ML19320B441
| ML19320B441 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 06/19/1980 |
| From: | Schnell D UNION ELECTRIC CO. |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| ULNRC-361, NUDOCS 8007100379 | |
| Download: ML19320B441 (40) | |
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b U N IO N EttcTRic COMPANY iso. caavio, stac ci - sv. Louis y June 19, 1980 ,,, ,, , _ , , , F G F9 ", a a49 s1 Love *2. u t. 63 66 Mr. James G. Keppler, Director THis DOCUMENT CONTAINS Region III POOR QUALITY PAGES Office of Inspection & Enforcement U. S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137 ULNRC 361
Dear Mr. Keppler:
NRC QUESTIONS ON UE EMBED REPORT ADDITIONAL INFORMATION CALLAWAY PLANT In response to requests by NRC Region III representatives at a meeting at your offices on May 29, 1980 for additional input on the subject report we are submitting herewith one copy of the following information.
- 1. BLUE-700, dated June 12, 1980, including all attachments.
- 2. Daniel International Corp. Telecon Record Sheet, dated May 29, 1980, Acceptance Criteria Used for Inspection of Undercut Welds, including attachments.
- 3. Daniel International Corp. Quality Control Procedure QCP-507, Rev. 5, Inspection of Structural and Misc.
Safety Related Welding. In reference to our investigation to determine the exact number of embeds involved in the subject report, we are in the process of determining this count and expect to be completed in the first part of July. Very truly yours, t .' I
- q. . k , ,
W& DonaldF{.Schnell Manager - Nuclear Engineering DBS/sla cc: E. Gallagher w/a i l hbC b"M (, AN 2 31980 pa Ig, souv.NG PRoeLEMS THROUGH INVENTION & INNOVATION 8oo71 oo37c
Bechtel Power Corporation
- Engineers-Constructors 15740 Shady Grove Road Gaithersburg, Maryland 20760 301-258 3000
. D. F. Schnell Manager - Nuclear Engineering Union Electric Company Post Office Box 149 JUN 121980 St. Louis, Missouri 63166 BLUE- 7 0 0 File : 0499.4/C-131 Bechtel Job Number 10884-001 SNUPPS Project Investigation of Welded Studs -
Additional Information Ref: 1. ULNRC 238 dated 3/10/78
- 2. ULNRC 349 dated 4/24/80
- 3. ULNRC 354 dated 5/23/80
- 4. AIF Program Report on Reactor Licensing and Safety, Vol. 2, No. 1, May, 1975 Enc 1: A. Cives Steel Company Letter SL:367 dated June 10, 1980 B. Bechtel Surveillance Inspection Reports for Assignment 10466-C-131 Report Nos. 2, 3, 7, and 45 C. Sample Calculation for Manually Welded Plate Assemblies (EP 312)
D. Sample Calculation for Machine Welded Plate Assemblies (EP 512) - Reduced Capacity Due to a Postulated Inef fective Stud E. DIC Memo -
Subject:
UE Inquiries - Stud Welding
Dear Mr. Schnell:
This letter provides additional input requested by NRC Region III representatives at a meeting in their office on May 29, 1960. Specifically, this information includes:
- 1. Documentation of the fabricator's stud welding practices for (
machine velded embed plates prior to June 9,1977. RECEIVED Jur,'j9197; D.F.SCHNELL 1 1 l l
Bechtel Power Corporation i Mr. D. F. Schnell 2 2 A sample calculation, including discussion of approach, for , establishing the reduced capacity of machine welded plates due to a postulated loss of one weld stud. Embed Plate EP 512A is used as a basis for this discussion.
- 3. A sample calculation, including discussion of approach, to determine the reduced capacity of manually welded embed plates (specifically embed plate EP 312) resulting from a postulated 1/16 and 1/8 inch undersize weld, as well as the analytical basis for accepting a 1/16 inch undercut on the shank of the anchor rod.
The following additional information is also offered as an aid to the NRC personnel in their evaluation of the welded studs: 4 The effect of a maximum 1/32 inch undercut on the shank of manually welded machine weld studs. S. A discussion of the logic employed in the probability analysis for machine welded studs. Item I In response to Item 1 above, the practice employed by the machine welded embed plate supplier for installation and inspection of machine welded i studs prior to June 9, 1977 is su=marized in Enclosure A. Enclosure B f provides examples of Bechtel inspection reports which indicate the I review of welded studs (and stud bending) by the Bechtel inspector during the period in question. Items 2 and 3 Sample calculations for the embed plates discussed in Items 2 and 3 above are included in Enclosures D and C respectively. Item 4 Although the vast majority of machine welded studs are installed auto-matically with special " guns" under controlled conditions, there are a limited number of occasions where the studs may have either bedh
, installed or repaired by manual fillet welding. As indicated by field personnel in Enclosure E, such field welding was on a very limited basis. UE has indicated that the field practice in inspecting these limited number of studs for undercut was to use a 1/32 inch acceptance criterion on the shank of the stud in lieu of the more restrictive requirements of .01 inches as cpecified in AWS D1.1-75 Para. 3.6.4 The result is that some reduction in the safety margins could occur on these isolated studs. However, in the unlikely case i
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Bechtel Power Corporation 4 Mr. D. F. Schnell 3 that a maximam 1/32 inch undercut is postulated to extend around the entire perimeter of a stud, the revised stud capacity, as computed using the udnimum specified yield strength, still would exceed the design requirements. Design drawings have been revised to clarify the design intent. Item 5 The probability analysis for plates with machine welded studs presented in Reference 1 was prepared to evaluate the potential for failure of plates installed in concrete prior to the reinspection effort. In order to estsblish this probability the analysis accounts for several f actors; the probability of a stud being ineffective (P1 ), the probability of a plate (which is assumed to have an ineffective stud) supporting a safety related attachment (P2 ), the probability of a load on a plate being of sufficient magnitude and at a location 7. ~ ative to an assumed failed stud to exceed the failure capacity of cne plate (P3 ) and the probability of the plate to ever experience the attachment design load (P4). None of these factors in itself is representative of plate failure. Rather the resultant probability against a single plate failure is the product of these factors, or: P = [(Pg
- P2
- P'n3 . P"3
- P'"3
- P4)
The factor (P1 ) is established from the reinspection data of 81,673 studs which were installed and shop inspected in the same manner as those studs on the plates in question. One could express the results of this reinspection in terms of a " Confidence Level" in a fashion sbnilar to that employed by the NRC in IE Bulletin 79-02. This bulletin requires licensees to review concrete expansion anchors which serve essentially the same function as the embed plates in question. The acceptance criterion established in this bulletin was to have a 95% confidence level that less than 5% defects exist. Using the formu-lations included in the bulletin (which are based on a 95% confidence level) and the reinspection results, less than 0.1% defects are identified. Many of the plates support attachments which are not safety related. Although these plates share an equal probability of having ineffective studs there is no safety consequence. Plates retrieved from the laydown area prior to June 9, 1977 would have been taken from the same stock whether used for a safety related or non-safety related function. The factor (P2) accounts for those plates which have safety related attachments. The factor (P3) addresses the effect the attachment load and its location have on a given plate, assuming the plate has an ineffective stud on or adjacent to the attachment location. Actual loads resulting from the attachment for each plate were determined. In order to include the possibility that the attachment may be at any location on the plate, the load was applied in each of 9 zones shown in Sketch la of the report (Reference 1). It is assumed the load has an equal possibility ' of being in any one of nine zones, hence P"3 = 1/9. This is a conserva-tive assumption in that the load will normally be applied in the center
r-h Bechtel Power Corporation 4 Mr. D. F. Schnell of the plate. In f act a drawing revision since the report was prepared requires that the centroid of the attaching weld be within the middle third of the plate. These applied loads were compared to the f ailure load in each zone of each plate assuming the stud La zone I to be ineffective. If the actual load exceeded the failure load a postu-lated failure was identified. The failure load is identified for each of these zones if any of the stresses reach the minirnm specified yield stress. For computational purposes the ineffective stud was A finite number of postulated failures assumed to occur in zone I. were identified for zones I, II, III and VI as shown in the report (P'3).
