ML19329E265

Responds to NRC Re Violations Noted in IE Insp Repts 50-329/78-03 & 50-330/78-03.Corrective Actions:Weld Size Adequacy Evaluation Rept to Be Submitted by 780701. Documentation Supporting Noncompliance Denial Encl

ML19329E265
Person / Time
Site:	Midland
Issue date:	06/07/1978
From:	Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML19329E259	List: ML19329E258 ML19329E265 ML19329E268 ML19329E269
References
HOWE-89-78, NUDOCS 8006120558
Download: ML19329E265 (36)

Text

{{#Wiki_filter:. Q -: e, Consumers s ol: power 'O s f. Stephen M. Howell / Vsco Presodent General oHices: 212 West Micnigan Avenue..r.ckson. Mich. gen 49201 e Area Coce 517 788-0550 June 7, 1978 Hove-89-78 "/ Mr J. G. Keppler, Regional Director Office of Inspection and Enforce =ent US Nuclear Regulatory Coc=ission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND NUCLEAR PLANT - NRC ITDG OF NONCO!@LIANCE INSPE TICI REPORT NO. 50-329/78-03ANDNO.50-330/78-03 This letter, with its enclosures, is in response to your letter of May k, 1978 which transmitted the results of your inspection of the Midlend constr;;ction site on March 21-23, 1978 and which requested our vritten statement an the ite=s of noncompliance. ) J T' D.0D e-~, " L I 197c p ) 8006120 r b

Enclosura 1 ~ Hove-89-78 ,,9 (/ CONS 11GRS POWER COMPANY RESPONSE TO THE ITB/.S OF NONCOMPLIANCE DESCRIBED IN NRC INSPECTION REPORT NO. 50-329/76-03 AND NO. 50-330/7o-03 I. ERRONEOUS DOCIMENTED INSPECTION RESULTS A. Descriptions of Noncompliance h 6 of Section II, of Paragraph 1 of Appendix A, and paragrap/78-03 provide the following: Report No. 50-329/78-03 and No. 50-330 " Contrary to the requirements of 10 CFR 50, Appendix B, Cr!*:erion IX, and Paragraph 5 2 of the Consumers Power Compcuy quality Assurance Program for Design and Construction, Procedure No. 9-1 it was determined that the documented inspection results, asserting that the velds on cable tray supports in the lower cable spreadin6 room were acceptable, vere erroneous."... "The inspector observed the velds on the seismic Class 1 cable tray supports in the lover cable spreading room at /N elevation 6h6' in the auxiliary buildin6 and noted that 's,) several velds were inadequate in size. At the request s of the RIII inspector velds on Column 19, which vere documented as inspected and acceptable in QCIR-C30k-2hhW, were reinspected and the _esults documented as follows in Bechtel Discrepancy Log WO97: Welds on Column 19 vhere attach =ent is made to structural steel are.equired to be 5/16" cize with a 5/8" return, by Detail 3 of Drawing E7h0(Q). Reinspection by the Bechtel QC inspector indicated the followin6 as velded conditions: (1) Weld Southwest Side Leg 1/h"x5/16" one end return undersize one end return short (2) Weld Northwest Side Undersize throat, complete length of the veld one end return short (3) Weld Southeast Side Legs 1/h"x5/16" s ) one end return short 1'3 # one end return undersize l l l l ) l i

2 - W/ (k) Weld Northeast Side Undersize throat, complete len6th of the veld The inspector stated that QCIR-C30h-2h4w vas in error in that the reinspection results established that the velds did not meet the criteria established in Drawing E ThO (Q). The Inspector further stated that this is considered an item of noncompliance and is contrary to 10 CFR 50, Appendix B, Criterion IX and Paragraph 5 2 of the Consu=ers Power Company Quality Assurance Program Procedure for Design and Construction Procedure 9-1. The inspector recommended that corrective action to correct the above noncompliance should include a complete reinspection of all the velds in liance with the lower cable spreadin6 room to determine comp /78-03-03)" the relevant drawinEs. (50-329/78-03-03;50-330 B. Corrective Action W R #1287 was issued by Bechtel QC on March 23, 1978. This report a ntained the reinspection report of 10 vertical columns consisting a h0 velds in the lower spreading room at elevation 6h6'. Under-sized velds were detected in all 10 columns. NCR #1306, issued on A;ril 13, 1978 reported 550 veld discrepancies out of 2,058 inspected The discrepancies consisted of oversize, undersize and veld V -- es. J.! ets in the lover cable spreading room. Bechtel vrote a quality .4urance Program Management Corrective Action Report (MCAR-1, Report ". 23, dated April 17,1978) to address the nonconfoming conditions M a management level. This report was provided to you as an attach-

ent to the 50 55(e) report provided by letter Hove-75-78; subject, Eidland Nuclear Plant - Unit No.1 Docket No. 50-329, Unit No. 2 Docket No. 50-330, seismic Cable Tray supports, dated May 12, 1978.

Engineering's evaluation effort examined the adequacy of the etual reported weld size to the specified design load at each connection. Poblems related to oversize, veld defect and violation of AISC =inimum veld size were evaluated by Bechtel veldin6 en51neers. Etaluation of the undersized veld was performed by examining the -:.ximum load-carryin6 capacity of an undersized veld connection to the minimum required load-carrying capacity from structural analysis of the support system. NCRs #1287 and 1306 were dispositioned "use-as-is" on May 18, 1978, and it was concluded that the project design stress requirements had been met and no safety implications vere involved. Deviations pertainin6 to r'f. imum veld size and oversize velds were reviewed and found acceptable. v

c, 3 O To evaluate velding adequacy in the areas other than those velds in the lover cable spreading room, Bechtel Project Engineering selected a sample of 53 velded support connections from installed cable tray supports in the auxiliary building on April 25, 1978. Field velding engineers conducted a detailed inspection of the selected connections and transmitted the summary results to~ Project Engineering on May 19, 1978. Project Engineering is currently evaluating the veld connections results trans=itted by field engineering. The results of this evaluation vill be presented in a final report to MCAR-23 scheduled for July 1,1978. The final report vill also document those actions taken to prevent recurrence, namely the instruction to crafts, supervision and field engineering personnel and any necessary instruction and training for Quality Control engineers to assure proper inspection, including any requirement for inspection of cable tray support velds prior to the installation of the cable tray. All of the required actions to make the project in compliance with requirements should be completed by July 1,1978. Consumers Power vill advise you of the completed corrective actions and the date when full compliance was achieved through submittal of the final 50 55(e) report on the Seismic Cable Tray Supports. ( II. UNSPECIFIED VOLTAGE IN BECHTEL WPS NO. Pl-A-LH-A. Descriptions of Noncompliance Paragraph 2 of Appendix A, and p/78-03 provide the following: aragraph 5 of Section II, of Report No.50-329/78-03andNo.50-330 " Contrary to the requirements of 10 CFR 50, Appendix B, Criterion IX and Paragraph 5 2 of the Consumers Power Company (CPCo) Quality Assurance Program Procedure for Design ant Construction, Procedure 9-1, CPCo failed to assure that Bechtel Welding Procedure Specification No. P1-A-LH Structural specified the velding voltage requirements. "... "The inspector reviewed Bechtel Welding Procedure Specification (WPS) Pl-A-LH Structural which was being used to veld structural steel and determined that the velding voltage requirements were not specified. The above WPS referenced a General Welding Procedure (GWP) which was to be used in conjunction with the WPS Pl-A-LH Structural. Paragraph 4.2.1, on Sheet 3 of 18, of the GWP Revision 2, dated September 1,1977, states " Electrical process variables shall be specified in the applicable WPS." The Bechtel personnel informed the inspector that the velding voltage (O was never measured and recorded. American Welding Society ,/ (AWS) Dl.1-1972 Code which was referenced in the WPS in Section 4, Paragraph 4.10.2, states "The classification and =

