ML17272A905

Project Engineering Directive Re Replacement of Slot Welds W/Partial Penetration Welds

ML17272A905
Person / Time
Site:	Columbia
Issue date:	03/25/1980
From:	BURNS & ROE CO.
To:
Shared Package
ML17272A904	List: ML17272A903 ML17272A905 ML17272A906 ML17272A907 ML17272A908
References
215-W-1604, NUDOCS 8004070370
Download: ML17272A905 (15)

Text

CO~='ROJECT ENGINEERING DIRECTIVE

.84RNS AND ROE, INC. PROJECT 1 5 W 1604 WPPSS ENGINEERING 1 2, 3 4 5 6 7 8 9 10 12 \3 14 'IS

'NUCLEAR PROJECT D I R E CT I V E DATE 1 7 PR IOR ITY 0 9 NO. 2 INFORMATION l COPIES 16 17 18 'l9 20 21 SHEET I OF l

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S ot welds required per detail D 2038 (S782) made to top of shims and do TIot connect ring 3 (Beam type 3) and ring 4 (Beam type 2) as required. REFERENCES SUBJECT. Sac. Shiel Wa e s LOCATION El. 541'-5" All A ENG. SYSTEM - N A S/U SYST EM QUALITYC LASS ORIGINATING-DOCUMENTS'CR 2].5-5688 DESCRIPTION OF WORK:

Replace slot welds with a partial penetration weld between the upper and lover rings as'shown on attached details with FCAW process;being used for complete joint welding except for buttering that is required with SMAW E7018 All welding is to be performed per direction of Burns and Roe Welding Engineers, Addenda System and this PED which includes a vork procedure vith buttering, peening, grinding, visual inspection, KZ inspection and a sequence.

1. THIS PED REVISES DIRECTION REVISE:

PREVIOUSLY PROVIDED BY NONE DRAWINGS

2. THIS PED VOIDS DIRECTION SPEC IF ICATION P R E V IOU SLY PROVIDED B Y THE FOLLOWING APPROVALS:

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I-0Z THIS PED WORK SHOULD BE

'INEER DATE

• S I LI OTHER WORK UNDER THE FOLLOWING PED'S: LEAD DISCIPLINE ENGINEER DATE

4. THIS PED DEPENDS ON THE S/U LIAISON ENGINEER DATE PR IOR INSTALLATIONOF THE FOLLOWING PED'S'. N A RESIDENT PROJECT ENGINEER DATE REV 1 BR 803.2 80040'r0 ~3D

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REPAIR PROCEDURE FOR NCR I'/05688 AT THE 541 -5" LEVEL IN REACTOR'CONTAIh~EKNT EVESSEL

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PURPOSE The purpose of this procedure is to establish the requirements for the structural steel repair welding inside the containment. Any deviation from the requirements of this procedure will require specific approval of the Burns and Roe Welding Engineer, Deviation approvals will be granted only after examination of the problem areas and a resolution given by Burns and Roe Welding Engineer by Addendum system.

Welding sequences shall be issued as attachments to this procedure.

Any changes or additions to weld sequences or other .special instructions shall require approval by the Burns and Roe Welding Engineer.

The Quality Control Manager shall be responsible for assuring compliance with these procedures.

2) DOCUMENTATION Work packages shall be used for all structural steel work and shall be prepared in accordance with this procedure.

The Structural Steel Weld Record form shall be used for structural steel welding documentation.

Weld

'eld repairs, if required, shall be documented on the Structural Steel Repair forms.

The loss of Preheat/Interruption of'eld Sequence form shall be used to document such occurences. If cracks are discovered, an Inspection Report will also be initiated. Upon completion of the form, a copy will also be immediately given to Burns and Roe Welding Engineer on duty for approval.

Preheat recorder charts shall be identified by weld, iso., or dwg. no.,

and transmitted, upon completion of work, to the Q.A. vault.

3) MATERIAL Electrode Control shall be in accordance with the work procedure. Electrodes shall be purchased in hermetically sealed containers and shall be dried for at least one(1) hour at temperatures between 750 0 F. and 800 0 F. prior to issuance. Electrodes shall be maintained at a minimum temperature of 250 F.

after the high temperature bake until withdrawn: for use or temporary storage in portable ovens or a storage oven conveniently placed near the work area.

Electrodes. shall be removed from portable ovens one at a time and used immediately. 'lectrodes that have been or are wet shall be bent and giscarded in an a roved container. (Note: FCAW wire does not require pre-bakingr.

REr, DQQ PCN NPPSS NUCLEAR PROJECT NO. 2 BURNS AND ROE, l"C.

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4) WELDER QUALIFICATIONS Ill welders using this procedure shall be qualified to unlimited thickness and all positions in accordance with approved weld pro-cedures and AMS Dl.1.

Welders qualified by groove welds on 8" sched. 120-pipe or larger and on plates 1" or oyer are qualified for all 'thicknesses of s.ruc-trual steel

5) PROCiDURE PREHEAT PROCEDURE AND REQUIREMENTS The ollowing material shall be on hand p'rior to preheat and weldint operations:

a) Heating torches d) Clips for holding coils, b) E ating coils or blankets . blankets, etc., in place.

c) Heat retaining blankets e). Temperature control and re-cording equipment.