- Since the ineffective stud has an equal chance of occurring in any one of the four studs within a cluster the chance of it being in zone I is one in four. Conversely, zones IV, VII and IX have as equal chance a2 zone I of having the load applied over a postulated ineffective stud. Combining the random possibility of an ineffective stud at a given corner with the possibility that one of four corner zones could have a load over a postulated ineffective stud yields a f actor of 1/4 X 4/1 = 1 (P'"3). A similar argument holds for loads applied in other zones. Since a one in nine chance was assumed for the load to be applied in a given zone, it is necessary to sum the result for all nine zones. In f act, since no potential f ailures were identified for zones IV, V, VII, VIII and IX (P"n3 = 0) the actual summation indicates only theincludes proba-only zones I, II, III and VI. Note that P3 bility of a plate failure for a postulated ineffective stud adjacent to the load point whichis a safety related attachment with the computed attachment load applied.
in itself is meaningless for it is computed on the The factor P3 premise that every attachment is on or adjacent to an ineffective stud. Furthermore, it is based on applying each attachment load Realizing in each of the nine zones to deliberately seek postulated failures. that plates with safety related attachments have a combined total of approximately 2,500 studs, the reinspection results would suggest that Of course only approximately two studs could be postulated to fail. thesc two studs may be located in areas of the plate not affected by the attachment loads. The point is that one cannot isolate one f actor Rather, the independent of others in the probability analysis. probability of a plate failure must consider all f actors in concert. An equally important considerationAs is one the possibility of the plate example, a sigaificant ever experiencing the design load. contribution to the loads bnposed on the plate is dce to the seismic event. Dr. Newmark, in Reference 4 suggests that La combining the safety margins used to identify the seismic event and the multipli-cation of margins of safety resulting from the criteria and analytical methods imposed, a probability that the structure will ever experience the design loads may be in the order of 10-8 A probability of 10-4 was conservatively assumed in the report for this consideration. 9
- Bechtel Power Corporation 2 Mr. D. F. Schnell 5 In summary the probability of a plate f ailure is the product of the probability of having an ineffective stud, the probability of the plate with an assumed ineffective stud supporting a safety related load, the probability of that load exceeding the plate capacity due to an assumed adjacent ineffective stud, and the probability of the attachment load actually occurring.
As provided in Reference 1, a total of 10 plates had multiple stud failures. Multiple stud failures on a given plate have no additional effect on the probability analysis unless they cccur on adjacent studs. Four occurrences of adjacent stud failures can be identified from the data. No case exists where more than two studs f ailed within a stud cluster (the basis for design being a four stud cluster). An analysis has not been conducted to evaluate the probability effect if a two adjacent stud failure were considered. Based on some simple comparisons we believe it is evident that this consideration will not substantially affect the results. The probability computation for a two stud failure is similar to that given above for a single stud f ailure, except that rather than considering the probability of a failed stud to the total number of studs inspected (P1) one must compare it to the total number of stud clusters available. Based on a total of 81,673 studs, at least 81,673/4 = 20,418 stud clusters exist. Actually there are somewhat more than this number of stud clusters available since plates with more than 4 studs have studs that can be in more than one stud cluster. However, a similar equal increase in the number of cluster possibilities for the pair of ineffective studs also exists so that the effect is essentially self-cancelling. The result is that P1 becomes 4 = 1 or less than 1/4 the value 20,418 5,104 for the single stud failure. An increase in the probability of P3 will occur. Although the calcu-lations have not been generated to establish magnitude of this increase firmly we believe it to be in the neighborhood of a f actor of 2 to 4. All other factors remain essentially the same as for a one stud failure. The net result is that the probability for plate failure due to a postulated multiple stud f ailure is of the same magnitude (exponent wise) as for a one stud failure i.e., the increase in P3 is approximately offset by the decrease in P l. Since the probability for a one stud failure and a two stud f ailure are additive, the overall probability may at worst double. However the order of magnitude (exponent wise) remains essentially the same as presented in Reference 1. Ve truly yours, l J. h. EWT:bg Project ginee og Manager cc: N. A. Petrick 1
ENCIASURE A TO BLUE 700 8 CHURCH STREET, GOtJVERNEUR, NEC YORK 13642 (315) 287 2200 TWX: 510-257-6951
'- c-
) 1 hk$hh iM DVEJOn June 10, 1980 SL: 367 Bechtel Power Corporation P.O. Box 607 Gaithersburg,?ID 20760 .
Attention: Mr. Paul Divj ak
Reference:
SNUPPS Proj ect 10466-C-131 Miscellaneous Metals Gentlemen: In regard to Purchase Order Item No. 2 embedded plates with concrete anchors, we hereby verify that Cives intent since the beginninE of the production of these plates has been to obtain a 360' fillet on the machine welded studs. If the applied stud did not have 360*, the stud was either a) bend tested per AWS 4.30.1, or b) repaired per AWS 4. 29. 3, or c) replaced. Very truly yours, CIVES STEEL C0ffPANY Northern Dixision L - / s _ Ted Totten Project Manager TT:sw CC: Dean W. Parshley
E ~ WM ( 't SURVElLLANCE INSPECTION CEPORT
- SPl.221 nEPO'.T NO. 2 "O" List
.,,3,E CTiON ASSiGNvE NT NO.
10466-C-131 2 DATESINSPECTsON 6 cm M/R 10466-C-131(0) RE v. PE m p ORutD Dec. 30, 1975
,,,.g oN onog R Miscellaneous Steel PAGE 1 or 2 Cives Corporation
,,,wg sunter m mE F . N O. None _
suaPtin g Same 5900 s.O. N O. _ LOCATsON Couverneur. NY .
- 1. SUPPLY m CONTACTS TITLE l NawE Mr. Dean Parshley Project Manager Mr. Alex Teed Q. A. Manager
- 2. STATUS 08 SUPPLIE A DR AWING
S. PROCEDURE
S AND DATA SMEE75 THAT RE - OURING THis REPORT PERIOO Paint procedure - level 3; drawings and weld procedures - level 1. .
- 3. MA11Re AL RELE ASE D F OR SHIPMENT DURING THIS REPORT PE RIOD Wrne.
- o. STATUS 05 PREVIOUSLv REPORTED UNCORRECTED NONCONFORM ANCES N/A.
- 5. DESCRIPTION Of UNCORRECTED NONCONFORM ANCES DtSCOVERED DURING THis REPOR N/A.
O DR AWiNGS AND SPE CIFICATIONS USED FOR INSPECTION PURPOSES REV. R E V_. SPECIFICATION NO. D7a*.1NG NO 10466-C-131(Q) 4 2 A 75-243 0 - Weld Procedure A 75-244 0 - Weld Procedure 102 CZ-11-1 1 - P-int Precedure
- 7. SUMM ARY OF WITNESS POINTS. HOLO POINTS AND OTHER INSPECTIONS PERFORM Visited the supplier's plant for two witness points established during the initial visit as follow :
- 1. Fit-up and welding on a first time basis for each veld process.
a) Shielded metal are veld of anchor bolts to plates to dwg. #2 Rev. A, tack welding procedure 75-244, fillet welding to procedure 75-243 unrevised. Results Qualification records for the velding, C. Patchin, are in order.
- of inspection were satisfactory for workmanship and dimensions.
Nelson studs were welded to plates in accordance with AWS D1.1-75 and Thedws, layout b)' (102 Rev. A. Twelve studs were welded to each of Che two plates. One. stud on each , was dimensionally checked and found to be satisfactory. around the perimeter. Both plate did not have a fillet extending quite 360o parted from the plate when bent with a ham:ner in accordance with the AWS requirement. Several of the visually satisfactory welds were tested in the Continued DISTRIBUTION j Original to: E. J. Simanek PREPARED eY Manrv E 'M" aa j Copies to: J. L. Turdera S. J. Seiket. * * ' R. E. Merriman N. A. Petrick l T. J. Clark R. D. Chappell 1/1475 l nEviEWED ev (DATEI SJECT INSPECTION SUPE RVISORi l l . , _ . .
i Eh:10 sura B to BLUE 700 I.. She2t 2 cf 7
~
Contmuotion Sheet REPORT NO. 2Q 10466-C-131 Pog, 2 .4 2 thSPECTIO:: ASSIC!:Y.I::7 ::O.