l h /^N size of the electrode, are length, voltage, and emperage shall be suited to the thickness of the material...." Also, in Section 5, Paragraph 5 5 2.1(h), the AWS Code states "A chen6e of more than 15% above or below the specified mean are voltage and amperage for each size electrode used is considered a change in the essential variable and requires establishing a procedure qualification." The inspec, tor stated that the control of velding was considered inadequate in that the velding voltage was not specified in the WPS and that this was contrary to 10 CFR 50, Appendix B, Criterion IX and Paragraph 5 2 of the Consumers Power Company Quality Assurance Program Procedure for Design and Construction Procedure 9-1. This is an item of noncompliance identified in Appendix A. (50-329/78-03-02;50-330/78-03-02)" B. Cerrective Action it, response to the item of noncompliance stated above, Consumers P7uer takes the position that we can only be considered in ..... compliance with the AWS Dl.1-72 Code by not listing, for information only as is i= plied in the Code, a useable voltage range p/ on tne prequalified velding procedure specification. The AWS Dl.1-72 (,

does not consider are voltage an essential variable for pre-

cr.lified veldin6 procedure specifications. The Code only implies

...-. this information'should be provided on the WPS form provided in a--andix E. To comply, velding procedure specifications for shielded r.etal are velding vill be provided with an are voltage range. It is anticipated that this activity vill take approximately 90 days (Septe=ber 7, 1978) to complete. Arc voltage control vill continue to be provided throu6h are length control by qualified velders. provides more detailed arguments in support of the above stated position. t III. DEFICIENT DOCUENTATION ON PURCHASED MATERIAL A. Description of Noncompliance Paragraph 3 of Appendix A, and page 5 of Report No. 50-329/78-03 and No. 50-330/78-03 provide the following: " Contrary to the requirements of 10 CFR 50, Appendix B, Criterion VII and Paragraph 5 3 of the CPC EPPQASD, Procedure No. 7, CPCo failed to assure that the docu-mentary evidence on purchased material was sufficient to identify that the purchased material met the specifi-cation requirements."... \\# "UnresolvedItem(50-329/77-12-04;50-330/77-15-Oh): It was identified that Shop Welding Inspection Reports of Haven Busch

i ?, 5 Ov did not document whether root passes which vere repaired vere reinspected after repair. Bechtel visited the vendor's facility to determine whether any additional records were available. During the vicit, it was reported that examination of the available records indicated only in some instances the reexamination was documented on the reverse side of the report. The reverse side was not copied and sent to the site. There appeared to be a misuse of the documentation of the inspection results; consequently there was not documentation on reinspec-tions. Bechtel is avaiting an assessment by Haven Busch as to the extent of inadequate documentation, including a reasonable rationale to justify the inadequate documentation. This infor-mation is expected to be reviewed by the Bechtel Project Engineering personnel through the Project Supplier Quality Supervisor. It should be noted that in the meantime some of these embeds vould be buried under concrete precluding further inspections. This item has been escalated to an item of noncompliance contrary to 10 CFR 50, Appendix B, Criterion VII and Paragraph 5 3 of the Consumers Power Company EPPQASD Procedure No. 7 (50-329/78-03-01; 50-330/78-03-01)" B. "--*ective Action V 'rvo Bechtel quality Action Requests, QAR-SD-59 (12/28/77) and QAR-ca-90(12/28/77), had been issued to obtain the required corrective ... ions. As a result of the review of the Haven Busch doevr utation, v.o NCRs, #13h5 and 13h6, were written against the miscelle pus accal items from Haven Busch which had incomplete or inadeq te e.cu=entation for velding inspection. NCR yl3h5, dated May 17, 1978, covers all e= beds which are not yet installed. NCR #1346, dated !!ey 17,1978, covers those embeds that are installed, some of which are embedded in concrete. NCR #13h5 vill be field dispositioned in the following manner: 1. Haven Busch will revise its QA manual to allow reconstruction 4 of welding documents to correct errors in the use of their inspection form. This revision is subject to Project Engineering approval. 2. Where reconstruction of documentation is not feasible, the embeds will be reinspected to verify the integrity of the velds in question. 3 Some items which are no longer necessary, due to redesign, vill be scrapped. NCR #13h6 vill also be partially dispositioned by reconstruction of 1 x_,) documentation. Items which cannot be dispositioned by document

6 O . Q/ reconstruction vill be referred to Project Engineering for disposition in one of the following ways: 1. Perform a design stress analysis to determine if the embed could function safely if the nonconforming veld, or velds, vere non-existent. 2. Accept the velds by statistical analysis after re-inspection of available embeds. 3 Load test a percentage of the embedded items. NCR yl3h5 should be closed out by June 30, 1978. NCR #1346 should be at Project En61neering for disposition recommendations by June 30, 1978. CPCo vill provide to you by August 30, 1978 the final results of the disposition to the two subject nonconformance reports and the date that corrective actions will cause full compliance to be achieved. O l O f

I i l t a Howe 78 i Respense To NRC Item cf Ncnce=cliance ~ (50-329/78-03-02;50-330/78-03-02) Nenspecification of Welding Arc Voltage in Bechtel Welding Procedure Specification Pl-A-LH e i ~'l b. I' 1'arn)) Prepared by John W Walvecrd Engineering Services Censumers Power Ccmpany June 5, 1978 l l l - =

f^b \\v TAElE OF CO?TTEICS Page IntroductiCC...................................................... 1 1 Re s tat ement of IEC Viewpo ints..................................... 1 Consur.ers Power Position......................................... 7 Sur.=ary........................................................... Action Required for Ccepliance.................................... 7 - Item 5 of ImC Inspection Report - Bechtel WPS Pl-A-LH - Bechtel General Welding Standard 74S Structural Atta?.cnt 4 - AWS Dl.1-72, Paragraph 4.10.2 .Atte"--ent 5 - AWS Dl.1-72, Paragraph 5 5 through 5 5 2.1 Att:P..ent 6 - Weld Bead Profiles Picture - NJS Dl.1-72, Paragraph 3.6 Atta:. cnt 8 - AWS Welding Handbock " Arc Length" Attach =ent 0 - Lincoln Sa=ple Welding Procedure Attacn=ent 10 - ASM Handbook Volu=e 6, " Arc Length" \\

./O V

Response

To NRC Ite= of Nonce =pliance (50-329/78-03-02; 50-330/78-03-02) Nonspecification of Welding Arc Voltage in Bechtel Welding Procedure Specification Pl-A-LH Introduction The folicwing is a response to the NRC ite= of ncnce:pliance (50-329/78-03-02; 50-330/78-03-02) by Mr K R Naidu which resulted fro = his retiew of Bechtel Welding Procedcre Specification (WPS) Pl-A-LH Structural (Attach =ent 2). Restate =ent of ERC Viewpoint Frc= Ite: 5 of the NRC inspection report (Attach =ent 1), the NRC has taken the position that Consumers Power through Bechtel has violated the ARS Struc-tural Welding Code by failing to state the are voltage required for proper electrede operation. The state =ent of ncncompliance is based en three ref-erences. These are: 1. The NEC report quotes a Bechtel General Welding Standard as stating, " Electrical process variables shall be specified in the applicable WPS." (A,,) 2. The NRC report quotes the AWS Dl.1-72 Code as stating in Paragraph h.10.2 (Attach =ent h), "The classification and site of electrode, are length, voltage, and a=perage shall be suit 9.d to the thickness of the =aterial...." 2 3 The NEC report quotes the AWS Dl.1-72 Code as stating in Paragraph 5 5 2.l(4) (Attachment 5), "A change of more than 15% above or below the specified =ean are voltage and a=perage for each size electrode used is considered a change in the essential variable and requires es-tablishing a procedure qualification." These three references are the basis fer the NRC's issuance of nonce =pliance concerning the lack of control of the welding voltage. Consumers Power Position In respense to the citation of nonec=pliance stated above, Censu=ers Power takes the position that we can only be considered in nonec=pliance with the j AWS Dl.1-72 Code by not listing a useable voltage range en the prequalified i welding procedure specification for information only as is i= plied in the Code. The AWS Dl.1-72 Code does not consider are voltage an essential l (1) Structural Welding Code, AWS Dl.1-72, A=erican Welding Society, Miami, Florida, 1972, p 25 ( Ibid, p 40 I i

