY The only undertakings of the General Electric C6mpany respecting information in this document are contained in the contract governing this work and nothing contained in this document shall be construed as changing said contract.
The use of this information except as defined by said contract, or for any purpose other than that for which it is intended, is not authorized; and with respect to any such unauthorized use, neither General Electric Company nor any of the contributors to this document makes any representation or warranty (express or implied) as to the completeness, accuracy or usefulness of the information contained in this document or that such use of such information may not infringe privately owned rights; nor do they assume any responsibility for liability or damage of any kind which may result from such use of such information.
TABLE OF CONTENTS PAGE
1.0 INTRODUCTION
1 1.1 SCOPE 1.2 DEFINITIONS 1
2.0 TOP HEAD ASSEMBLY 2
2.1 VN 98-3 BOAT SAMPLE CAVITIES 2
2.2 VN 98-8 CLADDING CHEMISTRY OUT OF SPECIFICATION 2
2.3 VN 98-15 MISMATCH BETWEEN TOP HEAD TORUS AND FLANGE 3
- 2.4 CV 98-30 LOCATION OF NOZZLE IS OUT OF TOLERANCE 4
2.5 CV 98-32A REPAIR OF TOP HEAD FLANGE CLADDING
.5 2.6 CV 98-34A REPAIR OF PT INDICATIONS ON TOP HEAD 5
FLANGE CLADDING 3.0 SHELL RING 4 & VESSEL FLANGE SUBASSEMBLY 8
3.1 VN 98-4 CLADDING CHEMISTRY OUT OF SPECIFICATION 8
3.2 VN 98-6 UPPER SHELL INSIDE DIAMETER BELOW 8
MINIMUM REQUIRED 3.3 VN 98-10 UPPER SHELL CLADDING CHEMISTRY OUT 11
. OF SPECIFICATION 3.4 VN 98-13, REV 1 MISMATCH BETWEEN UPPER SHELL AND 11 VESSEL FLANGE 3.5 CV 98-26 SHELL FLANGE DIMENSIONAL DISCREPANCIES 13 3.6 CV 98-42 VESSEL FLANGE MONITORING HOLE OFF LOCATION 13 3.7 CV 98-49 SHELL FLANGE STUD HOLES WITH DISCREPANT 14 THREADS 3.8 CV 98-60 SHELL RING #4 DROP OF PREHEAT 14 FIGURE 1 TOP HEAD ASSEMBLY 7
FIGURE 2 SHELL RING #4 AND FLANGE ASSEMBLY 15 ATTACHMENT 1 UPPER VESSEL CONTRACT VARIATION ILLUSTRATIONS APPENDIX A LIST OF CONTRACT VARIATIONS FOR ENTIRE VESSEL
1.0 Dresden II Upper Vessel Contract Variation Review INTRODUCTION:
1.1
~
1.2 For the Dresden II vessel, the Contract Variations (CV's) were first reviewed to determine fabrication problems that were relevant to the findings in-service on the Quad Cities II Top Head cracking.
Based on the results of the CV review, selected fabrication records were then reviewed to further document the e~tent of the problem.
The Contract Variations (CV) and Variation Notices (VN) were provided by Babcock and Wilcox Company (B&W) to GE personnel during the vessel fabrication records review at Mt. Vetnon, Indiana.
The CV's and VN's were ~opied from microfilm. Since a complete list of all CV's and VN's generated during the vessel fabrication was not provided by B&W, the GE vessel records packages were reviewed and a complete list was. obtained and is included in Appendix A.
The CV's and VN's sununarized in this report are limited to the Top Head Assembly and, Shell Ring #4 and Vessel Flange Subassembly including the girth seam of shell Shell Ring #4 to Shell Ring #3
- Definitions During the vessel fabrication, Contract V~riations and Variation Notices were used.
A Variation Notice (VN) was a basic nonconformance record descriging a condition which required a formal, documented response from the GE Process Engineer (responsible d~sign engineer) for disposition.
Most VN's resulted in a "rework" to bring back into conformance with the drawing.
A Contract Vari~tion (CV) was a Variation Notice (VN) which is not reworked and* was forwarded to the customer Process Engineer for disposition.
- e 9011.wp
Dresden II Upper Vessel Contract Variation Review 2.0 TOP HEAD ASSEMBLY Figure 1 illustrates the Top Head construction details.
2.1 VN 98-3 Boat Sample Cavities DESCRIPTION:
Boat samples were removed from the Top Head for tests, examinations and chemical analysis of.th~ cladding leaving cavities as a result.
DISPOSITION:
B&W recommends weld repair of the cavities.
REPAIR PROCEDURE:
A 1/4" wide band shall be removed from the periphery of each boat sample cavity by grinding.
The areas shall be preheated from 3000f to soooF maximum.
Welding shall be by the Shielded-Metal Arc Welding (SMAW) method using type E8015 electrodes in accordance with. B&W Specification WS-35, Rev~ A.
A 300-0f to 3S00f preheat shall be maintained. Welding for the balance of each cavity shall be by the SMAW method using type E309 electrodes for the first layer and type E308 electrodes for the second layer.
The repaired component shall be stressed relieved at llOOOf to 11300f in accordance with B&W Specification HT.6-2 (Attachment 1).
- 2.1 VN 98-8 Cladding Chemistry Oyt of Specification DESCRIPTION:
Chemical analysis of the single pass 308L cladding revealed variations from the contract requirements for Chromium and Nickel content.
DISPOSITION:
B&W recommends the deposit of a second layer of 308L weld cladding in accordance with weld procedure WS-30, weld data sheet WR-4, Alt. 1.
