ML19329F225
| ML19329F225 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 05/09/1978 |
| From: | Martinez P BECHTEL GROUP, INC., BECHTEL POWER CORP. |
| To: | |
| References | |
| BLC-5936, MCAR-19, NUDOCS 8006230751 | |
| Download: ML19329F225 (68) | |
Text
{{#Wiki_filter:l Bechtel Power Corporation l
\ 777 East Eisenhower Parkway J Ann Arbor, Michigan h Mad Address- P.O. Box 1000. Ann Arcor, Michigan 48106 May 9, 1978 i
i BLC-5936 Consumers Power Company THIS DOCUMENT CONTAINS Mr. G. S. Keeley, Project Manager P0OR QUALITY PAGES 1945 West Parnall Road Jackson, Michi8 an 49201 l Midland Units 1 and 2 Consumers Power Company i Bechtel Job 7220 MCAR-19 FINAL REPORT UNDERSIZED HANGER WELDS PER i VENDOR DRAWING REQUIRD'ENTS s_ Files 2417/2801
Dear Mr. Keeley:
Attached is the Final Report covering the deficiency described in MCAR-19. The Final Report includes a description of the discrepancy, a statement of the safety implications, corrective actions to prevent repetition; conclusions, and recommendations. The analysis of the discrepant shop welds, the results of the dectructive loading tests, and the established conservatism of Grinnell's designs confirm that no safety problem exists. This deficiency is now considered nonreportable. MCAR-19 item 3a required site-inspection of the Grinnell hangers shipped on October 31, 1977. The inspection performed found this lot of hangers acceptable. This Final Report completes scheduled action on MCAR-19. Very traly yours,
, .x%.?Wn;[~6 A-< w
_) Ne'- P. A. Martinez PAM/WGM/pp Project Maneger
'. Attachments (1) Final Reoort by Bechtel, May 3,1978.
(2) ITI Grinnell's Field Surveyed Welds Stress Analysis For Bechtel Associates Professional Corp., April 20, 1978. cc: Mr. R. C. Bauman w/o Mr. J. L. Corley w/o h /16 Mr. B. W. Marguglio w/o ' 8006230. j f
. Bechtel Associates Professional Corporation
- (1 777 East Eisenhower Parkway .
j Ann Arbor, Michigan a usoemese:P.O. Box 1000. Ann Arbor. Michgan 48106
SUBJECT:
MCAR #19 (Issued 11/7/77) *
- FINAL REPORT, Revision 1 DATE: August 1, 1978 h PROJECT: Consumers Power Company Midland Plant Units 1 & 2 '
Bechtel Job 7220 Description of Discrepancy Shop welds for various pipe hanger assemblies designed and fabricated by ITT-Grinnell were noted as underfabricated when compared to ,the sizes - required on the design drawings. A sample size of 125 shop welds was selected as representative of the total group of shop welds on the assembles supplied by Grinnell. All 125 shop welds were examined; from this review, 54 welds (i.e., 43%) were identified as underfabricated in size. Generally, this discrepant condition was 1/16-inch or less undersize.
+ Paragraph K-1310 of Appendix K, ASME Section III, Subsection NA, which
- supplements Article NF-4000 of Subsection NF on the fabrication and
- (- installation of component supports, states that the recommended maximum
( tolerances for weld sizes is'"plus only, no undersize permitted." The reason for the discrepancy appears to be three-fold:
- 1) Grinnell's internal weld inspection procedure was a visual technique which allowed shop fillet velds in any single continuous weld to have an underrud from the nominal fillet veld size required of 1/16-inch without c.orrection, provided the underrrun did not exceed 10% of the weld length. This is an accepted industrial standard for welded, structural members. .
I
- 2) Only shop welds that visually appeared suspect were inspected with a gage.
Ambiguous and inconsistent criteria in Grinnell's written procedures
)
- 3) '
for measuring and sizing obtuse angle fillet veld. Safety Implications l Initially, this deficiency was considered a potentially reportable discrepancy because a safety problem could exist if a Q-listed pipe i support should fail due to an underfabricated shop weld. However, based 4
-on the results of follow-up analysis which established the design conservatism of the support designs, and the results of the full size destructive , . loading test with both underspecified and underfabricated welds (reference s MCAR #18), we conclude a safety problem does not exist.