6) 'ORCH HEATING

1) Torches may be used for applications involving arc-air gouging, attaching strongbacks, heater blanket clips> tacking, backing b rs, and minOr repairS. Preheat shall be 200 F.+,25 F. ~ith a 15 minute soak time.

2) Heating torches may be used to locally preheat the structure anC weld site in the areas to be tack welded.

3) Heating torches shall be used with a neutral flame.

0 4', h'hen preheat is obtained through torch heating .for other than temporary tack welds, g.C. shall frequently monitor the site both prior to and 'during welding to assure that minimum preheat and

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maximum interpass temperature requirements are main.ained.

SPPSS NUCLEAR PROJECT NQ. 2 SURES PHD RO=-, i.:=.

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RESISTANCE HEATING

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All areas to be preheated, except those specifically exefIIpted by the Burns and Roe Welding Engineer, .hall be preheated using elec.ric heating elements. Tno precise locations of the heaters wlfl; be, designated by the preheating i.cntractor's welding engineer..

Strip chart records of weld joint preheat and cool down are required.

Only magnetic holders shall be used to hold heaters and blankets to the Sacrificial Wall and to structures on the 541'evel.

The preheat and maximum interpass temperature shall be held from the center line of the joint outward 4o, at least,3,".,on each side of the joint. t1ore than 3" from the joint the temperature-~ange may be less thai! the minimum specified but shall not be more than the Nayimum specified. Thermocouples shall be located no more than 3" from the weld center line and their placementrequires approval by the Burns and Roe Welding Engineers.

Inspectors shall check preheat wi .h a '.contact pyrometer at fit-up before allowing welding to begin. During .welding, inspection shall monito~ minimum preheat and maximum interpass temperatures in the joint using a contact pyrometer.

After reaching preheat temperature, .soak the joint at temperature for I., hours before beginning welding. Maintain the temperature range'until all welding has been completed and then soak for another three (3) hours bef'are starting cool-down.

Heat retaining blankets shall be ised as necessary to control cool-rate. The cool-down rate shall not exceed 50 F. per hour. Blankets 'own may be removed when ambient temperature has been reached.

The heat retaining blankets, which must be maintained throughcut preheat, all welding inspection, and cool-down, may be adjusted to per-mit welding. For instance, a heater and blanket may be placed directly over the joint for preheat and soak, then removed during welding, When the preheat drops below the specified minimum, a Loss of Pre-heat form shall be prepared. The temperature shall be restored as soon as possible after the low temperature is detected.

8) 'EI1PERATURE REgUIREfiiENTS lhe preheat requir ment for local torch heating or attaching strongbacks, heater blanket clips, backing bars, and for tacking shall

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I be: 150 F. to 200oF. for at le'ast 2" in each direction from the weld site, with a 15 minute soak ume at temperature prior to beginning work.

Welders and/or operators shall be provided temperature indicatina crayons or contact pyrometers to assure that pr'cheat requirettents are being met.

MAXIMUM

• 'INTERPASS

9) PREHEAT 'EMPERATURE Welds to'acrificial Mall and within 24" of the Sacrificial Shield Wall.

Shield 200- 25 F"'50 F.

The minimum preheat and maximum interpass temperature for all weldina shall be as noted above.

10) FIT-UP AND TACKING The joint gap for structural and partial penetration welds shall not exceed 3/16" for material thicknesses less than 3". The joint gap shall not exceed 5/16" for material thicknesses 3" and above.

Such-joints shall incorporate adequate backina against which to weld.

The root opening for single bevel grooves against backing bars shall be as follows.

1/4" min. to 9/16" max. backing bar removed. after weld ng.

., 3/8" min. to 9/16" max. backing bar left on.

Tack welds shall be subject to the same quality requirements as the finai welds except that discontinuities such as undercut and unfilled craters need not be removed before the final arc weld.

Preheat is mandatory for single pass tack welds which are remelted and incorporated into continuous arc welds (final welds).

Tack welds must be large enough to prevent shifting or cracking during subsequent welding. They mvst be clean, contain no cracks, lack of fusion,:or slag and should be desioned to become part o the final weld.

Tack welds which are incorporated into the final welds shall be made with electrodes meEting the requirements of the final welds and shall horouahlv.

NPPSS NUCLEAR PROJECT NO. 2 BURNS AND ROE, I C.

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li) All we ding sna'll b perfo=ed using approved weldi g procedure according to A>>S Dl.l znc Spec'.cetic".. Sectio.. 2808-215-17D. A stringer bead technique sh-'1 be used to the greatest ex-ent poss ble. In any 'case, tne width o=

bead shall no" exceed three (3) core diame-ers of~ the electrode (except

=o" cua'h'e'd ='ux cored wire which shall not exceed 3/8" in width.

he minim m si e of a root pass shal'e sufficient to. prevent cracking and the maximum tnicMess o'ayers subseouen- to root pass shall be 1/8" fo welds made in the flat position and 3/16" for welds made in any other position.