This will restore the surface layer chemstry to specification requirements. *.
9011.wp
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2.3 Dresden II Upper Vessel Contract Variation Review VN 98-15 Mismatch Between Top Head Torus and Flange DESCRIPTION:
A visual and dimensional inspection of the fit up between the Head Flange forging and the Head Subassembly revealed a 5/8" mismatch in a 23" long localized area on the circumference.
The offset is located at the "y" axis and extends 10" towards the "x" axis and is 13" towards the "z" axis.
DISPOSITION:
B&W recomends the acceptance of this mismatch based on engineering calculations.
Sufficient weld metal shall be deposited in this area at the time the circumferential seam is welded.
This additional deposited weld metal will permit a smooth blend of the offset using a 3:1 taper.
Fabrication Summary for VN 98-15:
Fabri~ation records were reviewed concerning the 5/8" mismatch between the Head Flange and Side Plates (Torus}.
The following activities were recorded:
After fit up the head and torus a dimensional inspection revealed 5/8" mismatch and rejected the fit up (ref. inspection ticket # E-47057} the
. disposition for the VN was to "ACCEPT AS IS" and additionally that as the circ seam is welded sufficient metal will be deposited to permit a blending of the offset using a 3:1 taper.
The Flange and Torus were set up for the circumferential seam.
The seam was welded first from the outside using single wire Submerged Arc Welding (SAW}
per WR-58 Rev. 0.
After the welding was completed, the backing ring* and fitting blocks were removed by air arcing.
The seam was ground on the ID and OD and Magnetic Particle Test (MT} examined.
The OD was rejected (ref. inspection ticket # E-47544} and cleared after probe grinding (ref. inspection ticket # E-47851}, the ID was also 9011.wp
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Dresden II Upper Vessel Contract Variation Review rejected by MT (ref. inspection tick~t # E-47852) and cleared (ref:
inspection ticket# E-47854).
Areas of base metal grinding on the ID were MT examined and found rejectable (ref. inspection ticket # D-5646), these areas were probe ground, reinspected and found acceptable (ref. inspection ticket #
D-6013).
Next the transition angle between the clad and base metal was Liquid Penetrant Test (PT) examined and accepted (ref. inspection ticket
- D-5661).
- The seam was reexamined by RT.
Weld repairs were made on both the ID and OD.
The Torus and Flange assembly was then setup on the positioner for welding.
The ID portion of the seam was welded using the SAW process, per WR-58, Rev. 0.
Weld build was also made on the ID at this time.
The assembly was stress relieved at llOOOf to 11300f (ref. inspection ticket #J-4495), run #432.
The seam was Radiographic Test (RT) examined.
The next series of events was to clear defects in the weld.
Cavities had been gouged out of the head from probe grinding to remove RT defects, these cavities were MT examined and found rejectable (ref.
inspection ticket #F-39266).
These areas were probe ground and reinspected and found acceptable (ref. inspection ticket# F-39363).
The cavities were repaired by the SMAW process per WS-35, Rev. 4.
The ID was back clad per WR-59, and ground to contour.
2.4 CV 98-30 Location of Nozzle is Out of Tolerance DESCRIPTION: *A visual and dimensional inspection revealed a variation in location of MK.206 nozzle on MK.201 closure head. (Attachment 2)
DISPOSITION:
B&W recommends acceptance of this condition since the discrepancy will not detrimentally affect the functional or structural integrity of the vessel.
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9011.wp
Dresden II Upper Vessel Contract Variation Review 2.5 CV 98-32A Repair of Top-Head Flange Cladding
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DESCRIPTION:
UT indications from the clad on the face of the closure Head Flange were ground out resulting in cavities requiring weld repair.
(Attachments 3 thru 6).
DISPOSITION:
B&W recommends the weld repair in accordance with the repair procedure submitted.
REPAIR PROCEDURE:
The cavities were cleaned for PT and weld repair, repaired using the half bead technique and Inconel 182 electrodes in accordance with B&W Specification W-58, Rev. 1.
The Head Flange was preheated to 35QOF.
One layer of weld m~tal was deposited covering all exposed base metal using 3/32" diameter lnconel 182 electrodes.
The actual thickness of the first layer *was determined and then half of this layer was removed by grinding.
Using 1/8" diameter Inconel electrodes sufficient weld metal was deposited to insure that* 3/16" minimum cladding had been deposited.
The Head Flange was heated at 4QQOF to 5000F for a minimum of two (2) hours.
Preheating was not required for subsequent repair welding, which was completed using Inconel 182.
electrodes in accordance with B&W Specification WS-35, Rev. 7.
The flange was stress relieved for one (1) hour at llOOOF to 113QOF.
2.6 *CV 98-34A Repair of PT Indications on Top Head Flange Cladding DESCRIPTION:
An unacceptable PT indication on the closure Head Flange was ground out leaving a cavity that reqiured weld repair (Attachment
- 7).
DISPOSITION:
Repair in accordance with the procedure submitted.
REPAIR PROCEDURE:
The cavity was cleaned for PT and weld repair.
The area was welded using the half bead technique and Inconel 182 electrodes in accordance with B&W Specification W-58, Rev. I.
The flange was 9011.wp
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Dresden II Upper Vessel Contract Variation Review preheated t6 3SQOf.-
One layer of thi p~ocedure was the same as discussed in detail for CV-98-32A covering all exposed base metal using 3/32" diameter Inconel 182 electrodes.
The actual thickness of this first layef was determined and then half of this layer was removed by grinding.