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. l Bechtel Associates Professional Corporation
*MCAR #19
'I' s 'Page 2 ~ Grinnell states that although some of the shop welds are underfabricated from the weld sizes specified on the hanger drawings, there is no safety problem as the welds were sized using allowable weld stress levels that were conservative when compared to the code. To confirm Crinnels's contention that no safety problem exists,.Grinnell : performed a reanalysis of the 54 discrepant shop welds of the 125 shop welds noted above. The results indicatcd that the underfabricated shop welds reanalyzed had weld stress levals less than the maximum permitted by the ASME Code, Section III, Subsection NF. The complete details of the reanalysis is set forth in Grinnell's report entitled " Field Surveyed Helds Stress Analysis for Bechtel Associate Professional Corporation," dated April 19, 1978, which is attached to this report. The reanalysis of the discrepant shop welds, the results of the full cize destructive loading tests conducted on underspecified and underfabri- ! cated welds associated with MCAR 918, and the established conservatism of Grinnell's designs, confirm that the safety of the plant' operation is
- not jeopardized by underfabricated shop welds. This deficiency is now '
considered a nonreportable deficiency. *
. 1
' .~ l Corrective Action' -
l To prevent the reoccurrence of underfabricated shop welds Grinneli has: ~ k.\ss'
- 1) Revised its QA/QC procedures 02A001 " Dimensional Tolerance Standard i for Component Supports" Rev D dated December 13, 1977, and 02A006-
" Visual and Dimensional Accentance Criteria for Welds" Rev D dated .
March 17, 1978. These vere approved Level 1 by Bechtel on March 1, 1978, and March 28, 1978, to conform to Paragraph K-1310 of Appendix K, ASME, Section III, Subsection NA. -
- 2) Initiated additonal in-house training sessions for its weld inspectors.
(Started November 18, 1977 - Completed December 15, 1977.)
- 3) Initiated a 100% veld inspection program in September, 1977.
PSQR activities were intensified in the Grinnell shop including a i chop weld size inspection on 100 percent of Q-listed hangers shipped ! October 31, 1977. PSQR routine inspections since that period have i shown satisfactory results. An incoming inspection of al'1 hangers at the jobsite has confirmed the cffectiveness of Crinnell's corrective actions to date. The inspection of 100 percent of the ' hangers was initiated on December 22, 1977, and , discontinued June 9,1978, since the last four shipments had no deficiencies j noted. , I 1 s N
,,_, , ,_. +,- -r
Bechtel Associates Professional Corporation (~ MCAR #19 Page 3 Cenclusions and Recommendations The results of Grinnc11's reanalysis of underfabricated shop welds, the results on the full size destructive loading tests conducted on under-specified and underfabricated welds associated with MCAR #18, and the established conservatism of Grinnell's design confirm that no safety problem exists due to an underfabricated shop weld. It is recommended that hangers with existing discrepant shop welds be used "as-is." ' M Submitted by ( ~. Approved b 1 _ pf ,
~
Concurrence by ! RNT/ cap [ 7/31/1 1 (. i l a , M
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, ff 1T l 3 L- -- -
ITTGrinnellCorporation ExewtiveOffices 260WestExchangeStreet Movidence,RhodeIsland02901 l Mpe HangerDivision Telephone (401)8317000 April 20, 1978 , I I
\
Bechtel Associates Professional Corp. ! P. O. Box 1000 777 Eisenhower Parkway Ann Arbor, Michigan 48106 l Attn: Mr. R. L. Castleberry - Proj. Eng.