p m N.)\\ / variable for prequalified welding procedure specifications. The Code only i= plies that this infor:ation should be provided on the WpS fer= provided in Appendix E. To ec= ply, welding procedure specifications for shielded metal are welding vill be provided with an are voltage rence. Arc voltage centrol will continue to be provided through are length centrol by quali-fled welders. In response to the specific argu=ents provided in the 12C finding we effer the folicwing arguments: 1. The measurement and monitoring of are voltage for the shielded cetal are welding process are unnecessar/ since are voltage is a direct func-tien of are length and the control of are length is a natural function showninFigure2.6gitageiscadeupofthreeseparatevoltagedrops cf the process. Arc v , below. c: i E ese , Aus w a j 15 = g j l e.+ wooe,

• c e.n u.

m l. i.'!-!'; e.. n v CamG hg 2.6 - Arc potennal(volts) distnbuten bermen meaode and work. These voltage drops are the anode voltage, cathode voltage, and placca voltage. Only the plasma voltage is affected by are length changes. Since the plasma voltage is a s=all portion of the total are voltage, acceptable changes in are length have s=all effects on are voltage. Arc length bounds are established by the process itself without external control or monitoring. The mini =um are length is establishe:1 as the eini=um are length which will support an are without sticking the elec-ti ede. The maxi =um are length is established as that are length which will support a stable are or prevent gas entraptent. Beycnd that maxi- =us are length, the are is unstable. and metal transfer is hapha::ard er porosity results. Both the mini =us and taxi =um useable are lengths are ob.ious characteristics to a qualified welder. Since we are controlling the useable are length with qualified welders and are voltage is a Welding Handbook, Volu=e One, Seventh Edition, A=erican Welding Societ7s Mia=1, Floricia,1976, p 55 (

3 ( function of this are length, we are therefere controlling the voltage within useable li=its. In a discussion of energy input during velding, the fol10 wing state-ment is made in Weldability of Steels: VI "In this expression [E=dg, where E is energy input, d is a constant of prcportionability, V is are voltage, I is a=perage, and S is the travel speed], E is the energy input to the weld. It includes all sources of heat; that transferred by superheated filler metal, that produced by the anode or cathode, and that radiated frc= the plas=a. Although the plas=a energy may be great, =ost is radiated to the at=osphere and little of the plas=a heat is transferred to the work. Therefore, a voltage increase caused by a longer arc does not contribute proportionally =0re heat to the work but =ay, in fact, have no effect. However, with most arc-welding processes, the are length is established on the basis of optimum weld congeur and are stability and, therefore, can be considered constant." The effects of sete process variables are shown in Attach =ent 6. For tne purposes cf construction and fabrication, we interpret epti=um v:ld centours to be these which are ageeptable under Paragraph 3.6 ef

ne AWS Dl.1 Structural Welding Cede.

The required are length (are voltage) is that which provides acceptable bead contours. Since the {' welder is trained and qualified to use an appropriate are length to pro-a;.a a sound weld with acceptable conteurs, the =easure=ent of are vol-4 ';g: would represent an unnecessary duplication of effert which is costly u. would not i=preve weld quality. 5:rthermore, due to the operating charneteristics of =achines used for shielded metal are welding (SMAN) the s=all changes in are voltage vhich occur over a normal operating are voltage range (usually about i six volts) have very little ef{ect on the heat input to the weld. Figure 1.18 frc= the Welding Handbeck shows sc=e typical voltage /acperage curves for a constant currentctype power source, the type of power scurce used for the SMAW process. If a particular curve is chosen which repre-sents one =achine current setting such as the " Range C, Max" setting, the voltage vs a=perage curve illustrates that an increase in are voltage i (are length) results in a slight decrease in current. This ce=pensating feature has been designed into a SMAW power source to allow the welder sete variatien in are length without variation in heat input. 1 i (4)Weldability of Steels, R D Stout and W D Doty, Secend Edition, Welding Ee-search Council, New York, New York,1971, p 42 (3)The Procedure Handbook of Are Welding, Twelfth Edition, The Lincoln Electric Company, Cleveland, Ohio,1973, p 6.2-17 (6) Structural Welding code, AWS Dl.1-72, A=erican Welding Society, Mia=i, I Florida, 1972,_p 20 (7) Welding Handbook, Volume Two, Seventh Edition, A=erican Welding Society, Miami, raorica, lyso, p 26 -m ,--m.

---

,_y u

-.m-, 4 <-g-, w .-7 w g--y-- =*-r-gg

h O -Q Again, the control of are voltage is dependent on the velder's control of the are le=gth within reasonable limits as he was taught prior to qualification. 100 Maximum open-circuit voltage Ranges A, D C, anc o are four current range settsnas of the power supply Range A, mea Reage B, man R:np C, man Range o.maa Minimum '"#'8"I' "oltW)e

• 50 v

q Reage of typ cal /ll,/, n,, 7,,n., e min o min 8 min A men e O O 100 200 300 400 Amperes g%) Fig.1.10-Volt. ampere relationship for a typical constant current rotating type power source Fev if a=y velding handbecks or other sources of infer =ation list are 2 voltage as a process variable for the shielded retal are velding (SMEa') process. 8 The Welding Handbook under the section on velding procedures for SPXJ lists the following variables: a. Electrode Diameter b. Welding Current (1) Type and Polarity (2) Amplitude c. Arc Length d. Travel Speed Are voltage is mentioned peripherally in the paragraphs on are length (0) Ibid, pp 66-69 L y

5 x ( Attach =ent 8) with the following two sentences : " Instantaneous are voltage varies as droplets of =olten metal are transferred across the are, even.vith constant are length. Hev-ever, any variation in voltage vill be =ini=al when velding is done with the proper a=perage and are length." In The Procedure Handbook of Arc Welding the sa=ple procedures pro-vided for SMAW (see Attach =ent c) list the following variables: a. Position b. Weld Quality Level c. Steel Weldability d. Accessibility e. Plate Thickness f. Weld Pass g. Electrode Class h. Electrode Size 1. Current Including Type, Polarity and A=plitude

j. Travel Speed Fer the above procedures, are voltage is assu=ed to be controlled through proper are length crutrol by a qualified velder.