Using 1/8" diameter Inconel electrodes sufficient weld metal was deposited to insure 3/16" minimum cladding had been deposited.
The flange was preheated at 4QQOF to soooF for a minimum of two (2} hours.
The part was allowed to cool to 700F.
Repair welding was completed using Inconel 182 electrodes in accordance with B&W Specification WS-35, Rev. 7.
The flange was remachined to restore drawing dimensional requirements.
Figure I illustrates the Top Head weld locations and repair areas. 9011.wp
DRESDEN 2 TOP HEAD ASSEMBLY FIGURE 1 SEAL SURFACE REPAIRS 5/ff' MISMATCH 23" LG WELD DEPOSIT TO 3: 1 TAPER.
CLAD CAVITY REPAIRS AREAS FROM BOTH SAMPLES REMOVAL ORESOTHO 062390
Dresden II Upper Vessel Contract Variation Review 3.0 SHELL RING #4 l VESSEL FLANGE SUBASSEMBLY Figure 2 illustrates the Upper Vessel construction details.
3.1 VN 98-4 Cladding Chemistry Out of Specification DESCRIPTION:
Chemical analysis from the clad on the shell showed variations in Chromium and Nickel content (Attachment 5).
DISPOSITION:
B&W recommends the ~cceptance of these variations based on test results.
3.2 VN 98-6 Upper Shell Inside Diameter Below Minimum Required DESCRIPTION:
A dimensional inspection has revealed that the inside diameter of the shell subassembly has 3-9/32" difference in local areas (Attachments 8 & 9). 9011.wp
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,~t Dresden II Upper Vessel Contract Variation Review DISPOSITION:
B&W recommends splitting the shell and increasing* the diameter by making two (2) additional long seams in accordance with the repair procedure submitted.
REPAIR PROCEDURE:
A layout for two (2) long seams shall be made on the shell. A 2" wide band of the cladding shall be removed by machining for the entire length of the shell.
Restraining bars shall be fit and welded to each of the end faces of the shell.
The area of the long seam layout shall be preheated from 300°F to sooor maximum.
The first long seam shall be parted by thermal cutting to the layout line.
Jacking plates shall be fit and welded to each of the end faces of the shell.
The long seam shall be expanded to increase the shell travel in this area by 2"*.
The long seam shall be preheated from 3000F to sooor maximum.
Fitting blocks shall be welded into place by SMAW using E8015 electrodes.
The areas for fit up of the backing strips shall be ground to remove any weld cladding.
The long seam* shall be preheated from 3000F minimum to aooo maximum.
A 6° weld prep angle shall be thermal cut on each side of the long seam.
The long seam shall be preheated from 3000F minimum to sooor maximum.
The backup strip shall be fit and welded by SMAW using E8015 electrodes.
At this time the long seam shall be welded by the automatic SAW process
The shell shall receive a stress relief of ll00°F to 1130°F.
Th~ above procedure shall be repeated for ~he second long seam.
After completion of the second long seam, the inside surface of both seams shall be clad by the automatic SAW process in accordance with B&W Specification WR-28, Rev. 3.
The shell shall receive a stress relief of llOOOF to 113oor. 9011.wp
Dresden II Upper Vessel Contract Variation Review
.Fabrication Summa~y for VN 98-6 Fabrication records were reviewed concerning the unacceptable condition of the Shell Ring #4 inside diameter, and the following activities were recorded.
The shell assembly was setup on stands and inspected for circularity and diameter which resulted in a rejection ticket being written (ref.
inspection ticket #E-25384) on 12/16/66 (in ref. to inspection record #
E-25384).
Center lines for two (2) additional welds were layed out, located at 300 off the "W"and "Y" axis on the shell ID.
A 2" wide groove ~as machined to expose the base metal, also a 450 angle was machined on the edges of the cladding, the center line of the machine cut was then transferred from the ID to the OD for flame cutting.
The seam was preheated to 3000 and flame cut for the full length of the shell (1 seam only).
A 60 weld angle was flame cut on each plate edge.
The shell was jacked apart suitable for grinding and MT, after grinding, the weld preps were MT exam.i ned and found to be acceptable (ref.
inspection ticket # E-25475).
The Shell was jacked apart futher and fitting blocks were attached to the inside.
Backup strips were welded
. to the clad with E309 electrodes and the long seam was welded from the inside using the SAW process per WR-12, Alt. 1, Rev. 1.
The same procedure was followed for the second long seam with the exception that an additional l" of cladding was machined away on each side of area to be flame cut on the IO.
Backing strips were welded on the OD using 8015 electrodes and the long seam was SAW welded from the inside of the shell per WR-12, Alt. 3, Rev. 0. 9011.wp
Dresden II Upper Vessel Contract Variation Review 3.3 VN 98-10 Upper Shell Cladding Chemistry -Out of SpecificatiOh
3.4 DESCRIPTION
Chemical analysis of the single pass 308L weld cladding showed variations in Chromium and Nickel content.
DISPOSITION:
B&W recommends the deposit of a second layer of 308L weld cladding in accordance with weld procedure WS-30, weld data sheet WR-4 and 8, Alt. 1.
This will restore the surface layer chemistry to specification requirements.
VN 98-13, Rev. 1 Mismatch Between Upper Shell and Vessel Flange DESCRIPTION:
A review of dimensional inspection data has revealed a mismatch between the Vessel Flange and the Shell course.
(Attachments 10 and 11)
DISPOSITION:
The first 4-1/2" of the bore in the Shell has been machined to remove cladding and establish a uniform diameter.