- 7. SnetARY OF k'IT::ESS POI::TS , !!OLD POINTS AND OTilER INSPECTIONS PERFORMED DURING TitIS REPORT PERIOD.
same manner with satisfactory results. This machine type welding is done without filler metal.
- 2. Surface preparation and coating on a first time basis each procedure. Three plates were prime painted in accordance with the supplier's procedure SCP-CZ-11-1 Rev. 1 and Bechtel Specification A-122 Rev. 3. Surface prepacation was checked
- by comparative means through use of the approved blast sample and Keane-Tator profile comparator disc. The satisfactory profile was then solvent cleaned and dried before painting, after it was blown with compressed air and vacuum cleaned.
The paint was mixed as required and agitated continuously during application. Paint was skillfully applied by P. Irish. Pains were taken to spray as little Wet film thickness was gaged paint as possible on plate edges and inside holes. at 6 to 7 mils. Dry film thickness could not be checked during this visit. Paint storage conditions are excellent. A separate building, with overhead heat ir provided. Temperature is controlled and charted. O O
m y.7 m g - g Sheat 3 of 7 ,,d
- SU7NEILLANCE INSPECTION CEPORT SPI 221 3 "O" List
," " eNSPt CTiON ASSIGNMENT NO. 10466-C-131 mEPoRT NO.
10466-C-131 -1 thru -5 Rev. O DATt% INSPE CTiON p o. NO. Miscellaneous Steel , PE Rr oRME D Jnn. 14-16. 1976 uAt t oN oaoE a ,A GE 1 os 7 Cives Corpora tion PRIME 5U* PLIER mE F . NC. None Same
$URPLIE R s.O. N O. 5900 gocAT3oN Gouverneur. NY
- g. SUPPLIER CONTACTS Naut MTLE Mr. Dean Parshley Project Manager Mr. Alex Teed Q. A. Manager Mr. John Jones Project Coordinator
- 2. STATUS 08 SUPPLit R OR AWiNGS, PROCEDURES, AND DATA SHEET 5 THAT REOUIRE SECHTEL ENGINSERING . APPR DURING THIS REPORT PERIOD Approved level 1.
Item I embedments: mark #EP211 (1 pc) 1 ' MATE RI AL RE LE ASE D FOR 5HiPMENT DURING THIS REPORT PE RIOo: 20" x 3'-8", EP611 (8 pes) 14" x 2'-6", EP711 (15 pcs) 14" x 2'-3", EP611 (20 pcs) Item 2 embedments, mark #EPS12A (10) 12" x l'-0", EPS12B (80) 12" x 2'-0", 14" x 18". EPS12C (50) 12" x 3'-0", EPS12D (60) 12" x 4'-0", EPS12E (40) 12" x 5'-0".
- d. STATUS OF PREvlOUSLY REPORTED UNCORRECTED NONCONFORMANCES N/A.
S. DESCRIPT80N OF UNCORRECTED NONCONFORM ANCES DISCOVERED DURING THis REPORT PERIOD N/A. 6 DR AWINGS AND SPE CIFICATIONS USED FOR INSPECTION PURPOSES REV SPECIF#CATeoN NO RE v. OR AW'NG NO 2, 3, 4, A 10466-C-131(Q) 4 75-243 0 weld procedure 102, 103, 104 A 75-244 0 weld procedure CZ-11-1 1 paint procedure
- 7. SUMM ARY OF wtTNESS POINT 5. HOLE "OiNT5 AND OTHER INSPECTIONS PERFORMED DURING THIS REPORT P Visited supplier's plant on Jan.14 for progressive inspection on embedments as follows:
- 1. Checked heat number record. No heat numbers stamping required on plates.
- 2. Verified that Nelson type studs welding was being checked by stud bending per requirements of AWS code.
- 3. Checked weld materials storage and control - satisfactory.
- 4. Performed random dimensional inspection as needed to assure conformance.
- 5. Witnessed surface preparation and painting with carbr, zinc #11 to approved procedure. This included the verification of satisfactory atmospheric -
conditions.
- 6. Requested t'.at nuts on threaded studs be drawn up tight to prevent loss due to vibration during transit. Mr. Parshley agreed to make them " finger '
tight" for first shipment and await results. - Returned to supplier's plant on Jan.16 for final inspection of material readied .for gitialshipment. Mr. Rav Chappell of Bechtel Project Inspection, and Mr. Wm. Baldwin DISIRIBUIl0N Original to: E. J. Simanek Henry E. Oufnn Copies to: J. L. Ibrdera S. J. Seiken PREPAREDav "' " * "' R. E. Merriman N. A. Petrick W. H. Rapp 2/3/76 R* D. Chappell naviEWE D ev loATEl , tP R OJF rY N?PE C fiON SUPE RvisoRI
I Encicsura B to BLUE 700 o, k Sh20t 4 of 7 Conemuotion Sheet REPORT No. 3 ana It,sPICTIO: 2SSIC .?I::7 ::0. 10466-C.131 p.g, 2 .# 2
- 7. StW1ARY OF WIT::ESS PO!!;TS. !!OLD POINTS AND smlER INSPECTIONS PERFORMED DURING T1115 REPORT PERIOD. .
ef SNUPPS Staf f were on hand as observers / advisors. Witnessed additional surface preparation and painting to approved procedure. Wet film thickness attained was 7 mils, dry film 3 mils. Performed more dimensional cod visual inspection as necessary to assure conformance. Embedments were metal b:nded together in pairs, back to back, with wooden spacers as an excellent means , of protecting painted surfaces on the supplier's own initiative. Truck loading w s witnessed and counts verified. Satisfactorily completed inspection and review of documentation for embedded plates with studs as identified in Section #3 of this report. The material was released for shipment without any exceptions to the procurement dscuments. The jobsite is notified of this release for shipment by the completed form G-321-D, which will accompany shipment. No TWX relee" is required for this order. e um
Sheet 5 of 7
,e ". b URVEILLANCE S
INSSECTION REPORT . 598 221 REPORT NO. 7 -l# gN$'iCTION ASSIGNMENT NO. /Udd "C"/ 3 / ~ 1 DATE3 INSPECTION REV: / /3 / 97d. P.U.C'3. /o d/4 6 - C- /3 / " A PE R FORME D APA o L-WATL ON ORDE R ,01/3C
- STdl L. / _OF d.-
PAGE pn:ME SUPPLIER C l'/d5 C#M* REF.IWD._ A O d d / OME 5.0.MC._890f SUPPLIE A LOCATlDN 6 08' V6#fM6#4- -
- 1. SUPPLIE R CONTACTS NAME T87tf MA OUY lAAStW4 Y'-- /s4DS"ECY W/.s.
M/. A t aE'X TcED - t? A s+164 2, STATUS OF SUPPLIER DR AWINGS, PROCEDURES, AND DATA SHEETS THAT REQUIRE BECHTEL ENG DURING THIS REPORT PE RIOD AU.- Dt1.ss.)> )q) A/pste/cp ltvtL. ,) ,
- 3. C'ATERI AL RELE ASED FOR SHIPMENT DURING THIS REPORT PERIOD
+/OdC
- 4. STATUS OF PREVIOUSLY REPORTED UNCORRECTED NONCONFORMANCES U4 S. DEECRIPTION OF UNCORRECTED NONCONFORMANCES DISCOVERED DURING THIS REPORTPERIOD ff166DDED At'OC. / WCS COMPLETCO BUT" RE7CC7ED Br'SJo/L.ict fo<. PtomcA'. c.'c.CS,*tA9oy od EDGCS AHo 8Acn 3iDc3- To 8c- Cc.'Ltac7E0 s 8,Y .54~D Bt AST;-AvA K J B e dr- fe, A c oLsc 80y /fAS Sc"WrCM s'JEL3caJ 3rt'b.s s./ELDED By SA4 AW fAsCC Cr- ALA Bux.zAw Vs.su4LLy'.sATisr=ac 4 DR c/E Fos'< FALMU AWiNGS AM ormstwo AND SPECIFIC Fe~. dim ATIONS USEcusioJALL D F OR INSPECTION PURPOSES gjeggo g/j g f7 g,7
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- 7.