Subject:
Consumers Pwr. Co. ~ Midland Plant - Job 7220 P.O. 7220-M-106-AC
, -GLBE-867 1
y Gentlemen: In accordance with the agreements reached between ! Eachtel and ITT Grinnell, we are submitting the attached .l report entitled " Field Surveyed Welds Stress Analysis for Bechtel Associates Professional Corp.". This report was generated.~to demonstrate that the welds made in our Warren, Ohio fabrication facility, though not in strict accordance s
. with the design details, are more than adequate for the purpose intended. '
I In the preparation of this report, several very conservative assumptions were made. First, if any weld deviated from the design drawing for any percentage of the
, 'angth; we assumed it to be the smaller size for the-entire Ler.gth, when in fact, the average amount of deviation from *
.he design drawings, for all assemblies inspected, was less than 50%. 'Second, the analysis performed on the support designs was done for loadings which would only be seen during an " emergency" condition, but we did not take credit
- for the increase in the allowable stress as allowed by the ASME III Subsection NF. Third, for purposes of this report, we assumed that an overstressed shop weld was reason for re-jectio_n of an assembly, yet in many cases, a slightly over-stressed weld would not adversely. affect the function of the support. ~ This is based on extensive testing we have performed
- on welds which demonstrate the conservatism pf the ITT Grinnell '
allowables. e e j
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PAGE 2 9 _
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( Ta Mr. R. L. Castleberry - April 20, 1978 s s In'the conclusions of the attached report, you will note that, based on the sample size and the fact that no sup-ports were found with overstressed shop welds, we state with a high degree of' confidence that there is an extremely low probability that any overstressed welds exist. However, due to the conservatism in our method of analysis as outlined
, above, we feel confident the actual " acceptance rate" would
, be much higher than stated in the report, Therefore, based on the extremely low probability of detecting a support with --
'. an overstressed shop weld due to fabrication tolerances, we advise that supports shipped from our Warren plant to the Midland jobsite be accepted as is. -
Further, based on the results of this report, we feel that reasonable fabrication tolerances be e'stablished - for future work processed at our Warren-facility. In the subject report, we have demonstrated a very conservative design approach and have proven with a high degree of con-fidence that the probability of, finding an overstressed shop weld, even though fabricated at 1/16" below its design value for up to 100% of the weld length, is very low.. Since ASME Section III, Subsection NF does not
- (- -
specifically address weld tolerances for-component supports,
., the fabrication tolerances normally imposed are those as -
listed in the American Welding Society's Structural Welding Code which allows 1/16" underrun for 10% of the weld length. Based on testing we have performed and on the results of the subject report, we feel that even this tolerance is overly conservative. We feel that a more reasonable tolerance would be 1/16" underrun for 30% of the weld length. In con-clusion, we feel confident that this report.provides adequate justification for the use of supports previously shipped to the Midland jobsite and that in the future reasonable fabri-cation tolerances can be established in line with the result of this report. We trust this meets with your approval, and look' forward to discussing any comments you may have.
. Very truly ours, -
.. WW ~
RJM/ecm R. J. Masterson, P.E.
'Att* Manager of Research, Developm.edt & Engineering ,
cc: M. Rothwell-(Bechtel/AA) Pipe Hajged7 Division J. F. Newgen -{Bechtel/M) s' f ' D. Riat -{ Bechtel/AA) /, .d
,.- R. Riblet - Cleveland H. Brennan - Taylor-
,rjf '6' Milman - Prov.
g LD. Panoff - (Bechtel/AA),,-(vjy2T Meiss --Prov. M. Grosso Prov. R. Tomlin - (Bechtel/AAJ- F. Stanish - Prov. K. Brafford - (Bechtel/Prov) N. DeCristofaro - Prov.
'H. Thielsch - Prov. F. Bigos - Prov.
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D Field Su':veyed Welds - ~ Stress Analysis For Bechtel Associates Pro fessional Corp. Midland Power Station Units 1 &.2 ~ ( -- Midland, Michigan .
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Date
- f-//98
- R, Vandeputte/D. Turnquist
! Proj. Mgr. Engineer t -
i f I 1 Reviewed By
' .F. Bigos Date d -/f-7A ' ~
Project Supervisor
//
Approved By /. [j [ M P. At'hnish ' Date /f' N ' f (Project Manager * - ( .._ 9
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R. Ma(sterson , P.E. ate
~ Y/9'~70* ,
Mgr., Research, Development and Engineering i i l l . t _.._..o--
(. w CONTENTS
, PAGE I. Introduction 1 Method of Survey
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II. 2 III. Method of Analysis -
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3 IV. Analysis of Results 4
- v. Conclusions 6
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VIII. Appendices: I. Letter of Authorization of Report 8 II. List of Supports with Undersize Welds lo and Accompanying Cover Letter
- i. .. III. List of Stress Calculations 30 IV. Determining Force en Welds 5 54
': V. Properties of Welds Treated as a Line i 56
! VI. Poissons Distribution Calculation 58 e
4 e 9 l 1
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l : x . -
.( , 1 ABSTRACT The ~ results of a field survey- of supports with shop welds, made by ITT Grinnell's Warren, Ohio facility, conducted by Bechtel Associates
; Professional Corp., are analyzed to verify the adequacy of the supports on the Midland Project fabricated by ITT Grinnell in the fulfillment *
[ of Purchase Order #7220-M-106-AC Rev. 5 In accordance with MIL-STD-105D representative sampling guidelines, 125 ASME Nuclear Code Class 2 and 3 supports are surveyed and 17, supports are found to have portions of shop welds below the size specified on the ITT Grinnell support detail. These welds are analyzed for the "as-built" stress levels using the smallest weld section found along the 1 j, particular weld. [~ The result.3 of this' analysis show that all surveyed supports meet weld stress requirements of ASME Boiler and Pressure Vessel Code, Section III, Subsect*,on NT. . Based on the above analysis, it is determined with a high level of con- 1 4 fidence that there is an extremely low probability of finding any supports with overstressed shop welds. l
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1 a i 1 I . i INTRODUCTION s i I -
\
- 4) .