The machine cut was blended to the bore using a 4:1 taper.
A 3:1 taper shall be machined on the top outside surface of the shell to maintain a 264" diameter at the top edge.
The weld joint shall be preheated from 3000F minimum to soooF maximum.
The preheat temperature shall be
- maintained to the stress relieving operation.
The weld seam shall be completed by the SAW process in accordance with the regular fabrication process. A 3500 weld buildup shall be made over the top inside surface of the shell to blend with the inside diameter of the flange and to extend to within 1/4" of the cladding on the surface of the shell.
The majority of weld metal shall be deposited by the SAW process using 1/8" diameter, high Mn-Mo-Ni wire.
The balance of the weld metal adjacent to the cladding on the shell shall be deposited by the SMAW method using E8015 electrodes, as an 9011.wp
Dresden II Upper Vessel Contract Variation Review alternate to the SMAW method, weld metal may be deposited b-y the semi-automatic method using 80C3 flux core electrodes.
The entire weld build-up area shall be examined by UT to determine the wall thickness, the ground surfaces shall be examined by MT.
The inside surface of the weld seam and the build-up area shall be cl added by *the automatic SAW method, the temperature control during cladding will be maintained within the 3QQOF to 35QOF range.
The assembly shall be stressed relieved at llQQOF to 11300F.
Fabrication Summary for VN 98-13, Rev,. #1 Fabrication records were reviewed concerning the fit up mismatch between the vessel Flange and the Shell Ring #4.
The following activities were recorded.
After fit up of the vessel flange to the Shell Ring #4 a dimemsional inspection revealed a mismatch.
A deviation dated 5/26/67 was written to address the problem.
The Vessel Flange and Shell Ring were refitted and the inspection of the fit up was accepted (ref. inspection ticket #
E-47457).
The assembly was then set up for SAW welding on the OD per WR-71, Rev.
- 0.
After welding the OD, the fitting blocks and backup rings were removed by air arcing.
At this point another deviation was written dated 7/11/67 to address the ID welding.
Preheat was maintained at 3000F and the ID biuildup was made per WS-30, Rev. 3.
Sufficient metal was deposited to obtain a 4:1 taper between the shell and flange. After welding, the buildup was ground to form a 4:1 taper and the OD was ground to contour.
The seam was MT examined on the ID and OD.
The ID ~as acceptable, the OD was rejected.
After probe grinding and repair welding the area was 9011.wp
Dresden II Upper Vessel Contract Variation Review
- reinspected and found acceptal:>le.
The ID of the seam* was cl added with ER308L usirig the SAW process per WR-28, Alt. 3.
3.5 CV 98-26 Shell Flange Dimensional Discrepancies DESCRIPTION:
A dimensional inspection of the shell flange has revealed various dimensional distrepanci~s on stud holes, cladding thickness, and nozzles off location.
(Attachments 12 thru 15)
DISPOSITION:
(Stud Holes):
B&W recommends re~orking the stud holes.
(C)adding Thickness):
B&W recommends machining the Inconel clad surface on top of the shell flange.
The 1/2" +/- 1/64" thick cladding shall be machined to 3/16 (+l/64 -0), staying on the high side of the tolerance as much as possib~e.
(Nozzles off Location):
B&W recommends acceptance "as is" since these variations shall not adversely affect the structural integrity or fun ct i ona 1 operation of the component.
3.6 CV 98-42 Vessel Flange Monitoring Hole Off Location DESCRIPTION:
A dimensional inspection revealed the 3/16 11 diameter High Pr~ssure Monitoring hole in the vessel flange assembly was drilled off location.
I
- DISPOSITION:
B&W recommends acceptance of the vessel flange assembly based on the repair procedure and Detailed Engineering Justification.
REPAIR PROCEDURE:
A 300 chamfer was machined at the top of the incorrectly drill~d 3/16" hole.
An lnconel plug was inserted in the hole leaving a gap of 3/8" to 1/2" between the bottom of the plug and 9011.wp
Dresden II Upper Vessel Contract Variation Review the bottom of the hole.
The first-layer of weld was deposited by the SMAW process using 8Nl2 electrodes in accordance with B&W Specification WS-35, Rev. 7.
the remaining weld metal, except the final layer, was deposited by the SMAW method using 8Nl2 electrodes. The final layer was deposited by the manual Gas Tungston Arc Welding (GTAW) process using 82T bare wire, in accordance with B&W Specification WS-35, Rev. 7.
The weld repair was ground to blend with the surrounding surface.
The repair area was PT examined in accordance with B&W Specification S-102C, Rev. 5.
3.7
- CV 98-49 Shell Flange Stud Holes with Discrepant Threads DESCRIPTION:
A dimensional inspection of the vessel Flange revealed variations on many of the tapped stud holes, discrepancies included stripped or missing threads, pitch diameters greater than nominal, thread height less than nominal.
DISPOSITION:
- B&W recommends the acceptance of the variations to the tapped stud holes based on engineering justification.
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3.8 CV 98-60 Shell Ring #4 Drop of Preheat
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DESCRIPTION:
It was discovered that the minimum preheat temperature of
- 3000f was not maintained on the circumferential seams between the #1,2,3 and 4 Shell Rings as required prior to heat treatment.
Th~se seams were heated to 6000f for four to six hours and then allowed to drop to room temperature.
DISPOSITION:
B&W recommends acceptance of this discrepancy based on the acceptance of the welds by RT before stress relief and UT testing after completion of stress relief.
The weld seams were examined by MT following the hydro~tatic testing of the vessel and were found to be acceptable.