T.c the Metals Handbook, the section on SPAW =entions are voltage in the v' raragrapns on are length (see Attach =ent 10). These paragraphs place the j e-ntrol of are voltage in the hands of the qualified velder through his j car.crol of are length. l 8 3 As =entioned previously, are voltage changes instantaneously. Although this has no effect on the SMAW process since the i=portant control is that of are length, the =easure=ent of are voltage is a difficult pre-First, are voltage is only truly =casured between the end of the cess. electrode and the point of contact on the work. Measure =ent of are vol-tage fro = any other point such as at the =achine ter=inals will be er-reneous due to voltage losses in cables, contact points, etc. These lesses are not 1._portant when kept within reasonable li=its since the 1 qualified velder and the power source vill ce=pensate for a slight change of heat input, but these voltage d.rops vill have a =enacing effect en any atte=pt to =easure and =onitor are voltage. Second, are voltage changes instantaneously with =etal transfer through the are. (9)The Procedure Handbook of Arc Welding, Twelfth Edition, The Lincoln Electric Co=pany, Cleveland, Ohio,1973, P o.2-30 ) Metals Handbook, Volu=e 6, Welding and Eracing, Eighth Edition, A=erican O Society for Metals, Metals Park, Ohio,1971, p 9 O \\

6 O Third, violations of are voltage ranges are guaranteed by the nature cf the process. To start an are with the SMAW process, the welder =ust strike the are on the work and draw the electrode away as the are is initiated. Striking an are implies short circuiting the path between the electrode and work. A short circuit is defined as a path of essen-tially no resistance which will provide no are voltage drop as the are is being initiated. As the are is extinguished, the wulder will draw the electrode away from the molten puddle resulting in a long are length and a corresponding high are voltage. Both of these circumstan-ces are normal characteristics of the shielded metal are velding pro-cess and will occur ever/ time an are is started and stopped. It is not-the intent of any censtruction or fabrication code to cause con-trol of are voltage for the SMAW process to be a QC problem because of these voltage excursions. 4 In respense.to the NRC argument which quotes the Bechtel welding stan-dard, the Bechtel General Welding Standard GWS Structural, Revision 2, states in Paragraph h.2.1 on electrical characteristics, " Process variables shall be as stated on the applicable WPS." This statement does not require these variables to be stated on the WPS nor does it require their measurement or menitoring. 5 In response to the NRC argument which quotes the AWS Dl.1-72 Code, Para-eraph 4.10.2 under " Procedures for Shielded Metal Arc Welding" which states, "The classificatien and size of electrode, are length, voltage, anc amperage shall be suited to the thickness of the material, type of ..asve, welding positions, and other circumstances attending the work;" i a.- stated previously, we are controlling the are length at Midland 'hreugh welder qualification and, since are vcitage is a function cf i I. nre length, we are in effect controlling the are voltage within a suit-able range as required by this paragraph of the code. 6. In response to the NRC argument which quotes the AWS Dl.1-72 Code, Para-graph 5 5 2.l(4), this paragraph is under the heading of " Procedure Qualification." Since the welding procedure in question (Pl-A-LE Struc-tural) is a prequalified welding procedure as specified in Paragraph 1.3 1 of the AWS Dl.1-72 Code and does not require procedure qualifi-estions, Section 5, Part II, on procedure qualification does not apply. As stated in Paragraph 5 51 of AWS D1.1-72: "When necessary to establish a welding procedure by qualificatien as required by 5 2 or contract specifications, the follewing rules apply...." The limitations of variables which are called out by Paragraph 5.5 1, such as those specified in Paragraph 5 5 2.l(4), apply to procedures which require qualification, not to prequalified procedures such as i Bechtel Welding Procedure Specification Pl-A-LH. Paragraph 5 5 2.l(h) does not apply for Bechtel WPS Pl-A-lH. g *ta 2/20/69 Metallurgical 4 Qialiti Cons riel I __+..--_-__..__--e.-._ .c - -=

llLt.li 1 ; t, sevw t.n i.v a r.m n a se p, ,, g,g g .y' W r.LDING PROC 1:'.DUR E Ol' A L.!F!C ATION RI-COR11 P O R N o.') Date R/M/t3 ')rnecclure 5pecification No. P I - A - f.h Location San Francisen Shieltler! M etal A rc 3cif *); Process California ( to i t s elf ,... )ii. l Specification: As r A A106 Gracio H k $hemistry e a rban utant hSME P-No. I to 1 Shape Pine Thickncss 0. 365" Thickness Rance Qualified I /16" th ru O. 7 30" Outside Dian.cter (O. D. ) 10-3/4" O. D. Range Qualified All Filler Metal Specification: hSME SFA 5.1 AWS Classification E7018 F-No. 4 A-No. I hSME AWS Classification F-No. A-No. ~-- ~~~ ~~~ Filler Metal Chemistry Wire / Electrode Diameter Y.4 nufacturer and T rad. Name FL H 170LA Shielding Gas None Flow Rate JOINT DESIGN: Consumabic Insert Position of groove 2 G I, 5 G ).7y" t gy' Backing None li 4 - M. ~ Backing Gas Flow Rate Polarity DCRP ,, ' ~5 '"!'/gh Amperage k 1 i Voltage I 'I Multiole pass per side v,.. bN Welding Direction un far 50 T ravel Speed HEAT TREATMENT: (ambient 60 F) N"e Preheat Temp. Min. None Pos.. weld Heat Treatment Temp. Postweld Heat Treatment Time Maximum Interpass Temp. Minimum Interpass Temp. UTS. nsi l Position l Remarks Width (In. )l Thickness (In. } l Arca (In.1 Loa d, lb s. Reduc ert l70.370 l ZG l Ssetion 1 169.250 l ZG l Tensile f69.250 SG l Tests 69.440 l SG l l Guided Type i Result i Tvoc i Result Bend 4 rootdu i 180*OK 2 root 5G i l ev _OK j _ Tests 2 face 2G l 180"OK 2 face SG l 180 ' OK l lLmoa ct s ^ lOthcrl } Mechanica1 Testing By Testine Eneincers & Dechtel Lab No. Weldefs Name Burt Blalock Symbol Test Conducted By p er n,.,,,,,. We certify ihat the statements in this record' arc corrcet and that the test' welds hre pr'epared. welded, and tested in accordance with the requirements of Secti<>n IX ofte) ASME Code, V Revised from AWS to ASME filter metal DECHTEL POWER CORPORATION f / specificatione 3/12/73 By 3.M.h v M u.......,...,...,........ ~- .N,__ _y

Form Wit -2 A. llev. DECllTEL POWER ColtPOR ATION E# "' I "Il WELDING PROCEDURE OlJALIFICATION RECORD POR No.10 PI*A*Lb Date 3/3/65 P-cceiure Spet ification No. ( )ing Process Shielded Metal Arc Location San Francisco V Califo rria Material Specification: ASTM A106 Grade B to itself Chemistry carbon steel ASME P-No. I to 1 Shape Pioe Thickn e s s 2" Thickness Range Qualified 3 /16" thru 4" Outside Diameter (O. D. ) 10-3/4n O. D. Range Qualified All Filler Metal Specification: ASME AWS 5.1 AWS Classification E7018 F-No. 4 A-No. I ASME AWS 5.1 AWS Classification E7016 F-No. 4 A-No. I Filler Metal Chemistry Wire /Elcetrode Diameter Manufacturer and T rade Name Arcos (7016) Alloy Rods Atom Arc (7018) Shiciding Gas None Flow Rate JOINT DESIG5: ~~~ .. I o Consumable Insert N2 - N Position of groove 2G and 5G o o jg g j Backing None Backing Gas Flow Rate j - ~ - - }, l ,g - --- Polarity DCRP 4 \\ 9 g Amperage yf Voltage i, a N. I S ) gR~~i j. Multiple pass per side Yes g Welding Direction Up for SG 9 II e, a J/d Travel Speed ii % _ o. HEAT TREATENT: o o Preheat Tc .p. Min. 200 F Postweld Heat Treatment Temp.1150 F 125 _ o Maximum inte rpass Temp. Postweld Heat Treatment Time ~ 2 hours Minimum Interpass Temp. Width (In. ) Thickness (In. ) Arca (In.2) Loa d, lb s. UTS. osi l Position l Remarks Reduced ~ !65,306 1 2G l Section 68,367 4U 1 J Tensile 68,307 5G l l Tests 65,30o l 5G j l Gutded Tyne Result T ype i Result Bend 4 ride ZG 1 B0"OK l l i Tests 4. ,1,. cn l 180*OK i Imoa ct s lOthe rl Mechanical Testing By PTI. and Bechtel Lab Lab No. -- Wclder's Name W. B. Keyse r Symbol Test Conducted By w. n. K..v n e r Q We certify that the statements in this record are correct and that the test wclds c prepared. welded. and tested in accordance with the requirements of Section IX l Uhe ASME Code. l ..nto: Revised from AWS to ASME filler metal BECHTEL POWER CORPOR ATION specifications 3/12/73 D y_ (3. h. )Pism8'/,,/ Recordc<l on New Forin_ 1/?.3/73 Materials L Fabrication