An agreement between Bechtel Associates Professional Corp. ' i (Bechtel) and ITT Grinnell (ITT-G) was reached on 11/16/77, in which Bechtel established a representative sample size to ; conduct a field survey of ITT-G shop fabricated assemblies.
~
ITT-G agreed to ccmpile and analyze each shop weld questioned on the subject assemblies, based en the smallest section of I weld. The basis of this report intended to justify the acceptability of the questioned assemblies, by showing that none of the assemblies has a weld that would be overstressed in the "as-built" condition, as well as to give a reasonable (
~
, assurance that supports with overstressed welds due to fabrication tolerances, have an extremely low probability of occurence.
. The ASME Boiler and Pressure Vessel Code, Section III, Sub-Section NF, Paragraph 4222 entitled Tolerances for Linear Tvee Supports _ advised that " tolerances....may be as recommended in Non-Mandatory Appendix K, unless specified in the design specifi-cations". Since specific tolerances are not required by Subsection NF, or the Design Specification, hangers fabricated with shop welds i
below the tolerance of Appendix K are acceptable provided that no shop welds are overstressed in the "as-built" ccndition. e a f
, __ L
i l,
., 3 METHOD OF SURVEY
~
Bechtel conducted a survey which consisted of a representative sample of 125 supports fabricated for use on ASME Nuclear Code
. Class 2 and 3 systems. This survey encompassed supports in-stalled in various buildings as well as the warehouse /Q.C.
I
" holds" area. The supports found with portions of_any shop .
weld below the size specified on the support detail were tab- i ulated and forwarded to ITT-G for analysis. The results of 1 this survey are included as Appendix II of this report. ' The basis for the sample size was the military standard for ' { sampling procedures, MIL-STD-105D, dated April 29, 1963. A maximum lot size of 3200 supports was used in conjunction with 1 m
?- inspection level- II, on Table I.
s. From thj. 't code letter "K"
', was used to determine a sample size from Table II-A. This table also identified the number of rejects per lot acceptable for various quality levels.' For the purpose of this report a reject is defined as a support that has any shop weld that is l overstressed in the "as-built" or "as-fabricated" configuration.
8 9
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( I METHOD OF ANALYSIS Weld stress calculations were performed for each support to verify that none of the shop welds were overstressed in the "as-built" con-dition. These. calculations were performed using the smallest section I found, carried the full length of the weld. This represents a conservative approach, since most welds que'stioned were undersized I for 5 to 25% of the weld length.
- I Forces on th'e welds were determined using tables identical to those shown by O. Blodgett in Design of Welded Structures table 4 (Appendix IV) , and table ' 5 (Appendix V) , pages 7.4-6, and 7.4-7.
' All forces due to tension or compression, shear, bending and twisting, a were combined vectorially. The resultant load per linear inch was then calculated and compared to the maxiraum allowable stress per '
linear inch as specified in ASME Section III, Subsection NF-3000, Table 3292.1-1. Consideration for through plate loading was given in accor-dance with paragraph NF-3226.5 and Appendix XVII-2211c, Using the data provided by the weld calculations and test sample, we opplied Poissons Distribution. This equation (Appendix VI) approximated a point on characteristic curve for determining percent confidence vs. cample number. 96
+-.
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4 ANALYSIS OF RESULTS f .
~.