Figure 2 illustrates Upper Vessel weld locations and repair areas. 9011.wp
I -
(Jl I
DRESDEN 2 SHELL COURSE #4 AND FLANGE ASSEMBLY FLANGE DISCREPANCIES:
STRIPPED THREADS THREAD LENGTH LESS THAN NOMINAL PITCH DIA GREATER THAN NOMINAL 8N30 8N3C D3 SEAM N128 0
- 4 339*
MISMATCH UP TO 3/4" IN LOCAL AREAS BUILD-UP ON SHELL ID TO 4: 1 TAPER.
D2 3: 1 TAPER MACHINED ON SHELL TO FLANGE 0.0.
CLAD CHEMISTRY VARIATION, SECOND CLAD LAYER TO RESTORE CHEMISTRY OF CD N388 8
N3A SEAM D1 0 N12A
- 5 99*
O" 1
TWO ADDITIONAL SEAM WELDS MADE AFTER CLADDING DUE TO SHELL ID DIMENSIONAL VARIATION UP TO 3 9/32" DRESDSHL' 062290 FIGURE 2
VN/CV No.
16044 and 16204 16107
"£0006 16169 16280 98-1 98-2 v
Part MK 7 - Recirc Inlet Nozzle MK 28 - Safe End Plates 198-8 6-198-9 6-198-12 MK 59 - Upper Inter-mediate Shell MK 59 - Upper Jnter-medi ate Shell MK 10 - Feedwater Nozzle MK 58 - Lower Inter-mediate Shell Course MK 209 - Closure Head Flange A end Dresden II LIST OF DEVIATION REPORTS Checklist Book Subject Sheet No.
Cavities in nozzle-to-s~fe end weld FN 4.2 and ferritic base metal.
S/N 7-198-3 & 5 Surface cavities M 2.1 M 2.3 M 2.3 Discrepant dimensions of the inside FS 2.2 diameter Discrepant circularity after reroll FS 2.2 Dimensional discrepancies*
FN 4.4 Distorted circular}ty, flat spot FS 2.3 The 6-inch diameter pilot hole FH 1.0 started off proper location GE Approved Status Weld repaired*
Weld repaired Rerolled at 1100°F - 1130°F Accepted as is Accepted as is. Transitions blended on 3:1 slope.
Warped area removed and replaced.
The fourth longitudinal seam resulted per Detail E Dwg. 113759£-12.
Weld re pa ired and rebored.
.N CJl
<1>
l)
VN/CV Ho.
Part Subject 98-3 98-4 98-5 98-6 98-7 98-8 98-9 98-10 HK A-201 - Closure Head Boat sample cavities MK 57 - Lower Shell MK B Upper*Torus of Lower Head MK 60 - Upper Shell MK C Dome Plate of Bottom Head MK 60 - Upper Shell MK C-1 Bottom MK A-201 - Closure
- Head.
MK B Bottom Head Upper Segment MK 60 - Upper Shell
\\
Cladding chemistry out of specification Cladding chemistry out of specification Inside diameter below minimum required Dimension deviation of CRD and flux monitor penetration rouqh bore Cladding chemistry.out of specification Cladding chemistry out of specification Cladding chemistry out of specification Checklist Book Sheet No.
FH 1.0 FS 2.4 FH 3.0 FS 2.1
- FH 3.0 FS 2.1 FH 3.0 FH 1.0 FH 3.0 FS 2.1 Page 2.
GE Approved Status Weld repaired Not approved.
See CV No.
98-10 A second layer of 308L weld cladding was deposited.
Two longitudinal seams were
- added per Deta i 1 E Owg. 113761 E-13.
Repaired by weld buttering and remachining.
A second layer of 308L w~ld cladding was deposited; the resulted dimensional devtations accepted as is.
A second layer of 308L weld cladding was deposited.
A second layer of 308L weld cladding was deposited.
N Ul
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l}
VN/CV No.
98-11 98-12 98-13 98-14 98-15 98-16 98-17 98-17A 98-18 v
Part MK 57 - Lower Shell MK 59 - Upper.Inter-mediate. Shell MK 60 & MK 48 - Upper Shell & Vessel Flange MK C-1 & MK e.:2 MK 202 & 209 - Bottom Head HK 41 - Skirt Flange Ring MK 57 - Lower Shell MK 57 - Lower Shell Subject Cladding chemistry out of specification 10 dimension below minimum Mismatch between the shell and flange Mismatch between the bottom head dome and torus Mismatch between the closure head and flange Ring too small Areas with insufficient wall thickness Mismatch between the lower shell and bottom head Checklist Book Page 3.
Sheet No..
GE Approved Status FS 2.4 A second layer of 308l weld cladding was deposited.
FS 2.2
. One long seam was parted, expanded and rewelded per.
Detail F Dwg. 113760E-14.
FS 2.1 Mismatch corrected but not eliminated. Justification of the transition between the shell and flange accepted.
FH 3.0 Weld build ups were made to overcome the mismatch.
FH 1.0 Blended with access of weld deposit.
M 3.3.B 18 inch segment was fit up and welded in to extend the ring FS 2.4 Repaired by weld build ups.
FS 2.4 Excess of weld metal deposited to permit blendin~.
N Ul co
- )
YN/CV No.
98-19 98-20 98-21 98-22 98-23 98-24 98-25 98-26 Part MK 59 - Upper lnter-medi ate Shell MK 57 - lower Shell MK 90 - Measuring Rods MK r Lower Vessel Sub-Assembly Mk 11 - Core Spray Nozzle MK 61 - Studs MK 63 - Bushings Mk A Shell Flange Checklist Book Subject Sheet No.