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- R. E. Merriman
- l W. H. Rapp V T. I. Gillespie PREPARED BY ,
j N. A. Petrick
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,s , .tSURVEILLANCE INSPECTION REPORT Shf 2t 7 cf 7 BPI221 REPORT NO. W b'L'IP lNSPELTION ASSIGNMENT ."1 NO. /# N ~ C ~ #3 /' DATES INSPECTION p,p, ca. _ /o V4 6 - C - / .3 / REV-_ 9 PE RFORME D Fid /0 s /f77 l MAT *L ON ORDE R MrSC. STcCc-- / _O F /
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- 1. SUPPLIER CONTACTS NAME DTLE
- f. , /% " ZdT~e. set - j'A.D.T. /J Cl*,
- 2. STATUS OF SUPPLIER DRAWINGS, PROCEDURES, AND DATASHEETS THAT REQUIRE BECHTELENGINEERING APPROVAL US DURING THIS REPORT PERIOD sat#fttd* VE.O CODC / ,
l
- 3. MATE RI AL MELE.*. SED FOR SHIPMENT DURING THIS REPORT PERIOD MedE
- 4. STATUS OF PREVIOUSLY REPORTED UNCORRECTEDF NONCONFORM ANCES
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itne esas couer-mo na se,s.sizean. , S. DESCT.lPTION OF UNCORRECTED NONCONFORMANCES DISCOVERED DURING THIS REPORT PERIOD
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- 6. DRAWINGS AND SPECIFICATIONS USED FOR INSPECTION PURPOSES p,R AWtNG NO. REV. SPECIFICATION NO. R E V_.
- 7. SUMM ARY OF WITNESS POINTS, HOLD POINTS AND OTHER INSPECTIONS PERFORMED DURING THIS REPORT PE RIOD o s . Er a o
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, ENCLOSURE C TO BLUE W
. SAMPLE CA14ULATION FdR MANUALLY WELDED PLATE ASSEMBLIES (EP 312)
The subject plate assembly consists of two face plates connected by anchor The assembly detail was obtained
, rods and its rated capacity is 175 kips.
by attaching another face plate to an embedded plate capable of the rated capacity - specifically an EP 311. This approach is very conservative be-cause of the following: a) Rated load is based on the total load applied to both faces s ina21tane ously. On this basis, the actual capacity is twice its rating. b) The bolt gross area rather than the net tensile area is available (no threads to contend with although, as shown below, the bolts can support a 1/16 undercut). Because of the methodology used in the selection of the plate in question, the design procedures used for the one faced plate will be addressed. (i) Design of Y1 ate EP 311: The rated capacity of 150 kips for plate EP 311 was computed using the shear-friction provisions of ACI 318-71, Section 11.15. An eccentrici.ty of 4" was assumed for design purposes to account for secondary bending effects of the attachment clip angles. Design of the bolts is based on a modified version of formula 11-30 (AC1 318-71), l J A = Vu .e + Vu = Total area of steel
$Fy. d $ Fy p required I
Where: Vu = ultimate load capacity = 1.6 the rated capacity e = Assumed eccentricty d = depth of the connected beam member
= 30 inches for this plate All other terms are as defined in ACI. ,
)
A = 1.6(150)(4) + 1.6(150) ST 0.F' (36) (0.7) 0.9(36)(30) e 2
= 0.99 + 11.2 = 12.hi in
~
ENCLOSURE C TO BLUE 85@ - - 15 - It" $ bolts are used, therefore; 2 Area of steel provided: A Gross = 15 X 1.23 = 18.45 in A Tensile = 15 X 0.97 = 14.55 in
' The ultimate bolt capacity is T = A Tensile XFy = 0.97 X 36 = 34.9 kips Weld size required to develop bolt capacity:
W= T Where w = weld size d d = diameter of bolt Fs = factored allowable veld s tress = (.707)(21.0)1.6 = 23.76 KSI W= 34.9 = .374" = 3/8" 13? X 1.25 X 23.76 Weld size used is 1/2" > 3/8" (ii) Wcld undersized 1/8": Assuming an effective weld of 3/8" rather than the specified 1/2", the weld capacity is: 9rr(1.25)(.375)(23.76) = 34.99 = Bolt capacity
. No reduction in bolt capacity by the weld undersize.
(iii) Undercut of 1/16": The net area of steel available as result of the assumed undercut value is: Anet = 'Tr(1.125) = .994 in2 > .97 in 2used in the design 4
. No reduction in bolt capacity due to the undercut.
89 1 i
F ENCIDSURE D TO BLUE 700
- Shest 1 of 4
~
Sample Calculation for the Design of Machine Welded Plate Assemblies (EP512A) The subject plate assembly censists of four 3/4" f X 7" long . taded studs
' machine welded to a 1/2" X 1 ' X 12" f ace plate.
(i) Design of plate EP 512A: Embedded plates were analysed taking into account the plate flexibility, headed stud stiffness, shear-tension interaction and stud spacing. The allowable design loads were initially determined using a simplified beam model by hand calculation. These results were verified by finite element analysis using " ANSYS" Engineering Analysis System, Computer Program by Swanson Analysis System, Inc., Houston, Pennsylvania. The ANSYS model used in this verification is described on Sheet 3 of this Enclosure. The allowable load combinations resulting from the analysis are: P = 14.5 V = 39.0k Ve = 56"k for d = 4" Ve = 84"k for d = 6" Ve - 112"k f or d = 8" Where V = Shear load P = Tension load, including direct tension and tension due to moment of fixed end of cantilever beam, d = Depth of cantilever beam (attachment). e = Eccentricity The plate stress in no case exceeded 27 ksi. ; (ii) Reduced capacity due to loss of a headed stud. I The plate was divided into nine zones and the reduced capacity was l computed for three recurring zones. I r 1 L_
ENCWSURE D TO BW E 700 g o - Sh22t 2 cf 4
,g o n g g at 1 s !b ~ ( Broken stud and point of load
*[ B d hA 'W (application U G k6 9
. y
,4 \o s N
.b
\a.
VIG. \ . - . - EP G l2. A The solution for a plate with a broken stud was developed for two different conditionsi (1) simple plate bending about line a-a due to a tensile load at the broken stud (2) A com' lex analysis considering a strip along b-b supported by a beam su ip along line a-a and the stud at c. By equating deflec-tions at point E for strips a-a and b-b the resultant load distribution was established along both axes. From the resulting load along each strip resultant stresses were computed. The reduction in bending and increase in stud loads due to prying i action were computed for both directions. The analysis was done by , hand using McCauley's method for numerical integration procedures l ) for beams and was supplemented by the moment area method. The , results were checked by the "BSAP" computer program. l l After both these analyses were completed the results were compared and it was found that method (1) yielded conscrvative results for plate stresses whereas method (2) yielded conservative loads on studs (due to prying action) . Thus the plate stress analysis which governed the overall load on the plate was primarily based on method (1). The outline of analysis is shown below. r
- 1. Mechanics of structures, volume I, by S. B. Junnakar.
Vivek Publications,12th Edition, 1965 4
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ENCLOSURE D TO BLUE 700 Sheat 3 of 4 Assuming a 5 kip load acting at "B" Homent about line a-a = 5 X 4.8 = 24 k-in since the bending occurs along a-a (full width of the plate is considered due to rigidity of line a-a established by studs A and D). 3 Thus the section modulus = 1/6 X 15 X (1/2)2 = 0.625 in Fs = 24 = 38.4 kai 0.625 To restrict the load for 36 ksi plate stress (yield stress) allowable load = 36 X 5 = 4.71 kips used as capacity of plate 38.4 in zon I. Maximum stud reaction found by method (2) fo; an assumed applied load of 19.5 kips = 25.4 kips (including prying). However the stud load was conservatively restricted to 9 kips for the overlapping shear cone effect. Allowable load for the plate = 9 X 19.5 = 6.9k>4,71k : 25.4 i Thus the capacity for the plate was established as 4.71 kips for zone I load.
' Zone II load was computed on the same basis.