Listed below are the "as-built" weld stresses for the shop welds in question"on the surveyed assemblies, the Section III code allowabl,e l for the "as-built" size, and the "g ratio" which is the allowable stress divided by the actual calculated stress. All welds analyzed, as listed in Appendices II and III, meet the mav4 mum stress requirements of ASME Boiler .and Pressure Vessel Code, Section III, Subsection NT, Summer 1974 Addenda. ~ Sk. # S.W.
- Stress (#/in.) ' Allow (#/in.) @ !
1-610-6-7 1 1854 2380 1.3 2-611-5-20 1 323 238'0 ' 7.4 2 145 2380 16 2-611-6-7 3 150 2380
~. 16 3.
W_ .
~
4 76 1591 21 2-611-6-8 2 163 1190 7.3 1-619-6-15 l' , 130 2380 18 1-616-6-14 1&2 1756 2380 1.4 3 - 10 286 2380 8 2-617-9-10 2,3,5,7 51 2380 47 1,4,6,8 9 1591 177 1-610-3-12 2&4 58 2784 48 1-610-3-27 , 1 805 2784 3.5 1-617-8-10 , 1&2 1535 2380 1.6 , 1-616-7-9 1 482 1190 2.5 2 909 1190 1.3
.- 0-614-8-12~ 1-4 65 1190 18 K. '" '2-619-3--31 1 57 2380 42 2-612-3-18 4 - 11 57 2380 42
- U
[. 1., Sk. # , S.W. # Stress . (#/in.) Allow (#/in. ) 6 2-617-6-12 3-6 91 2380 26 0-616-8-23 3&4 767 2380 3.1 1-619-6-16 1 15 1190 79
~
2&3 283 2380 8.4 The 54 welds analyzed all maintained a certain safety margin (4 ratio) which ranged from 1.3 to 177. The reason for this wide variation in safety margin is that many of the welds questioned were designed with a si.za that we consider to be minimal for fabrication (3/16" - 1/4) regardless of loading. A Poissons Distribution applied to the results of the survey indicates (
' N --
that it can be stated with a 95% level of confidence that less than 21it
, of the supports may have an overstressed shop weld. '
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( . 4 CONCLUSION Of the 125 supports surveyed, in accordance with a representative sample-as determined by MIL-STD-105D, 17 were found to have welds
- that were shallower than the size specified on tSie support detail.
These welds were recorded,' scbsequently anal.yzed, and the actual' stresses in the "as-built" condition were compared against code allowables. The calculated safety margins (q ratio) ranged from 1.3 to 177. Through observation, it was seen that all welds were below code allowables; therefore, none of the surveyed supports have any d' v.w _ shop welds which are overstircssed. A Poissons Distribution indicates, with a confidence level exceeding 95$ that less than 2.5% of the supports may have an overstressed shop weld. o O a
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- g;-
.- . s
.(\_3 1 . . REFERENCES
.I I ASME Boiler and Pressure Vessel Code. Section III, Subsection NF. Ccmponent Suoports. New York, i' N.Y. : ' United Engineering Center, 1977. . Blodgett, O.W. - Desien of Welded Structures. Cleveland: The James F. Lincoln Arc Welding Fouhdation, 1976. Smith, Lee H. and Donald R. Williams Statistical Analysis for Business: A Concentual Accroach. 2nd Ed. Belmont, California: Wadsworth
- Publishing Company, Inc., 1976.
Kreyszig, Erwin. Advanced Encineerine Mathematics. 3rd. Ed. New York, New York; Jchn Wiley and '
. Sons, Inc., 1972.
Military Standard, MIL-STD-105D. Samo!.ine Procedures and Tables for Insoection by Attributes. Dept. of Defense, April 29, 1963. a ' L
e e '6 s s t . ( t e '.4 e .g en e g e
. APPENDIX I -
LETTER OF AUTHORIZATION OF REPORT . e I t, ~. - s . e O s S e ' t W ' O -
i -) %) . . t . CRINN,CL(. 40RPORAT10N OUTCOINC StESSAGE ELANK . PRIORITY: @ URCENT SECURITYs (CA!NNEU. PouCY CF.1. $/I,)
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'; O acLtAa O SYSTEM CoNrIDENTIAL . CootD , osie.a., MUST e ,1. . S
- *** *
- W' *'h *'-i -
O PEaSoNAL ANo CoNrioEsTiAt . Cooto . . e. wu!h. , .,..a j f @ UNCLAS$1FIED . NoT cooed .- e. .,r,; :.,. oR CINAToR*$ , 3,,a g,;,,3 ,, A -- Communi as.a. Dept. P.H.E. 12-30-77 a,gacg,o, oggg e -> MESSAGE TEXT SHoULD BE TYPED oNLY. TCt - CoPIE3 TO:
- .. ", ,_ R. L. Castleberry J.P. Neween - Midland - (malladi w-> -
Ecchtal Assoc. Prof. Corn. E. Soumbere - Eschtel 1' s c- > Ann Arbor, Michigan 48106'
.R.