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ATTAC10ENT 3 e< e BECHTEL PO4IR CCRPCF.ATICH Materials & Quality CENEPJd. Services WELDING STANDARD Authorized in use CWS-Structural Date Septe=her 1, 1977 Rev. 1 Prepared G /ja.'. C - dj Reviewed k/ # 4L./ By w Approved h h %.._ 9, Manager of Engineering W.R. Smith. Sr. TPO Authorized for use only when signed

• the Manager of Engineering-TPO.

1.0 SCOPE 1.1 This General Welding Standard is to be used in conjunction with the cpplicable Welding Procedure Specification (WPS) for general structural velding cpplications such as building steel or e= bed =ents. Other applications such as hoppers, tanks, fuel pool liners, and circulating water pipe =ay use this specification as,a project require =ent. 1.2 When required, each W75 has been qualified in accordance with the require-nents of the applicable construction Code. Under AWS Dl.1 Code, certain procedures cre deemed "prequalified" and do not require qualification testing prior to use. Each WPS vill indicate which qualification tests, if any, have been performed. 1 2.0 ?ROCESS Ibe velding process or ce=bination of welding processes shall be as specified in the applicable WPS. 3.0 KATER!ALS 43.1 hose Materials Base =aterials used in confor=ance with this standard shall have che=ical, cechanical and di=ensional characteristics specified in ASME and/or ASTM Standards er in :pplicable job specification. For applications in which AWS Dl.1 is =andatory, culy those L.;crials listed in AWS Dl.1 and steels which have had veldability cstablishu..2 required shall be used. For applications where AWS Dl.I has been referencec as a convenience, the =aterials listed in AWS Dl.1, in job specifica-tiens er *'- s given an ASMI P Nu=ber =ay be velded, and used in conjunction with prequalif'.e! procedures. For velding with other than prequalified procedures only caterials listed in the WPS =ay be used. 3.1.1 !f velding is required for any steel with =inimu= specified yield strength 60,000 psi or higher or a steel with =ini=u= specified tensile strength cver 71,000 psi, M&QS shall be consulted. 3.2 Backine Meterials 3.2.1 Metallic eacking =aterial, if required, shall be si=ilar in che=ical cerpetition to the base =aterial and shall not cause har=ful alloying or conte =i-nation of the veld =etal. Alternatively, =etallic and non=etallic backing =sy be specifie$ in the the WPS. A 3.3 Weld Filler Meterial 3.3.1 Enless etnervise stated in the applicable W?S the veld filler =atericls to se used shall confor= to the require =ents of AWS specifications. 3.3.2 Covered electrodes that have vet or da= aged coatings shall not be used. 3.3.3 Lov hydrogen type (IXX16 and EXX18) electrodes and sustenitic stainicss steel electrodes shall be purchased in hermetically sealed containers. All cevered electrodes shall be scored in a clean, dry area. Lov hydrogen electrodes re=oved from sealed containers shall be stored as required by job specifications. 3.3.4 Flux-cored electrodes and other spooled electrodes (vire) shall be pur-chased in sealed containers. All bare electrodes, rods, flux-cored electrodes and flux shall be stored in a clean, dry area. 7s ( ) s-MOS-Urs-009-1 ~ Rsvision 0, 1/7/76 \\ cA.N'C -m.,. n .. se

Hiscellaneous $$1 dine Hsterials '[3.4 Inc composttion snc slow rate of shiciding gases shall be as spacified A' }. 4.1 in ene WPS. Csses shall be velding grade or better. Shielding gas manifold purging and bleeding of lines and systems shall contain suf ficient valves to permitshould be drained or replaced if to prevent backfilling with sir. The system . condensation accumulates in lines. All joints shall be tight to prevent aspiration ( of air. The velding electrode' to be used with the gas tungsten-are velding (CTAW) 3.4.2 process shall be an electrode per AWS A 5.12, as shown in the WPS. ) 4.0 WELDINC REOUIRI."INTS Prepsrstion of the Base Material 4.1 Ine methods permittec for veld end preparation are machining, grinding, 4.1.1 flame cutting, and arc-air gouging. See dra 'nr CWS-Structural-1 for the mini =u: preheating requirements prior to and during all thernal gouging, ther=al cutting and velding. Fla=e cut veld end surfaces and repair cavities shall be ground to bright metal prior to velding. The method of weld end preparation shall leave the surfaces reasonably 4.1.2 smooth and free frc= notches or other har=ful irregularities which could cause lack of fusion or slag entrap =ent. The bevel angle, spacing and other details shall be in accordance with A 4.1.3edge preparation drawings included in the job specification or referenced Codes veld Where veld symbols are used in lieu of veld end preparation drawings, these details -13 shall be essentially in accordance with Drawin;s CWS-Structural-2. thro-which are prequalified and cay be detailed with the following toleran:es: Tolerance Plus(+) Minus(-) Root Face (land) 1/16-inch 0-inc h j Root Opening (gap) 1/16-inch 0-inch j Croove Angle 10 degrees O degrees "U" or "J" Croove Radius 1/8-inch 0-inch Additionally, the following verkmanship tolerances may be applied to the prepared joint as s e=bly : TOLERANCES Dimension ROOT NOT COUCID ROOT COUCID Plus(+> Minus(-) Plus(+) Minus(-) Root Tace (land) 1/ le-inen 1/le-inch No li=i't Root Opening (gap) open bute 1/16-inch 1/16-inch 1/16-inch 1/S-inch Root Opening (gap) with backing 1/4-inch 1/16 inch Not applicable Croove Angle 10 degrees 5 degrees 10 degrees 5 degrees T/10 or 1/8-inch whichever is less, where T Align =ent equals the thickness of the thinner part. l Two exa=ples of the tolerances; of root opening (gap) and how they can accumulate Example #1 Example #2 Q Prequalified gap 1/4 1/4 e 0 q Design tolerance + 1/16 ?- Asse=bly tolerance + 1/4 -1/16 ec; Total gap as velded 9/lo 3 / lo o i e "S 3 ,E 4.1.3.1 The gap between parts to be joined by fillet velding may exceed 1/16 inch $ only Li the leg of the fillet is incressed by the amount of the sepsration or it is e demonstrated that the required effective throat has been obtsined. The gap : hall not exceed 3/16 inch except for materisl 3 inch :: ; rester in thickness ubere fit-u- ) t 2 2 I8