Zone III load was computed using the strength along line a-a only. i l Description of ANSYS Model { l The ANSYS finite element computer program was utilized to verify the analyses of embedded plates in determining loads in the headed studs. The computer model was formulated with finite element representations for the base plate, headed studs, and concrete. The base plate was modeled using a mesh of 2-D rectangular plate elements (STIF46) o- rectangular shell element (STIF43) interconnected at corner l nodes. The site of the element used varies with the size of the plate i being analysed, from 1-1/2" X 1-1/2" for small plates to 2" X 3" for large
' plates. The element (STIF46) has pure bending capabilities. The membrane stiffness of the plate is not included so that no in-plane forces are permitted. The element has three degrees of freedom at each of the four nodes: one displacement normal to the plate; and a rotation
, about each of the two orthogonal axes in the plane of the plate. The in-plane (shear) loads on the plate, omitted from the computer analysis,
, are subsequently combined in the interaction analysis.
The element (STIF43) has both bending and membrane capabilities. Both in-plane and normal loads are permitted. The element has six degrees of freedom at each node: Translations in the nodal x, y, and z directions and rotations about the nodal x, y, and z axes.
~
*
- ENCLOSURE D TO BLUE 700 Shent 4 cf 4 A mesh of compression-only spring elements is provided using the combina-tion element (STIF40) to represent concrete behind the plate. This combination element is used at each plate element nodal point with its axis oriented perpendicular to the plate. The element has one trans-
' lational degree of freedou and is capable of resisting compression loads only, i
Tension-only spring elements are provided using the combination element I (STIF40) to represent the expansion anchor bolts. This combination i I element is used at each plate element nodal point that coincides with a bolt location, with its axis oriented perpendicular to the plate. The element has one translational degree of freedom and is capable of resist-ing tension loads only. When rectangular shell elements (STIF43) are used, two spring-damper elements (STIF14) are introduced to each bolt node to represent the shear forces in bolt transferred from the plate. Only the longitudinal capacity in one direction is used. No bending or torsion is considered. O O O
v - , , , - -
EnclCCura E to BLUE 700
, Memo to: John Baker / Ken Kuechenmeister .
Subject:
U. E. Inquiries - Stud Welding Per our6 discussion on 6/3/80, the questions posed by Mr. Snell were reviewed with responsible personnel and our responses follow below:
- 1. Are headed studs replaced on composite beams with manual welding?
ies, on limited occassions. If a stud would need replacement af ter the automatic welding setup is moved, that replacement would be by manual uelding. This would occur on a very limited basis.
- 2. How often have we manually replaced headed studs on plates?
In general, the economics of manual welding vs. automatic welding dictate which method is used to replace headed studs. Studs broken in shipment are replaced at the fab shop and they prefer to ;use automatic welding whenever possible. The majority of stud welding at the fab shop is by the automatic process.
- 3. How often did undercutting on headed studs occur?
Reviewing this question with welding inspectors and supervisory personnel indicate undercutting occurred on rare occassions only. We also discussed repairing vs. replacement of headed studs on plates at that time. No one could recall a " repair' being made to a stud. The consensus of opinion was that bad studs were removed and replaced. Repairing a stud would have to be limited to isolated cases.
!. Don p per#
i CC: Dean McFarland John Long Jack Cook G l .
~
TELECON RECORD SHEET h , {,1 'DK Mr til - hN r.,m2mn ..m
~
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DEPT. UE Manlger l YOUR rdAME Nuclear Construction W. H. Weber DEPT. UE Ma g er PHONE T ALKED TO Quality Assurance F. D. Field SUBJECT T l'A E cATE 8:00 a.m. Acceptance Criteria Used for Inspection of 5/29/80 EUILJECT (Cont'd; Undercut Welds (AWS D1.1-751 . w;Tes In attendance in H. J. Starr's office at time of call: J. R. Cook J. L. Baker W. H. Weber J. V. Laux M. I. Doyne A. D. Arnold J. R. Veatch H. J. Starr E. E. Sterzinger J. J. Long M. M. Pugh J. A. Holland The call was placed to confirm the acceptance criteria used oy DIC The acceptance Qualitp Control for the inspection of undercut welds.the site a c those specifie criteria used at tions C-131, Paragraph 8.4, C-134, 6 sgraph 8.5.2, fabrication and erection of miscellaneous steel, and C-122, Paragraph 8.5.2, erec- , tion of structural steel, which state undercut invokes shall notcriteria acceptance exceea for1/32 in. Presently, OCP-507, Appendix II, undercut as stated in Paragraph 3.6.4 of AWS, with provision Danielfor Weld exceptions as delineated in the design specifications. Technique Sheet (fillet welds) N-1-1-A-6A, approved by Bechtel, specifically states undercut shall not exceed 1/32 in. Applicable portions of referenced procedures and specifications are attached. Nli'C c~r,,, ' O
%. L d 5/3Wre ID v e . ,
Above minutes crenared by }J.R. Cook.DICOCManacerEO . DISL RIBUTION: F. D. Fiel d. UE File A12.10 R. L. Powers, UE File A38.00 E. D. McFarland, DIC (6) Above Named Attendees
o e. Specification No. 10466-C131 7.8 The design, installation, and nspection of high strength bolted joints shall be in accordance with the AISC Speci-fication for Structural Joints Using A'STM A 325. 8.0 UELDING Welding shall be done in accordance with AUS D1,1' and the following requirements. 8.1 Uciding shall be performed by the r.anual shielded , r.etal-arc, submerged-arc, or gas rectal-arc processes. The gas retal-arc welding process ray be
~
used provided corposite flux-cored electredes are used with an external shielding gas and the operation is performed in the spray , transfer range. All applications of solid wire electrodes with a shielding gas are subject to' prior written approval. S.2 Uritten velding procedures and qualifications shall be submitted to the Buyer for approval in accordance with Forn G-3210. Frocedures other than these prequalified shall be qualified by tests as specified in Section 5 of AUS 31.1. ::o welding shall be perforred until the 3uyer has approved the procedures and qualifications. . Procedure qualification test records shall be nade available to che Buyer. B.3 Uciding shall be perforced only by welders er operators who nave been qualified in accordance with Section 5 of ANS D1.1. The perforrance qualification test records shall be made available I to the auyer. l 8.4 Each weld shall be uniform in width and size throughout its full length, unless indicated l9 otherwise herein.' Except as allowed by- AWS D1.1, I cach layer of welding shall be smooth and free of slag, cracks, and pinholes and shall be completely fused to the adjacent weld beads and base metal. Undercut shall not exceed 1/32 inch, except thaf uncercef'Ep to 1/ib inen .Tay cctur _;; 9
. 10 percent of the weld length in manual welding
. of anchors.
. P. . S Butt welds shall be . flush with the Lase raterial or have uniform crowns. Dutt ucids shall be fnll geenetration, unless otheruise specified and permitted ay J.US D1.1.
Page 5 Rev 9 .
~~
Specification 10'66-t-132
= . .
. . 8.3 Welders cnd welding operators shall be qualified in accordance with AWS D1.1. The owner will revi<2w such qualification records at the jobsite.
8.4 Welding Materials . 8.4.1 The Contractor shall establish a written procedure to describe the method uctd to control the receipt, storage, baking, dry-ing, and disbursal of all welding raterials employed in construction. This welding material control procedure shall be sub-mitted in accordance with form G-321-D for review
.and. acceptance prior to start of welding.
8.4.2 Unless specifically waived, all shielded-
. metal arc welding shall be performed using
. low hydrogen electrodes. . .
8.4.3.horflux-coredarewelding, the electrodes shall conform to AWS A5.20 Classifications E70T-1 or E70T-5. - 8.5 Miscellaneous Welding Requirements .. . . ~ 8.5.1 [Nelded joints shall be made by completing each
,we.ld layer before-succeeding weld layers are dep~osited.- Block welding is not permitted.
{ 8.5.2 Undercut shall not exceed 1/32 inch. 8.5.3 ,illet F welds shall be of the specified size
-with full throat and legs of uniform size Dver-as .
[.d[ elf.ined by Section 8.15 o~f'AWS Dl.l.
-si.z.e of . welds .shall be minimited as much as --
- pr.actical, and in~ no case shall exceed 100 percent or 3/8 inch greater
~
Unequal than leg specified, fillets
;whichever is less..
are acceptable provided the smaller leg
' - emeets or exceeds the m iin nta specified re-
quirements. Continuous welds are accept-t able in place of intermittent welds.