D. Riblet Pano ff - Bechtel
- Grinnell- (mailed) u- ~ ) 2. Tomlin - BechCel TEz.Ex/Twx , 23-0101 Bec'htel (ARS) '
M. Grosso - Prov. (mailed) -
- p. Milman - prov. (-nil am
?
TEXT - (at sRIEF, sUT EXPUCIT) GTSH-735 ,
.l Re: , Midland. Units 1 & 2 - Bechtel 7220-.M .06-AC ,
( Please refo2- to your letters BGH-532 dated 11-23-77 and BGH 539 dated These letters centained a total of thirty-six (36) shop welds -
- \ . ' a.12-6-77.
inspected by your field forces and fcund to have portions below si=a specified on the hanger ska tch.
, , Per. our agreement on 11-16-77, ITT-Grinnell has compiled calculations ! for each weld based on the smallest weld section and has found these ; .' wolds within NF Code allowable stresses. If any additional welds are ', questioned, ITT-Grinnell looks forward to the opportunity to verify
- their safety.
4 i Three weeks after the receipt of the las't " undersized" weld, ITT Grinnell will have a report including all detailed calculations along with an . analysis of stresses. .
.- If we can be of further assistance,- please contact P. Stanish or myself i.
j R. Vandeputta - i .
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- e APPENDIX II .
'. .,, ,_, LIST OF SUPPORTS WITH UNDERSIZE WELDS AND ACCOMPANYING COVER LETTER eme
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0 e 9 9 i I a I . .i 9 4 4 s f. t .I, 1 - e 4 9 e D
- +
. ,. - . .s Bechtel Associates Professional Corporation
, . 777 East Eisennower Parkway
. Ann Arbot, Mich4an
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newAsemes:P.O.Bos 1000. Ann Aroor.MW 48106 . December 6, 1977 ITI Grinnell Corporation , Pipe Hanger Division 260 W. Exchange Street Providence, Rhode Island 02901 Attention: Mr. P. Stanish _
Subject:
Consumers Power Company .
, . Midland Plant - Job 7220 Pipe Hangers, Supports, and Reatraints P.O. 7220-M-106 File: M-106 BGH-539 Gentlemen: ,g
.. Attached please find eight field inspection reports on hanger in the - 5 /6 ' ,
'7
/# 0 A 7g/
._, field that have undersized from the weld sizes designated on the ff
/
-( Crinnell hanger sketches.. p-
, pl These reports are iq addition to those sent under EGH-53 (11/23/77)..
The question of code minimum weld size was not addressed or considered
', in these reports.
Very truly yours, s
$4444k' R. I..
hMQ Castleberry Project Engineer - RNT/pv 12/6/6 - Attachments g N 819y ElkTHANGER Enag, f k i i e f
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O . l f Bechtel Associates Professional Corporation - i
;- 777 East Eisenhower Parkway , ,
Ann Arbor, Micnigan
~ l asmW Admesa;P.O. Som 1000. Ann Areot, Mactugan 481C6 -.
l l N M er 23, 1977 - ITT Grinnell corporation Pipe Hanger Division
. 260 W. Exchange Street . !
PrevLdence, Rhode Island 02901 ,
. Attention: Mr. P. Stanish - .
l .