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O ccnnot cisse ths gep to 3/16 inch cr loss. In such essas a caximu= gap of 5/16 inch is ccccptabic providad e saaling v31d or suitable backing =aterial is used to prevent =elting through. A 4.1.3.2 Root openings vider than those permitted in 4.1.3, but not grester than twice the thickness of the thinner part or 3/4 in. (19==h whichever is less, may be corrected by velding to acceptable di=ensions prior to joining the par:s by velding. 4.1.3.3 Root openings vider than those permitted above should be referred to the Project E gineer. 4.1.3.4 Fillet velded T-joints are prequalified when the T is skewed to no: less than 60 nor more than 135 degrees. 4.1.3.5 Joint di=ensions and fit-up require =ents for tubular structural =e=bers shall be referred to Project Engineering. ~ 4.1.3.6 Croove preparation =ay be in either or both ce=bers to develop the incluced angle, unless noted otherwise. 4.1.4 Prior to fit-up and welding, the groove face and adjacent surfaces shall be cleaned to re=ove all grease and oil. Rust, scale or other foreign ea:erial shall be re=oved to clean =etal by filing, brushing or grinding. 4.1.5 Deoxalu=inite (rust inhibitor) =ay be used on ferrous =aterials to preven: rus:Ing. If used, Bechtel's standard GWS-Deox must be followed. Deoxalu=ini:e need not be re=oved prior to velding. 1 4.2 Electrical Characteristics 4.2.1 Frocess variables shall be as specified in the applicable WpS. These ranges vill cover =ost applications but should no: be construed as inflexible since individus1 circu= stances =ay dictate operation out of the reco== ended range. For =schine/ auto =stic welding special require =ents for the velding equip =en: vill be specif M in the applicable WPS. 4.3 Technicues A 4.3.1 Welding shall not be perfor=ed when the surfaces of the parts to be velded g are. vet, or during periods of high vind, unless the velder and/or velding operator F /N and ven are properly shielded. See 4.1.5. If =oisture is present, based on visual Q exa=i w ien, the joint surfaces shall be dried by use of an approved solvent, by fla=e torch, by preheat equipment, or other engineering approved =ethods. A 4.3.2 Cla=ps, velded clips, tack welds or. other appropriate =eans shall be used to prcpetly align the joint for velding. Welded attach =ents used for fit-up shall be si= uar in chemical co= position to the base =a:erial. Preheat for velding a::ach-d een:s shall be in accordance vi:h this standard. The attach =en:s =ay be re=cved by any suitable means followed by grinding flush with the base =aterisl. When ther=al cutting is used to re=ove at:ach=ents, a: lesst 1/8-inch shall be lef: for final I 1 re= oval by grinding. The ground area shs11 then be visually examined for defec:s. Any defects found shall be re=oved by further grinding and/or revelded and reexamined if necessary. Revelding shall be perfor=ed with a WPS selected by the Lead Field U*ing Engineer (LFWE). The area from which attach =ents have been re=oved snall be given nondestructive examination as required by the Code or job specifications. 4.3.3 Tack welds shall be velded in full co=pliance with this Welding Standard and if no: re=oved shall be exa=ined visually for defects prior to star:ing a { per=snent v21d. Multiple pass tack welds shall have cascaded ends. 4.3.4 On all full penetration joints velded fro = both sides, the root of :he lC first veld shall be gouged, chipped, ground or =achined to sound metal prior to 3 velding the other side. Oxy-fuel gouging =ay be used only for plain carben steel n) =aterials. AA.4.3.5 Welding of critical joints or joints in restraint, which require prehes: 80 in excess of 150 F shall not be interrupted until at least one-fourth of the veld 4e groove is filled or the veld thickness reaches 3/8-inch, whichever is less. J @! 7 Operations such as slag re= oval, lunch breaks, shif: changes and nondestrue:ive T cxaminstions are not considered as interruptions. During lunch break or shift E change periods, the veld cres shall be suitsbly protected with insulation. CW3-8'~"CI"7"I 2 3 IS

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c 5.3.5.1 If us1 ding is interrupted for any reascn, the joint shall be allowed to cool slowly. Before velding is resumed a visusi examinscion shall be conducted, j a If defects are detected, repairs shall be in accordance with paragraph 4.5 of this standard. Prehest shall be reestablished before velding is resumed. 4.3.6 Each veld bead shall be cleaned essentially free of slag or other foreign I material before depositing successive beads. Each veld layer shall be free of excessive irregularitics, such as high spots, deep crevices and porosity. 4.3.7 The veld progression shall be upward for the 3G, 5c and 6C positicas except where otherwise permitted in the WPS. For velding in the 2C position, ebe veld metal shall be deposited using the stringer bead technique. A 4.3.8 In general esch veld layer shall be. ce=pleted before a subsequent layer i is started. 4.3.8.1 For purposes of caintaining alignment or controlling distortion, it is permitted that one or more partial layers be velded vichout ce=pleting a layer. Partial layers =ay be applied in one or more joint, seg=ents. 4.3.8.2 Partial layers may be velded to correct underfill conditions. 4.3.3.3 A veld joint or layer uay be started at any location. Either direct progression, or back step technique may be used. 4.4 Reeair of Defects 4.4.1 Cracks and other defects in excess of acceptance criteria that are detected during velding shall be removed by grinding, chipping, =achining or air carben-are gouging. When air carbon-are gouging is used, the gouged arca shall be ground to bright clean =etal. After re= oval of cracks, other than c$ater cracks, the area shall be examined by liquid penetrant or magnetic particle cethods to dete==ine that the defect has been re=oved. For other defects, including crater cracks, the areas shall *.~ exa=ined visually to deter =ine that the defects have been removed. A 4.4.2 Af ter velding has been co=pleted, defects in excess of the applicable standards required in the job specification shall be re=oved and accep - a repaired in accordance with the following sequence: 4.4.2.1 The repair cavity shall be prepared by air carbon-are gouging, chipping or Dross, scale and slag shall be recoved by grinding, filing or cachining. grinc nr. 4.4.2.2 The method of preparation shall leave the cavity with reasonably s=ooth surf aces free from er.cessive n'otches or other harmful irregularities which could trap slag c: -ause lack of fusion. 4. 4. :.. a Prict to velding, the surface to be velded shall be elesned to bright metal Dirt, oil or grease shall be removed by viping with a clean rag and a solvent such as acetone or alcohol as necessary. 4.4.2.4 Preheat te=perature, postveld heat treatment and nondestructive examina-tion for the repair shall be the same as required for the original veld joint unless otherwise per=itted by the Code or job specifications. 4.4.3 The repair shall be made with a WPS selected by the L7WE. 5.0 PREEEAT TEM?EMTURE 3.1 The m:.ni=us preneat temperature specified in Table I shall be maintained during all velding (See Drawing GWS-Structural-1). If the velding operation is interrupted, the veld joint shall be heated to the required preheat te=perature, before velding is resu=ed. 5.2 Preheating esy be performed using electrical resistance, induction units, or torches which provide uniform heating over the entire preheat stes. 1 5.3 Preheat temperatures shall be checked approximately three inches from the sh:11 3 bevel edge with temperature indicscing crayons or contact pyro =ecers. Preheat mD be maintained on the esterial beine velded at a distance equsi to the thickness of S. the veld, but not less enan tnree inches, in all directions from the coint of

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5 :/. Whsn the cmbisnt air temp 2rature in tha vicinity of the veld is in the l rcnge of 32 F - 150 F and the ninimum prsheat spacified in Tablo I is in the same range, verifiestion of the minimum preheat temperature by determining the actual metal temperature is not required. For ambient temperatures below 32 F, -t contact pyrometers may be used to verify that the metal temperature is not below the specified minimum preheat te=perature. Alternatively, to avoid measurement of metal te=perature the veld joint may be preheated'until varm to touch. l 6.0 POST *4LD EAT TREATMINT 6.1 The requirements Ior postveld heat treatment shall be as sp'eilfit.r M." ene WPS or as otherwise required by the applicable job specifications : (, shall be pe r f orme d in a c cerc.:inr,'; ,C""[,,g[" When required, the postweld heat treat =ent the applicable Code requirements. .. w 4,i '. ' ^ ;= : i 7.0 WILDER PERFORMAMCE OUALITICATION 7.1 Welders uno are requited to veld materials under this standard :'. be qualified in accordance with a WPS and Bechtel Performance Specific:- r., J WQ-2. 9 g ) [. '.+ 3 9 - , c4 ( l . ~... ',, - _9 / e hs N N me ies - oo I C i ~ t Fe'd i ie 2.C. 2 9/01/77 iGeneral Revision IRNS i Yj 1 6 2/12/75 IGeneral Revision IRWS 9, t 0 1 4/09/73 ilssued f or Cons:metion c; BY l FIVISICN NO. DATE I8 5 or 2 sutti M -F*'"'*H N arv. seccasicarise s o. - ~ ~ - m-