.~ - . ... . .. ..... .. . ,. ..... ...
8.5.4 - Elimination of defects and surf ace preparation P.o'f' welds by' chipping, grinding, or gouging shall' Ye dons ~ in suen 3 manner as not .to: gouge, c.djacent base material
' groove, or thickness below th.e reduce th - .imum required.
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- . 7..: .
-e Page 8 nev 4
-WFN. . es.mo. . einemmum . w.m.. .
Sp;cification No. 10466-C122 k 8.4.3 For flux-cored arc welding, the electrodes shall conform to AUS A5.20 Classifications E70T-1 or E70*-5. 8.5* Miscellaneous Welding Requirements 8.5.1 Wolded joints shall be made by ccmpleting each weld layer before succeeding Block weldis r.o't welding layers are deposited. . - permitted. , Undercut shall not exceed 1/32 inch. l10 8.5.2 , 8.5.3 Fillet welds shall be of the specified size with full throat and legs of uniform size Over-ai defined by Section 8.15 of AWS D1.1. size of welds shall be ndnimized as much as practical, and in no case shall exceed 100 per-cent or 3/8 inch greater than specified, ; whichever is less. Unequal leg fillets are - acceptable provided the smaller leg meets or 10 exceeds the minimum specified requirements. Continuous welds are acceptable in place of ' intermittent welds. 8.5.4 Elimination of defects and surface ! (l preparation of welds by chipping, grinding, or gouging shall be done in such a manner as not to gouge, groove, or reduce the l adjacent base material thickness .below the l minimum required. I 8.5.5 Submerged arc welding shall be used only with the following limitations: a.- The maximum individual layer thickness for submerged arc welds shall not 1-1/4 exceed 1/2 inch for materials inch thick or greater and 3/8 inch thick for materials less than 1-1/4 inch thick. . 1 l b. Removable starting and stopping tabs shall be used for longitudinal welds. 8.5.6 Peening shall not be used without prior
- j written acceptance of the method andUse of pneumatic tools l controls to be used.
for slag removal is not considered peening and is acceptable. O
* ' Page 5 *
. Rev 10
f . QCP-507 APPENDIX II
.Page 1 of 5 r * . Revision 0 (,w)
VISUAL I"SPECTION ACCEPTANCE CRITERIA FOR NAS D1.1-75 The followino criteria anolics.co AUS insnoctions exceot.e. spect fica : r m s rec::- o: ta-m encen :an to ,or n ca s o; where d m e. ()
~
GENERAL . ,
- 1. Welding shall not be done when the ambient temperature1.'sia, lower than 0 F or when surfaces are wet or exposed to snow, or high wind, or when welders are exposed to incl .ent conditions.
NOTE: O F does not mean the ambient environmental temperature but the temperature in the immediate vicinity of the weld. i.e.: a heated structure or shelter around the area to be welded cguld maintain the temperature adjacent to the weldment at
- 0 F or higher.
- 2. The sizes and lengths of welds shall be no less than tho'se specified by design requirements and detail drawings, nor shall they be substantially in excess of those requirements (
without approval. The location of welds shall not be changed without approval. and
- 3. Surfaces and edges to be welded shall be scooth, uniform, free from fins, tears, cracks, and other discontinuities which would adversely affect the quality or strength of the weld.
Surfaces to be welded and surfaces adjacent to a weld shall also be fice from loose or thick scale, slag, rust, moisture, l grease and other foreign material that would prevent proper welding.
- 4. Mill scale that can withstand vigorous wire brushing, a thin rust-inhibitive coating, or antispatter compound may remain with the following exception: for girders, all mill scale shall be removed from the surfaces on which flange-to-web welds are to be made by shielded metal arc welding with low hydrogen electrodes.
- 5. Excessive roughness and occasional notches or gouges no more than 3/16 in. (4.Smm) deep, on otherwise satisfactory surfaces, shall be left free of slag. Correction of discontinuities shall be faired to the oxygen cut surfaces with a slope not exceeding one in ten.
- 6. In oxygen cut edges,' occasional notches or gouges less than '
7/16 in. (11.1 mm) deep in material uo to 4 in, thick, or k-less than 5/8 in. (15.9 mm) deep in am'terial over 4 in. thick may, with the approval of the Engineer, be repaired by weldins.
Q'CP-507
- APPENDIX II
- Page 4 of 5 Revision 0
/r eQ.t ,
- 28. Steel backing shall be cade conti$uous for the full length of the weld. All necessary joints it. the steel baching shall be complete joint penetration butt welds.
TEMPORARY '.CELDS
- 29. Temporary welds shall be subj ect to the same welding proc e-dure requirements as final welds. They shall be recov:d when required by the Engineer. When they are removed, the surface shall be cade flush with the original surface. -
i VISUAL INSPECTION The following acceptance criteria is applicable to buildings znd tubular structures:
- 1. All welds shall be visually inspected." A weld shall be accept-able by visual inspection if it shows that:
- a. The weld has no cracks
- b. Thorough fusion exists between weld metal and base metal All craters are filled to the full cross section of O c.
the welds
- d. Welds shall be free from overlap p o
- c. Undercur. shall be no core than 0.01 in. deep when its direction is transverse to primary tensile stress in the part that is undercut, jor more than 1/32 in. for all other situations.
J f. Arc strikes outside of the area of permanent welds should be avoided on any base metal. Cracks or ble-mishes" caused by arc strikes shall be ground to a smooth contour and checked to ensure soundness.
} Weld profiles are in accordance with Fig. 3.6.
g.
- h. The sum of diameters of piping porosity does not ex-cced 3/8 in. in any linear inch of weld and shall not exceed 3/4 in. in any 12 in. length of weld.
The following is applicable to buildings only:
- 1. . Fillet we'lds in any signle continuous weld shall be perr.itted to underrun the nominal fillet size required by 1/16 in, with-out correction orovided that the undersize weld does not exceed 10 percent of the lencth of the veld. On web-to-flange welds on girders, no underrun is per=itted at the ends for a length equel to twice the width of the flange.
y - ~ - - Q, , .. . . . , . . e REvlsicN Nuv3ta: o AT E: ,
'ggnNicut set 1T.
2 4/24/80 Pact 2 _ oF 2* N-1-1-A-6A iTES: Fillet velds nay vary fron cenvex to conesve. The size of the veld shall be dete:.-ined O es shevs below: A. The size of an equal leg fillet veld is the leg length of the largest inscribed right 1 isosceles triangle. 1
+t C4 h C LLLt 5T M CLt Si2E. CE. :L.S l otrJ. cc w % c.omr4 mt.ir.T wr.tb B. For unequal leg fillet velds, the si:e of the veld is the leg length of the Isrgest right triangle unich can be inscribed within the fillet veld cross section. 1 SW.E N -
size op NELO f ,_ a WW.b i P, s a
"I _
r i The following rules apply to AWS Dl.1 velds: A. The parts to be joined by fillet velds shs11 be brought into as close centsce as. practicable. If the separation is 1/16" orThe greater, the leg of the fillet shall be gap between parts shall not exceed 3/16" increased by the a=ount of the se:aration. unlest ot15 a' . vise s;ecified by One Project Welcing Engineer, and in no casa s not enceed 1/32".
- 3. ac=L c/ercu':
EcS s'-'1 C. Post veld hea trest =cnt is not required unless specified by contrzet drawings c - specifications. exc t D. The =inint:s fillet veld si:a shall be in accordance with the following chst: . - . . veld si:e need not exceed thickness of thinner part joined. MI: Inn:M SIZE OF FIU.ZI P. ATE.tLU. WICUISS OF WELD (I:1. ) WICKIR P.GT J0!!TED (T) 1/3" T S 1/4" 3/16" si.r13 aes 1/ " 4 T $ 1/ 2" 1/ !." wi d .; -e : - O 1/ 2" < ! .. J i u" 3/ " 4 T 5/15" be used. O . l l . I : I \ . .
6% ,n r rn.u s sous.