Mislocated drilling for instrumenta-rs 2.2.
tion nozzle hole A cavity 5-7/8 inch long X 2-1/2 inch rs 2.4 wide X 3 inch deep was found in the recirculation inlet nozzle after it was welded to the shell N-A N-A Discrepant CRD boring rH 3.0 Tool grooves on I
- O. and 0
- D.
rN 4.5 surf aces Gouges on studs no. 61-198-3, 7. 11, M 6.1 36, 42, 47, 49 and 86 Bushings no. 63-198-6, 7, 10, 18, 19, M 6.4 22, 24, 28, 33, 35, 36, 37, 38, 43, 44, 47, 55, 59, 63, 70, 76, 79, 81, 83, 87, 90, and 99 were not machined to drawing dimensional requirements Dimensional discrepancies on stud holes rs 2.1 of shell flange assembly, and dis-crepant cladding thickness Page 4.
GE Approved Status Repaired by weld deposit.
Weld repaired.
N-A Accepted as is with reinforce-ment of selected areas.
Accepted as is and blended.
Accepted as is and blended the discrepant areas.
Accepted as is.
- Stud ho 1 es reworked to the acceptable condition. Cladding on upper surface maintained 3/16 11 + l/16 11
- 0 11 N en (D
l)
VN/CV No.
98-27 98-28 98-28A 98-29 98-29A 98-30 98-31 98-32 98-32A Part MK 62 lnch Castellated Nut Bottom Head and Lower She 11 - MK F -1 II II MK 8 Upper Shell MK 134 - Steam Dryer Guide Bracket MK C-201 - Dome Head MK C-206 - Instrument
- Nozzle MK F Bottom Head MK C-201 - Closure
- Head Flange II II l)
Checklist Book Subject Sheet No.
Dimensional discrepancies of two nuts M 6.2 Drop of prehea't in repaired areas FH 3.0
- 1. Circle seam upper-to-lower torus
- 2. Weld joint of two recirc inlet nozzles to lower shell II II Depression in upper shell steam dryer guide bracket The location of the nozzle is 1/16 11 out of tolerance Out of tolerance and a tool mark in a counter bore of a hole at the X-13 coordinate.
Repair in the closure head flange cladding II II FS 2.4 II FA 5.3 FH 1.0 FH 3.0 FH 1.0 II Page 5.
GE Approved Status SN 62-198-92 accepted.
SN 62-198-7 replaced.
Rejected.
See 98-28A.
Weld repairs accepted after UT inspection.
(
Rereamed the bore to the required inside diameter and atcepted the O.D.
impres~ion "as is".
Accepted as is.
Accepted as is. Tool groove blended.
Not approved.
SEE 98-32A.
Repaired by the approved inconel cladding procedure.
N (J) 0 98-33A 98-34 98-34A 98-35 98-35A 98-36 98-37 II II MK C-201 - Closure Head Flange II II MK F-1 lower Vessel Assembly II II MK 236 - Surveillance Bracket*
MK 2 & MK 4 - Torus Assembly in Bottom Head II II Repair of PT defects in the closure head flange cladding II II Discrepancies in dimension of jet pump holes and access holes II II Dimensional discrepancies of the six brackets Exceeded the stress relief time II FH 1.0 II Final Check Sheet II M 5. lOA w 3.2 W 3.2A 18 holes fitted with MK 180 plugs; gouged groove:
112-J 11 blended. Other holes approved "as is 11 Not approved.
See 98-34A.
Repaired by the approved inconel cladding procedure.
Not approved.
See 98-35A.
Repaired by weld deposit.
To be machined at the Site.
Accepted as is.
Accepted as is.
(
VN/CV No.
98-38 98-38A 98-39 98-40
-. 98-41 98-42 9R-43 98-44 98-45 98-46 Part MK 63 - Bush1 ng MK 48 - Vessel Flange MK 48 - Vessel Flange MK C-201 MK 48 - Vessel Flange MK 63 -
Bush1rig-~t~**';r MK 22 - Drain Nozzle MK 11 - Core Spray Nozzle Subject 19 bushings with dimensional discrepancies Stud hole No. 27 was bored over-size before tapping Gouge in bushing stud hole No. 53 Machining variations of 110 11 ring grooves in. closure head assembl~
Monitoring hole off location
- 68 vessel.flange hole oversized One bushing was tool undercut across the outer thread Four tool gouges and oversize of the 1.0.
The end of the core spray nozzle S/N 11-198-2 dented Checklist Book Sheet No.
M 6.4 FS 2. 1 FS 2.1 FH 1.0 FS 2. 1 FS 2.1 M 6.4 FH 3.0 FS 2.2 Page 7.
GE Approved Status Bushings to be replaced at the Site.
Accepted as is.
Accepted as is. Sharp edges removed.
Accepted as is.
We 1 d re pa ired.
Accepted as is.
Hand repaired.
Blended sharp edges and accepted as.is.
Cut off the dama9ed end after hydrotest (nozzle 1-11/16" shorter).
N CJ)
N
l)
(.
VN/CV No.