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• e TABLE I GENERAL PREMEATING R EQUIREMENTS Thickness Rances (inches)

{ i Over 3/4 Over 1-1/2 Electrode Tvee To 3/4 through 1-1/2 through 2-1/2 Over 2 1/2 E6011 E6010 150 F 225*F 300 F None E7010. A l A E7016,18,28 e o E70S None 70 F 150 F 225 F E70T Note 1: Welding shan not be done when the ambient temperatu e is Icwer than 0 F. Note 2: When the base metal temperature is below 32 F, the base metal shall be preheated to at least 70 F and the temperature maintained during welding. f A Note ?- This table applies to steel with minimus specified yield strength less than 60,000 psi, and with ninimum specified tensile strength 71,000 ps, and less. Preheat for higher strength steels shall be referred to M5QS. i N> 5 $,I e$ Drawine Number ROV-A CWS-Seructural-1 2 l ] rtic t tt r.1I 2 6 sFCCit te AflC E N O. g g y, ggggy ST n - -~- ~ ~ ~ ' p, . r.. mmmam.+ --

t ('~s O ATTAC}CEITT h AWS Dl.1-72, " Procedures fer Manual Shielded Metal Arc Welding i 4.10.2 The cLissi6 cation and size of electrode, arc length. voltage, and amperage sha21 be suited to the thickr.tsa of the materist. <>pe of grewc. weiding positions, and other circumstances attending the work. O 19tructural Welding Code, AWS D1.1-72, American Welding Society, Miami, Florida, 72, p 25 I I

h 2 ATTACmENT 5 40 l $rructural Welding Code tablished with a combination of base metals included in 10 2 of ddfer:nt minimuin spec 4ed yield strenges, one of uhich is greater than 50.000 psi. Shall quahty the procedure for welding that high yictd strength base metal to any other of those base metals having a minimum specified yielJ strength equal to or less than PQrt 11 Procedure that a ihe io.,r strenph eas, m iu used m the iest. QUclifiCQtion" 5.5.2 The changes set fonh in the following schedule shall be considered essential changes in a 5.5 Limiteilen of Variables scldins procedure and sha!! require estabbshins a new procedure by quahfication. When a combmation 5.5.1 Wh:n necessary to estnlish a welding pro. d *elang Processes as used, the variables applicable cedure by qualdicat:en as required by 5.2 or contract spectAcations, the following rules apply and the pro-to cach process shall apply. cedure sha!! be recorded by the manufacturer of 5.5.2.1 Shielded Metal. Arc Welding, contractor as a Procedure Specincation. (1) A change increasing 5Her metal strage 5.5.1.1 Ouslineation of a welding procedure es-level; e.g., a change from E70XX to E80XX, but tabbshed with a base metal included m 10.2 and not not wce wrsa. listed in 5.3.1.2, having a minimum specincd yield point less than 50.00a psi. shall quahfy the procc-(2) A change from a low-hydrogen type elec-dure for we! ding any other base metal or combina. trode to a non-low-hydrogen tpe of electrode, but tion of those base metals included in 10.2 having a not vice versa. miJmum specified yield point equal to or less than (3) An mercase in the diameter of the electrode that of the base metal used m the test. used, over that calied for in the procedure speci$ca. 3.5.1.2 Quali6 cation of a welding procedure es-

tion, tabhshed with ASTM A 4L A441. A337 Gr. A, f4) a change of more than 15% above or be-

. M72 Gr. 50, A388 API SLX Gr. 42, or ABS Gr. [m\\ AH. DH, or EH shall be considered as procedur, each saze electrode used. lo* the Spec 2fied mean arc voltage and amperage for \\"/ quah5 cation for meldmg the other steels of this group, combinations cf them. or with steels included (5) For a speci6ed groow, a change of more m 10.2 having a lower mimmum specified yield pomt. than :::25% in the specified number of passes. 5.5.1.3 Quali8 cation of a welding procedure es. If the area of the groove is iacreased, it is also per. tablished with a base metalincluded in 10.2 having missible to increase the number of passes in propor. tion to the increased area. a mmutum specined yield strenph greater than 50,000 psi shall quahfy the procedure for welding only base (6) A change in position in which welding is done metals of the same Material Specification (ad Grace as denned in 3.g. or T pe having the same mirumum spect6ed yield W A change in er type of groow; e.g., a change 3 s:reng:h as the base metal tested. reduction in yield I""

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strength for meresse in material thickness excepted; Lc a procedure qualified with a 1 in.-thick 100,000 (g) A change. exceeding tolerances of 2.9. 2.10. psi yield strength base metal also qualifies for a 3 in.. or 10.13 in the shape of any one type of groove in. hick 90,000 psi }ic!d strength base metal of the same volving:

• aterial Speci5 cation.

(a) A decrease in the included an51e of the 5.5.14 Qualificatien of a melding procedure es-groove or (b) A decrease in the root opening of the

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. s t a.. a .a (c) An increase in the root face of the groove ea aw . = = n Of a4== (d) The omissior of backing matertal but not vice versa. (9) A decrease of more than 25 F in the mini-mum specified prehest temperature. (10) In the case of vertical welding. a change from the progression speedied for say pass from upward to downward or vice versa. ' hiJid, p ho

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Y, $??.$p$.kYda. iS Fig. E 26. Effect of welding variables on bead characteristics. Proper current, travel speed, and arc length (a). Current too low (b). Current too high (c). Arc length too short (d). Arc length too long (e). Travel speed too slow (f). Travel speed too fast (g). EThe Precedure Handbook of Arc Welding, Twelfth Edition, The Lincoln Electric p Company, Cleveland, Ohio, 1973, P 6.2-17 + -w-w. e -,.----ie -.w--my.-p-cr-

i 1 l gs ( ) L.) 6 ATTACF2 G 7 3.6 Wek! Pro 6fes 3.6.1 The faces of Silet melds may be slightly convez, Rat or shghtly concave as shown in hg. 3 6. Dctads A. B. and C. sith no defcets as such shown in Fig. 3.$. Dr:sil D. Eacept at cutside cor. ncr joints, the cc,nseuty dian not exceed the value of 0.15 plus 0.03 in. where 5 is the actual size of the Silet wcld in arches. (See Fig. 3.6, Detad C) 3.6.2 Groeve utids shall preferably be made with shght or minimum remforcement except as may be otherstse prouced. In the case of butt and corner jomts. the remforcement shall not exceed % in. to height and shall have gradual transttaon to the plane of the base metal sunace. (Fig. 3.6. Detail E) They shall be free of ddects as shown for butt joints in Fig. 3.6. Detail F. 3.6.3 Surfaces of butt joints required to be Aush shall be Snished sn as nr4 to reduce the thickness of the thinner base metai cr meld metal by more than tj, In. or $r's of the thickness, whichever is smaller, or leave remiorcement that eteceds %: in. Howeser, all rear.forcement must be removed where N the weiJ forras part of a faying or contact surface. Any reinforcement must bicnd smoothly into the plate surfaces with transition areas free from edge weld undercut. Chippmg may be used provided it is followed by grinding. Where surface 6aishing is required. its roughness valuct s ha!! not exceed 250 s MU.in. Surf aces 6n:shed to salves of over 125 MU. in. through 250 MU.in. s: tall be Antshed parallel to the streetson of pnmary stress. Surfa;es anished to values of 125 MU.in. or less may be Snished in any directen. 3.6.4 For buildings and tubular structures un. dercut shall be not more than 0.01 in. deep when its Urection is transverse to primary tensile stress in the part that is undercut, not more than % in. for all other situations. 3.6.5 For bridges, undercut shall be not more than 0.01 in. deep when its direction is transverse to sne primarv stress in the part that is undercut. Undercut shall b: not more than 8is in. deep when its direction is parallel to the primary streu in the part that is undercut. 3.6.6 Welds shall be free from overlap. 6Structural Welding Code, AWS Dl.1-72, American Welding Society, Miami, Florida, (g 1972, p 20 d %) 1 ~