'Qlg.E'ARJX EL CONSTRUCTION PROCEDURE
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PROJECT N AME CALLAWAY PLANT UNITS 1 AND 2 ! i [. TiTtt INSI'ECTION MEUETURAL A':D "ICC. CT_Eg [ . Quality Procedu e No. Cont _rol 1-( ' SAI'ETY _ I' ELATED LTL.D_I.'.!.O 3' #'14 l j INSPECTION OF STRUCTURAL AND MISC. SAFETY QCP-507 ' von.m. ' section RELATED WELDING II VI PROJECT NO. 71BG FOR UNION ELECTRIC COMPANY CALLAWAY PLANT UNITS 1 AND 2 i
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Inspeetion, Added osaie' //18/1]caZ2fst/ I/o.,9 77 Daniel Fabrication owner 1;/4 ". I {- - General Added originator d.3 b 4 9- n .75 CocoletedRevision'Up Marked- Drawing oan,ei ,Q,p, G W y/n y 4 As a QA Record y o ner . - A//A. l . Title Change, General
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% DMJIT F* , Qj.w i..n u nXU CONSTRUCTION PROCEDURE
( , ,,- s u , e ," TITLE QCP-507 INSPECTION OF STRUCTURAL AND MISCELLANEOUS o. . n......,, SAFETY RELATED WELDING 3-27-79 5 1 4 ( p... of 1.0 SCOPE 1.1 The purpose of this procedure is to described the methods to be employed by Quality Control personnel (- when performing inspections on Structural and Miscel-laneous Safety Related Welding in accordance with AWS Dl.1-75.
2.0 REFERENCES
2.1 CONSTRUCTION PROCEDUP.E WP-ll3 " Erection of Structural Steel (Safety Related)" 2.2 Daniel Welding Procedure's (AWS Dl.1 - 1975) 2.3 CONSTRUCTION PROCEDURE QCP-502 " Qualification of Welders" 2.4 CONSTRUCTION PROCEDURE QCP-503 " Monitoring the ( Control of Welding Consumables" 2.5 Bechtel Technical Specification: 10466-Cl22 -
" Erection of Structural Steel" 2.6 CONSTRUCTION PROCEDURE QCP-508 " Visual Inspection of Welds" 2.7 CONSTRUCTION PROCEDURE AP-VII-04 " Calibration and Control of Construction Instrumentation and Tools" 3.0 GENERAL 3.1 Welding of Structural Steel shall be carried out in accordance with Reference 2.1. Acceptance criteria shall be in accordance with Reference 2.5 and Appen-dix II.
3.2 Miscellaneous safety related welding shall be carried out in accordance with applicable work and QC Proce-dures. Acceptance criteria shall be in accordance with applicable specifications and Appendix II. 3.3 Required NDE shall be performed in accordance with approved proj ect NDE procedures.
PMM EL n e unu mm CONSTRUCTION PROCEDURE , e v-. , , s , a w Procedure No. TITLE QCP-507 D*" " ' * " INSPECTION OF STRUCTURAL AND MISCELLANEOUS SAFETY RELATED WELDING 3-27-79 5 Page of _, 3.0 GENERAL - Cont. 3.4 Welding of materials within the scope of this proce-dure shall be performed by qualified welders using h F approved procedures. (Reference 2.2) 3.5 Monitoring of welder qualification shall be in accord-ance with Reference 2.3. 3.6 Monitoring the control of welding consumables shall be in accordance with Reference 2.4 3.7 The Welding QC Engineer shall be notified prior to the commencement of welding of matericl within the scope of this procedure. 3.8 Inspections and verification activities shall be per-formed as follows:
- 1. In-process inspections shall be performed on a random daily basis with particular attention paid l to items such as amp readings, welder qualifica- l tion and weld filler material control. 1 I
Final welds shall be ins'pected on a 100% basis for 2. compliance with code, specifications, procedure I and drawing requirements. 3.9 Size and contour of welds shall be measured with suitable gauges calibrated in accordance with Refer- , I ence 2.7. g 1 Visual inspection for cracks in welds and base metal F 3.10 and other discontinuities should be aided by a strong light, magnifiers, or such other devices as may be found helpful. 3.11 Inspection results shall be documented to the extent h prescribed on Exhibit A (Welding QC Surveillance Re- F port). 3.12 Welds shall be numbered in accordance with Appendix I, where applicable. Other weld configurations may have unique numbering systems established orior to commence" ment of welding. These weld numbers shall be shown on .. I a marked-up drawing. l
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Procedure No.
'"" QCP-507 n . . . . ,,
INSPECTION OF STRUCTURAL AND MISCELLANEOUS o.ie SAFETY RELATED WELDING 3-27-79 5 Page 3 ,, 4 4.0 PROCEDURE 4.1 The following activities shall be performed during the inspection of structural and miscellaneous safety I related welding. RESPONSIBLE POSITION , ACTION PROJECT WELDING QC ENGINEER
- 1. Upon notification by craft personnel of the intent to perform welding, assign a welding inspector to monitor activities.
WELDING QC INSPECTOR
- 2. Assign weld numbers to marked-up drawings in accordance with Paragraph 3.12,
- 3. Initiate Welding QC Surveillance Report (Exhibit A).
- 4. Perform welding inspection outlined in Paragraph
- 3. 8 in accordance with Appendix II, and applicabic specifications, drawings and procedures.
- 5. Accure that weld size, length and location conform to requirements of detail drawings, that no speci-fied welds are omitted, and that no unspecified welds have been added without engineering approval
(' 6. Identify all welds inspected and accepted by stamp ( or initials and date. Identification need not be permanent.
- 7. Record results of in-process inspections on Exhib-it "A" of Reference 2.6.
(~ 8. Record all applicable information and inspection results on Exhibit A.
- 9. After completion of Exhibit A, record applicable information on marked-up drawing.
., 10. Upon completion of inspections, forward Exhibit A
' to the Project Welding QC Engineer for review.
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QCP-507 INSPECTION OF STRUCTURAL AND MISCELLANEOUS on. n . . .. . SAFETY RELATED WELDING 3-27-79 5 Page of _ 4.0 PROCEDURE - Cort. 4.1 Continued RESPONSIBLE POSITION ACTION PROJECT WELDING QC ENGINEER
- 11. Review Exhibit A for completeness and accuracy and sign and date indicating approval.
- 12. Forward one copy to Project Discipline QC E 1gineer (if required) and retain one copy for file.
5.0 RETAINED DOCUMENTATION 5.1 The Welding QC Surveillance Report (Exhibit A) shall , be completed as required by this procedure. After ,
, review and approval, the original copy shall be transmitted to Document Control for filing as a QA Record. ,
5.2 The completed marked-up drawing shall be transmitted l to Document Control for filing as a QA Record. 6.0 EXHIBITS AND APPENDICES , 6.1 Exhibit A - Welding QC Surveillance Report - Revision 2 . 6.2 Appendix I - Structural Steel Weld Numbering System Revision 1 ) 6.3 Appendix II - AWS D1.1 - 75 Acceptance Criteria -
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_ m V ~ QCP-507 , EXHIBIT A -
- Page 2 of 2 . ,,
Revision 2 / INSTRUCTIONS FOR COMPLETING
. WELDING OC SURVEILLANCE REPORT l'. Enter applicable Proj ect No. g
- 2. If work is performed by Daniel personnel, enter check,
- 3. If work is performed by a subcontractor, enter nace .
of subcontractor.
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- 4. Enter area or building location (ex: Aux. Building EL-2100')
- 5. Enter date of inspections.
- 6. Enter signature or stamp of inspector performing activities.
- 7. Enter applicable file number.
- 8. Enter the drawing on which items being inspected is shown.
- 9. Enter Piece No/s or Item /s being welded as shown on the -3
,q applicable drawing. , i V 10. If available, enter Weld No. as shown on the applicable ,
drawing.
- 11. Enter the I.D. Nu=ber of the Welder performing the work.
- 12. Enter the Welding Procedure specification technique being used.
- 13. Enter the U-100 Serial No. for the weld filler material being used.
- 14. Enter S or U as appropriate indicating weld filler control status.
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- 15. Indicate code for phase of welding operation inspected.
- 16. Enter S or U as appropriate indf M bog results of inspection.