98-47 98-48 98-49 98-50 98-51 98-52 98-53 9A-54
~;
Part MK C-201 - Closure Head MK 40 - Vessel Support Skirt MK 48 - Shell Flange MK 1 - Bottom Head Assembly MK 79 - Support Skirt Insulation MK 48 - Vessel Flange MK 209 - Head Flange HK 16 - Isolation Condenser Nozzle c*J -
- Subject Various stud holes off location Mislocation of twenty-three holes the support skirt base plate Twenty-nine stud holes with discrepant threads CRO holes, 17H, 250, 27K with dimensional discrepancies after removal of gouges in Support skirt insulation ring-to-bottom head fit 7up out of tolerance Mislocation of the bolt circle Misplacing of the name plate A 1-inch long dented end of the safe end of one isolation condenser nozzle cut off fll.
checklist Book Sheet No.
FH 1.0 FH 3.0 FS 2. 1 FS 3.0 FH 3.0 FS 2.1 FH 1.0 FS 2.1
. ~*
Page 8.
GE Approved Status Approved as is.
Correction to be made at the Site.
The deviation was approved as is and the rough stripped or intermittent threads were smoothed and blended with adjacent threads.
Accepted as is.
Approved as is.
Approved as is.
Replaced the plate to its proper position and plugged the four holes of the wrong pas iti on.
Accepted as is.
f\\l c-u.J
VN/CV No.
98-55 98-56.
98-57 98-58 98-59 98-60 98-61 l)
Part MK 7 - Rec1rc Inlet Nozzle MK 12 - Instrumentation Nozzle MK 43 - liquid Poison Nozzle MK 59 - Upper lnter-medi ate Shell MK 79 - Insulation Rinq
~1K 41 - Support Skirt Base Plate MK 57, 58, 59, 60 -
Shell Courses MK G~l - Lower Head Assembly -
. *1 Subjec_t_. *- *-- __ _ --
A cavity caused by a sample removal Cavities were found after hydrotest in safe ends of two MK 12 nozzles and in MK 43 nozzle Cavity in the outer surface of the shell course resulting from grinding out MT indications The gap between th~ in~ulation ring and the bottom head '?XtN!dc; the drawing tolerance Discrepant* flatness Drop of post weld teniperatur"? to all circumferential weld seams jdining shell courses prior to heat treatment Variations *in the final "as built" configurations of CRD penetrations Checklist Book Sheet No.
FS 2.4 FS 2.2 FH 3.0 FS 2.2 FH 3.0 FH 3.0 FS 2.1, 2.2, 2.3, 2.4 FH 3.0
... ~
GE Approved Status To be repaired by GE at the Dresden II Site.
Cavities wer~ weld repaired.
Accepted as is.
Accepted as fs.
Accepted as is.
UT inspected and accepted.
Engineering calculations reviewed and accepted as is.
L).
... L--
VN/CV No.
98-62 9R-62A 98-63 98-64 9P.-65 93-66 98-67 Part MK G-1-A - Vessel Assembly II II MK G Vessel Assembly B 70 - Fuel Contain-ment Skirt r1r. 1 n ;rnd r-n~ 39 -
Feedwater Nozzle and Thermal Sleeve MK 57 Lower Shell Subject Discrepant azimuths and/or heights.
of the following nozzles MK 19. 8,
- 7. 12. 13. 11, 10, 15, 14 and insulation brackets II II Monitor bores and control rod penetrations with discrepant location and verticality Discrepant configuration of the fuel containment skirt II Correction.of Engineerin~
justification The as-bui 1 t gaps l'r*t1-1nr~n t:lic four nozzles and their thermal sleev~s was found 0.006 inch instead of 0.003 maximum required ttot applicable for Pressure Vessel Inside diameter below rninirnum required.
Checklist Book Sheet No.
FS 2. 1 2.2, 2.4 II FH 3.0 FA 5.9 FA 5.9 FS 2.2 FS 2.4 GE Approved Status.
Accepted with conments.
See 98-62A.
Accepted without comnents.
Accepted as* is.
Accepted as is.
Accepted asis.
Accepted as is.
One longitudinal seam was added per Detail E Drawing 113759E-12
................:...:... _... ~....-...-.......
N rn Ul
ATTACHMENT 1 UPPER VESSEL CONTRACT VARIATION ILLUSTRATIONS
.1..
VN-98-3
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- UIJ[CT QUALITY COUTROL INSPECTION
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lllE 81\\0COCK 6 YllLCOX C'O.
SOILr.n OIVISI0~4
['l\\IW[RTfJN, 01110 CV.98-30 (Attachment 2)
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MK C-201 C'lo:.;ur*.> '.'.c:ill
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. THC BADCOCK a YllLCOX ro.
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11~;*1-:.(*i*:-1 MK /:.*-.: *1 t.Jir: f./?! ?'.Jl* l:*;J*l 1:J.-.::Uf"\\! !l1*atl l-'l*,; ;~c.
BY
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~.:/u 201-1*.;n-1 DATC 0~*.-1 **
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THE BABCOCK a WILCOX CO.
BOILER DIVISION BARBERTON. OHIO y
N01'E:
'lbe flange is divided into sei;-nents one foot wide es indicated by the nwubere 32 throueh 48.
AT1AC!n>!ENT NO.
Ger.eJ'31 Electric NED CV 98-32A (Attachment 5)
The ct:.vities in each SCtQncnt are identified by nui:1bers and the sizes E'.re shewn on Attccru11cnt :so. 5.
NOTE: ':mis sketch shows U.c bottom sartoce of the closure heed flance.
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JECT Cavities fra:. gr1r.d1r.g to reu".'VC ultr..:sc~:1c i!'".t!1co.t1c-:*s the S/N 201-198-l
- Closure ile:>.d Flbnt,:e VN &"50481 S/N 201-198-l
.IOI NO. 610-00?8-52-l ir.DRG. NO. 113"f5(J-:-l MK II ':'-~
&1M DAT£
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QUALITY CONTROL niSPECT I ON
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- 1HE BABCOCK a WILCOX CO.