ATTAC1B'EIT 8 ~11 ~ l n f i tenty. Although the are length does change to some extent with changing condidens, certain fundamental pnnciples can be given as a guide to the proper ue length for a given set of conditiorA For downhand wc! ding, panieularly wna heavy electrode covenngs, the tip of the c!rtrode can be dragged lightly along the joint. The are length, in this case, is automatically determined by the coating t!uckness and the meldng rate of the electrode. Moreover, the are length is uni. ARC LFNCTH form. For vemeal or overhead welding, the are i length is gaged by the welder. The proper are The are length is the distance from the mol-length, in such cases. is the one that permits the l ten tip of the electrode core wire to the surface welder to control the size and motion of the of the molten weld pool. Proper arc length is im-molten weld pool. portant in obtaimng a sound welded joint. Metal For fillet welds, the are is crowded into the transfer from the tip of the electrode to the weld joint for highest deposition rate and best pene-pool is t.ot a smooth, uniform action. Instaman-tration. The same is tme of the root passes in cous are voltage varies as droplets of molten groove w elds in pipe. metal are transferred across the arc, even with When are blow is encountered, the are length constant are length. However, any varisuon in should be shonened as much as possible. The voltage will be minimal when welding is done vanous classifications of electrodes have widely with the proper amperage and are length. The different operating chractenstics, including arc laner requires constant and consistent electrode length. It is important, therefore, for the welder feed. to be familiar with the operating characterisues ] The correct arc length varies according to of me types of electrodes he uses in order to rec-the electrode classification, diameter, and cover-ognize e.; proper are length and to know the ing composicon; it also varies with amperage effect of different are lengths. The effect of : and welding position. Arc length increases with long and a short arc on bead appearance with a inereasing electrods diameter and amperage. As mild steel electrode is illustrated in Figs. 2.13(D) a general rule, the arc length should not exceed and (E). the diameter of the core wire of the electrode. The arc usually is shoner than this for electrodes with thick coverings, such as iron powder or " drag" electrodes. Too short an are will be erratic and may shon circuit dunng metal transfer.Too long an are will lack direction and intensity, which will tend to scar.:t the molten metal as it moves from the electrode to the weld. The spaner may be heavy and the deposition efficiency low. Also, the gas and flut generated by the covering are not as effecove in shielding the are and the weld metal from air. The poor shielding can cause porosity and cont.;mination of the weld metal by oxygen or nitrogen, or both.The qual-ity of the weld will be poor. Control of are length is largely a matter of welder :, kill, involving the welder's knowledge, experience, visual perception, and manual dex-1 li V ~delding Handbeck, Volume Two, Seventh Edition, American Welding Society, 1 Miami, Ficrida,1778, p 68 i I

o m ATTACF3'Et'r 9 S.240 weiding Carbon and L ow. Alloy Steel SHIELDED METAL. ARC (MANUAll re e.ea vcus we ne.e o. e, t.e. cue see.ne.ee.a.,r e e n ee see.e o.esee \\_ t 2..T.,- / L; 1:s".$ kkur' e...ev e. i e I ss { ut i see i I e.. . i 2 i i 2-3 i i i 2-7 i i -i.. t ectenee c.es. I f69,0 67019 I E6010 (7058 ! EC010 I f7Ott 36010 I t'O't l S 32 l 32 i 1,32 S'22 5'32 1M l'32 S 32 4 5.re C.see.s f.+et DCf.i l 300 I iGO l 160 160 l ied 960 160 l 360 l 4,e $se e e,=... 4343 e 2231*i a247 32 3 6' j a 34 7 32 3 $* l 4347 1 32 3la ' F ecease een e ser'st l 0 28 l 0 34i 1 0 28i l 0 75a 1 0 23, l i93 l 0 20s 4 3 52 tete. T.e e.hreet se me.e* I O 104 0 t76 i 0 34i e Q 659 o e e., -.. .. --ee e e. SHIELDED METAL. ARC (MANUAll P i.e. wei.es v. nees Queen, Lo et: Case [ f Sises ne.se*v Game weases #coen Tae suses w 3 4L 8 e-2 j d 8 f L'e-11t2"<, 1 ~ l '8 3 x<

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~ 1/8" ~ e.e.e.,.e. _, i 2-s 6 i i 2-3 i i 2-> i i 2-, e.. t ectrees Cies i tsuic l E7018 160io l I?cis E60io ! f? cts l 8d010 E 709 0 5.re 6,32 f 6 22 S/32 e 6,32 i

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6 32 ca. s oci.i i too 1 160 t se I sao I e40 sa0 l se I see a,e sse.e.,.. 354 i. a i.4,, 3 ca i, 354i 3 s.4 i 232s i 3 s4 i 2 30 f.en,,ee eee s te<tes l 0 240 I 0 9CC i 0 2a0 0 3 64 0240 l 2 40 I 0240 l 2is ie... T.=e.*w **t es weast 1 0 230 1 0 367 0 514 1 0 64S Geog. est.o.pn for ee.e see e.. sue.e mee. q 9The Prceedure Handbeck of Arc Welding, Twelfth Edition, The Lincoln Electric ,) Company, Cleveland, Chio,1973, p 6.2-30

9 10 'y/ ATTACE'ENT 10 Arc Lengih The end of an electrode must be close enough to the work to ensure that molten metal from the electrode wul be transferred directly and accurately into the weld puddle. Arc length, the dis-tance between the end of the electrode and the weld puddle, is a designed function of the electrode covering, but changes may be necessary under some welding conditions. In general, are length should not exceed the diameter of the electrode ct.,re wire. Welders should deviate from this rule only on the basis of their skill and experience. Arc length is usually shorter for the types of electrodes that have thick coverings. Maintenance of are length depends mainly on the skill of the welder-which, in turn, depends on his knowledge, visual perception, man-ual dexterity, and experience. Arc length largely controls are volt-age and directly affects welding speed and emetency. Shorter arcs allow an increase in current, which will increase g rate of deposition and thus welding speed. When an arc is too long, heat is dissipated to the air, the stream of i molten metal from the clectrode to the work is scattered in the form of weld spatter, and deposition rate is reduced. In addition, susceptibility to are blow, and porosity due to loss of shielding, increase as length of arc increases. In welding with direct current, the shortest possible arc is used, to mini-mi e are blow and contamination by the air. Control of arc length in vertical and overhead welding demands greater at-tention from the welder and more skill than in welding in the flat position. In overhead weldmg, only certain types of electrodes can be used and the welder must adjust the are length dar-ing deposition to retain control of the weld puddle. For fillet welds, and for root passes in properly prepared butt welded pipe joints, the arc can easily be crowded into the joint for maximum speed and penetration. The impcrtance of controlling arc length is demonstrated in the example that follows. OMetals Handbeck, Volume 6, Welding and Brazing, Eighth Edition, American Society for Metals, Metals Park, Chio, 1971, p 9 _}}