(] 17. Enter any applicable coc='n: 5
- 18. Signature (or sta=9 and date of person uho pe'rfor=ed review.and approval. l
- 19. Enter SNUPPS Unit No. (i.e. 2 for Callaway Unit 1) l ~gY Q) .
QCP-507 ' - - APPENDIX I
- Page 1 of 1
{ REVISIGN 1 ( STRUCTURAL STEEL WELD NIR'3ERING SYSTEM p v
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QCP-507
. APPENDIX II -
Page 1 of 5 . Revision 0 VISUAL INSPECTION ACCEPTANCE CRITERIA FOR AWS Dl 1-75 The following criteria applies to AWS inspections except where h specifications modify or take exception to portions of AWS Code. GENERAL
- 1. Welding shall not be done when the ambient temperature is lower than 0 F or when surfaces are wet or exposed to rain, snow, or high wind, or when welders are exposed to inclement f
conditions. NOTE: O F does not mean the ambient environmental temperature but the temperature in the immediate vicinity of the weld, i.e.- a heated structure or shelter around the area to be welded cguld maintain the temperature adjacent to the weldment at 0 F or higher.
- 2. The sizes and lengths of welds shall be no less than those specified by design requirements and detail drawings, nor ~,3 shall they be substantially in excess of those requirements -'
without approval. The location of welds shall not be changed without approval.
- 3. Surfaces and edges to be welded shall be smooth, uniform, and free from fins, tears, cracks, and other discontinuities which would adversely affect the quality or strength of the weld.
Surfaces to be welded and surfaces adjacent to a weld shall also be free from loose or thick scale, slag, rust, moisture, grease and other foreign material that would prevent proper welding. 4 .' Mill scale that can withstand vigorous wire brushing, a thin rust-inhibitive coating, or antispatter compound may remain k with the following exception: for girders, all mill scale y shall be removed from the surfaces on which flange-to-web welds are to be made by shielded metal arc welding with low hydrogen electrodes.
- 5. Excessive roughness and occasional notches or gouges no more than 3/16 in. (4.8mm) deep, on otherwise satisfactory surfaces, h shall be left free of slag. Correction of discontinuities shall be faired to the oxygen cut surfaces with a slope not exceeding one in ten.
In oxygen cut edges, occasional notches or gouges less than 6. 7/16 in. (11.1 mm) deep in material up to 4 in. thick, or less than 5/8 in. (15.9 mm) deep in material over 4 in thick
'g may, with the approval of the Engineer, be repaired by welding.
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- QCP-507 APPENDIX II
- Page 2 of 5
/ Revision 0
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- 7. Other discontinuities in oxygen-cut edges shall not be repaired by welding.
- 8. The parts to be joined by fillet welds or partial joint pene-(- t: tion groove welds shall be brought into as close contactex-as practicable. The gap between parts shall normally not '
cced 3/16 in.
- 9. If the separation is 1/16 in, or greater, the leg of the 1 fillet welds shall be increased by the mmount of the separa- ;
(' tion or the required effective throat must be obtained. l
- 10. The separation between faying surfaces of lap joints and of butt welds landing on a backing shall not exceed 1/16 in.
- 11. Abutting parts to be joined by butt welds shall be aligned as required by applicable welding procedures.
- 12. Tack welds which are incorporated into the final weld shall be made with electrodes meeting the requirements of the final welds and shall be cleaned thoroughly. Multiple pass tack welds shall have cascaded ends. .
- 13. Tack welds not incorporated into final welds for buildings need not be removed unless required by the Engineer.
- 14. Insofar as practicable, all welds shall be deposited in a sequence that will balance the applied heat of welding while the welding progresses.
- 15. In making welds under conditions of severe external shrinkage restraint, the welding shall be carried continuously to com-pletion or to a point that will insure freedom from cracking before the joint is allowed to cool below the minimum speci-fied preheat and interpass temperature.
.' 16. The faces of fillet welds may be slightly convex, flat, or 3 slightly concave as snown in Fig. 3.6 A, B, and C, with none C- of the unacceptable profiles shown in Fig. 3.6 D. Except at outside corner joints, the convexity shall not exceed the value of 0.1S plus 0.03 in. where S is the actual size of the fillet weld in inches. (See Fig. 3.6 C) ,
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- 17. Groove welds shall preferably be made with slight or minimum reinforcement except as may be otherwise provided. In the .
case of butt and. corner joints , the reinforcement shall not l I exceed 1/8 in. in height and shall have gradual transition to the plane of the base metal surface (Fig. 3.6 E). They j~ shall be free of the discontinuities shown for butt joints in Fig. 3.6 F.
T - r' . QCP-507 APPENDIX II - Page 3 of 5
- Revision 0 'h
- 18. Surfaces of butt joints required to be flush shall be finished so as not to reduce the thickness of the thinner base metal or weld metal by more than 1/32 in. or five per-cent of the thickness, whichever is smaller, or leave rein- g forcement that exceeds 1/32 in. However, all reinforcement must be removed where the weld forms part of a faying or contact surface. Any reinforcement must blend smoothly into'the plate surfaces with transition areas free from edge weld undercut.
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- 19. Welded joints shall not be painted until after the work has been completed and accepted.
- 20. Repaired or replaced welds shall be retested by the method originally used, and the same technique and quality accept-ance criteria shall be applied.
- 21. Ascertain the extent of cracks in weld or base metal by use of acid etching, magnetic particle inspection, or other equally positive means; remove the crack and sound metal 2 in. beyond each end of the crack, and reweld.
- 22. Members distorted by welding may be straightened by mechani- . s cal means or by carefully supervised application of a limited )
amount of localized heat. The temperature of heated areas as measured by approved methods shall ngt exceed 1100 F for quenched and tempered steel nor 1200 F (a dull red color) for other steels.
- 23. If, after an unacceptable weld has been made, work is per-formed which has rendered that weld inaccessible, or has created new conditions that make correction of the unaccept-able weld dangerous or ineffectual, then the original condi-tions shall be restored by removing welds or members or both before the corrections are made. If this is not done, the deficiency shall be compensated for by additional work per-formed according to an approved revised design.
- 24. Groove welds shall be terminated at the erfs of a joint in a manner that will ensure sound welds. Whenever possible, this shall be done by the use of extension bars or run-off plates.
- 25. In building construction, extension bars or run-off plates )
need not be removed unless required by the Engineer.
- 26. Groove welds make with the use of steel backing shall have the weld metal thoroughly fused with the backing.
- 27. Steel backing of welds used in buildings or tubular structures h need not be removed unless required by the Engineer. -
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, QCP-507 APPENDIX II ) Page 4 of 5
. Revision 0 k'.
- 28. Steel backing shall be made continuous for the full length of the weld. All necessary joints in the steel backing shall be complete joint penetration butt welds.
( TEMPORARY WELDS
- 29. Temporary welds shall be subject to the same welding procc-dure requirements as final welds. They shall be removed when required by the Engineer. When they are removed, the surface shall be made flush with the original surface.
VISUAL INSPECTION The following acceptance criteria is applicable to buildings and tubular structures:
- 1. All welds shall be visually inspected. A weld shall be accept-able by visual inspection if it shows that:
- a. The weld has no cracks
- b. Thorough fusion exists between weld metal and base metal
- c. All craters are filled to the full cross section of the welds
- d. Welds shall be free from overlap
- e. Undercut shall be no more than 0.01 in, deep when its direction is transverse to primary tensile stress in the part that is undercut, nor more than 1/32 in. for all other situations.
- f. Arc strikes outside of the area of permanent welds should bn avoided on any base metal. Cracks or ble-mishes caused by are strikes shall be ground to a smooth contour and checked to ensure soundness.
- g. Weld profiles are in accordance with Fig. 3.6.
- h. The sum of diameters of piping porosity does not ex-ceed 3/8 in. in any linear inch of weld and shall not exceed 3/4 in. in any 12 in, length of weld.
The following is applicable to buildings only:
- 1. Fillet welds in any signie continuous weld shall be permitted to underrun the nominal fillet size required by 1/16 in, with-out correction provided that the undersize weld does not exceed 10 percent of the length of the weld. On web-to-flange welds on girders, no underrun is permitted at the ends for a length equal to twice the width of the flange.
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