Bach weld pass of deposited weld metal shill be thoroughly cleaned using slaggirg picks, "'re brushes, or by grin ing.

Any cracks, blow holes, or other de ects that appear on the surface of weld beads shall be removed by ch'pping o" grinding befo"e the next covering weld bead is deposited.

All weld beads, except those in the root and final layers, shall be peened immediately after removal o" slag. However, any visible defects such as porosity, cracks, or slag pockets must be removed by grinding prior to peening. Peening shall be aone using an air nammer with a round nose tool of a minimum diameter of one quarter inch 4>"). Peening shall be done in a stra'ght and continuous line. Care shall be exercised to prevent scaling o" flaking of weld base metal from over-peening. Peening shall be used in all cases, except where spec'fically prohibited bv a note on the weld sequence sheet. Air operated "needle" slagging guns shall not be used for peening purposes. Peen per shetch attached.

No downhill welding will be permitted, Heat input range shall not exceed the following:

35k j%in. heat input shall be maximum for welding.

Buttering may be done horizontally, vertically (up); or any combination of the two. Requirements fo" buttering, <<f any, are shown on weld sequence sheet. Buttering does not require peening.

All groove welds and all fillet welds against the Sac. Mall require that the Sac. 4'all be but"ered, anc the I.D. of all weld joints shall be buttered prior to welding.

VCPPSS NUCLE'R PROJ"C NG. 2 BURHS AHO RO=, t,",~.

effo - should be made to provide, continuous~lding until the

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'sve.yoompleee. As auimum, foe base mais".ial shitless up ahoouph 2Q",

jo nt 3/4 th oat thickness snail be ob" ainec without an interruption. Por ma=e" 21 thicke" than 2~", 1>" hroat th'ckness 'should be completed without interruptions. "Interruptions" shall be,de ined as welding which ms discontinec -.cr more =nan 1

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'nail oe recordec. Any veld whicn is ciscontinued fo".i more than nou"

=. s- be dis"os.'ne and app oved b'he Burns 'an lhoe Welding "=n" neer.

Any weld whicn exceeds the 2 hour2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> interruption limit"shall requ're oocumentation on an IR/NCR i deemed necessary by the Burns and Roe Welding Engineer. Por all interruptions, the following action shall be take-..:

1) The last weld layer shall be peened before the weld 's le=t.

2) The weld shall be covered with insulation, blankets and the required preheat maintained. Q.C. snail sverify this.

3) The weld shall be visual inspected prior to resuming veldmng, The visual inspection report noting the interruption snal'e included in tne work package. If a crack-is, discovered, an IR shall be prepared.

Each weld shall f

4) be peened and inspected, per attached sketch.

12) INSPECTION Prior to any welding, the area to be welded shall be visual inspected in aCCOrdanCe with AWS Dleli and after any arC-gOuging, Cutting Or grinding.

All velding shall be HT inspected at 100K completion at preheat temperature.

All welding shall be MT inspected 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> after cool down, When the- finished weld will be inaccessible for the 72 hour8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> magnetic particle inspection because another weld or member vill h'eve covered it,

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.. acceptance vill be based on a hot MT made when the veld is complete and visual and 72 hour8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> HT of any remaining exposed areas. This exception is only allowed vhen it eliminates heat cycling a weld zone, and it shall be approved by the Burns & Roe Welding Engineers.

B & R Welding Engineer shall evaluate all rejectable indications revealed by visual or EZ inspection prior to any rework.

13) REPAIR SEQUENCE Remove the indication revealed by visual inspection to sound metal beyond each end of the discontinuity by grinding or chipping. If the defect extends one half..incn (4") arc-gouging may be used. The required preheat sga11 be specified. Arc-gouging is to be used sparingly to minimize the possibility of crack propagation.

Excavation snail be reinspected to assure that the defect has been removed.

Reweld excavated area following appropriate paragraphs in this procedure.

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1) After root passes have been applied all remaining passes'shall be peened. *

2) M.P.T. final weld at preheat temp. and 72 hrs. after complete cool down.

• Except cover pass.

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TYPIC.AL. PHABE 4/WERE LED E IB A MlklI4lLIVOF k" NIIDE 4 II VJELD DEF Q&l T-

1) After root passes have been applied all remaining passes shall be peened. *

2) M.P.T. final weld at preheat temp. and 72 hrs. after complete cool down.

• Except cover pass.

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NOTES: -.A) 4'-IL" cascade area's shal'e made first, to assure that "here is no movement to the wall, also to establish the stability for the remaini g welding.

B) All remain"ng welding may be completed in a different sequence i= so d'esignated by B 6 R Welding Engineer.

1) Pour (4) welders to weld simultaneously througnout sequence.

2) Pirst sequence to start zt AZ; 7 -30'.

3) Second sequence to start at AZ 191 -30'.

4) Third sequence to start at AZ. 1o3 -30 ~

5) Ho welder shall proceed ahead of any other welder in a sequence.

6) Each sequence number consists of approximately 11",

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