BOILER DIVISION BARBERTON, OHIO NO'.l'E:
The flange is divided into seer.ients cne.foot vlde 6S indicated by the numbers 48 throuf)l 64.
4 Gei:erol Electric
!GD CV 98-32A
'(Attachment 6)
'l'hv cavities in each ee~nent are identified by nwnbers nn~
the sizes n:rc shovn on Attnclur:c11t No. 5
- MOTE:
'1his sketch shows the bottan surface of the Closure Head Flange.
CV ~8-
..,A ________
.... (....
N9t to Sct!le)
- JOI NO.
610-(Y.)9~)-52-l Cavities from crindir.g to remove ultraso,:ic. indications 1n the S/N 201-198-l Closure !tead Flar.se.
VN :50481 S/H 201-198-l IV CAN DAG. NO. ll375oi:.!-l._ II ~-]~*
- 1 i DATE Feptember !l, l~(:~~
1/2" wide Act. 5/16".r;eep.*-.
f:ectio!1 A-!.
CV #?8-34.A
{licit to fc*~l.*:l) _____ _
ST~CA 0~:-ertl :r:icctri~ n:I>
JOB HO. C:l.O-OO:-:e-52-1 DAG. No.113753-5 MK II c:.:Jl IV CAN
. I DATE October 2S,, l;-w C:i.vity caused by gri!:dinr. dye pcnetz-..r.t indicc.~io:~
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oµt ot closure ht>:.i.d tl.c.:!gc surface
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!-Julrem..ts for The MK-60 Shell.
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Ref. C..1365 1.~
lef. Para. N516 ft*..
i ACTLI'L 1-3/8" At forging I *** *ft o I
o
- 252-1/2"..Urgest Diameter 249-7 /37' Smallest t'l~eter A/32* Dlff.-.nce In Diameter 125-11/16*
Forging Radius 125-1/4" 1... Smallest. Radius of MK-60 Shell 7/16* *.... Offset.........
- , I..
- 127-1/16*
largest Radius of MK-60 S,:;11 125-11/16'9 FOrging Ratli US".
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GENERAL ELECTRIC REQUIREMENTS 3/8" with 3/ 4* In Local Areas 1.S- *I '
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IO I LUt DI Y 111 OH BAAIERTOH, OH I 0.
VN 93-6 Atiachment 9
MtASUftlNG MARkS 11K 5
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5'1-1~8-I CNEltAL CLrCTRIC
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OU~LITY CONTROL INSPECTION I THE MICOCIC I WILCOX CO.
801LER DIVISION IAR&ERTCN. OHIO VN 98-13 Attachment IO
. er.t No. 1
- VN 198-13 Genera Ele'-tric APED fitupof MK-48 Vessel Flange to MIC-60 Shell Course r--- Weld.Backing Ring 1---+-t b;'
f
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STE.E.L CLAOOt~G C\\.AOOllvC.
PE:"-lE. '"Tr:.t*;T101\\l (Not To Seale)
.IOI NO. 610-0v98-51 HG. NO. 22904F3
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ACT. 2512 1~
Y.'l l':O. 98-13
{Not to Scale)
R General Electric A!'l'~D
.IOI NO. ol~-*.).)98-51 Assembly of MK-48 Vessel Flange to MK-6o Shell Course DRG. NO. 220~F-3 MK # A-48 8Y JD DATE 5-12-67
QUALITY CONTROL INSPECTION TllE DADCOCK 6 WILCOX C'O.
801 LER DIVIS I ON BAROEr-cTON. Otll 0
..-----------------*~--------------------------------~------~----------~~---.
CV 98-26 w
l'la!1 ViC."V of ~:hell Flanr:e y
A'1*11AC!!:::*:*7 *:o. l CV :i°9S-26 General ~:'Lcctric AP-:~:
Dimensional Discrepancies on ntud Holco of l-:K-A-113 Shell Flange Aoscmbl::
x s/:; A-hS-198-1
(!:ot t.C\\ 'n 1 *~ ~
JOB J,;O.
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DRG. No.113*,*611.-:-*r MK I:.*.-!;*~
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QUALITY CONTROL INSPECTION Morr;~:
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- i *Act.13""9l~"to 13-11./ (."
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~ct. -'J'o be r.iachlnccl to I
- 1* 13-3/8" 1nj all
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tuDJCCT J>.lmcnclonnl J~lccrep:inclc:; on :tud Hole:; of J-D\\-A-lt8 ;.bell }'~~ Aesemu~:1 BARBERTON. OHIO CV 98-26 AttachmentI3
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DATC G/3/(,8 I
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QUALITY CONTROL INSPECTION Dctnil 1111 11 l>ltr.c::r.lo:ial Jilf:crcpnncico o:i '.:tnd 1'olcn nml
- C'lnclcl illG
'l'hlcknc::3 of' :,.:-1,.->18 ::hell j'lanr.c J\\o::c:nhl~'
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BOILER DIVISION BAnernTON *. OJllO CV 98-26 5 tvc.70°+ o0 -
ii* Act.69°::' 23' - 5" Variatjon :*:o. 10 S/N A-48-l~-l CV :79S-26
<< l:c11otc:; o::t Clf tolcru::c.::
a ir.ieas ion c~:ot to :~call::
SUBJECT 1:ozzlco Off r.ocnt!O'.\\ on :-:< A.. 48. ~:ell ?lan{;e. Aooembl:r