Subject:
Consumers Power Company Midland Plant , Job 7220
. Pipe Hangers, Supports, ,
and Restraints P.O. 7220-M-106 File: M-106 BGH-532
- Gentlemen:
l; S~ Attached please find nine field inspection reports on Grinnell hanger e shop welds. These nine reports are for nine hangers existing in the field on which there werertwnhty-eight shh welds that were undersized from the sizes designated W cne ludi ccGal hanger sketches. The question of code minigun veld size was not addressed or considered in these reports. rh Very truly yours,
~
Vg j bh f/f , y R. L. ( atleberry hr,1) [ rroject z,sineer RuTIow yUY (gn,C,is s/ ~ cjuds ss':e.cd 12/6/5 {v- /4 Act=ch= at=
- REGIVED /2 ,
DEC 121977 PIPE HANGER ENGR. 4lmm
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e '** ' a i 1 . i .I llANGEnf 11108 111 2 SKETCill1-610-3-12 i I
. l Sil0p llELD # : 11 ELD SIZE CALLED FOR liELD SIZE HEASURED . REMARKS
' s 1 i 1 j 1/4" fillet - All around. . 1//." fillet '- All around. I t.ower stanchion weld to clamp.
, i '
/2 1/4" fillet - All amund, 50%-1/4C Lower stanchion weld to flat plate. '
50% ~ 1/4-7 -[/ju Appears to liave been gWund in sho ). 3 1/4" fillet - All around, 1/4" fillet - All around. Upper stanchion weld to clamp. ,
. V4 1/4" fillat - All around. 50%'1M
.50%b74",
Upper stanchion weld to flat plata. 7/ 3 s , Appears to have been ground in shop. e ? e 4 g . e *
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i i age ,42, Appendix III) i (See calculations, - n , y. -
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jlANGEREIndn-25H6 - SKETClif . 1 -610-3-2 [ - Sil0P , llELD i WELO SIZE CALLED FOR !
- e
; I-lELD SIZE HEASURED REMARKS -
l . .. : . .
/1 1/4" fillet .all around 905 - 1/4a fij1.t ,1 I -
, 10% - 1/4-"- fillet g i e e
. ~
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L , . 4 ' '
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I i : (See calculations page 4.'3 Appendix III) I .
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; SKETCHf 1-610-6-7 ilANGERf1FCB[35-H7 l Sil0P. , i WELO # WELD SIZE CALLED FOR WELD SIZE MEASURED . REMARKS ,
i
!1 , 1/4" fillet - all around. 3/16" fil'let - welded all around, i
9
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- i 8 . .
8e (See calculations pa je 31, Appendix III) 'I - i 8 I o
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SKETCiti 2-611-5-20 IIANGERI 2lltnf-1-il12 i l. S!!0P ! ' ' WELD # WELD SIZE CALLED FOR HELD SIZE HEASURED i REMARKS
!] 1/4" fillet - E sides 3/16" fillet Additional weld across face of flange. /2 1/4" fillet '- E sides
- 3/16" fillet Additional weld across face of flan 0e.
5 1/4" fillet - outerface on flanges 1/4" fillet - all around both gideg on web. _ r.
~
i I (See calculations page 3 ! Appendix III) i
; . . 4; I i 5
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l' . ilANGERf 2FCB'-35-H7 SKETCill 2-611-6-7 l l Sil0P HELD i . WELD SIZE CALLED FOR l WELD SIZE MEASURED REMARKS i : 1 1/4" fillet - all around.
' 75% - 1/4" fillet 25% - 1/4 " fillet l
- ~
I i 2 1/4" fillet - all around, 1/4" fillet - all around. Approximately 25% inaccessible due to grouting. Sottom side in grout top side 1/4" fillet
'/ 3 1/4" fillet - outer face of flanges 95% - 1/4" fillet and both sides of web. 5% - 3/16" fillet / 4 1/4" (111et - outer. face of flanges 1/8" fillet top of flange and both sides of web. 1/4" fillet bottom of flange 75% - 3/16" on web 25% - 1/4" on web '
i i ! I i '
; (see calculations page 3;4 appendix III)
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l-lIANGERI 2FCB' 35-il8 SKETClif 2-611-6-8 I I t Sil0P i i HELD # : WELD SIZE CALLED FOR ' WELD SIZE MEASURED REMARKS 1 1/4" fillet - outer face on flange i 1/4" fillet - All around, size or wala in obtuse angle both sides on web. - indeteuninate.
, l 4
/2 '
1/4" fillet . all around. 95% '- 1/4" fillet Fillet weld member #3 to base 5% - 3/16" fillet plate. Size or veld in obtuae ang1 indetenninate. 3 1/4" fillet.- All around. 1/4" fillet - all around. Fillet weld member #2 to base plate.
- i (See calculations page ,36 Appendix III)
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ilANGERf 1HBC-100-111 SKETCiti 1-619-6-15 4 Sil0P . ; WELD # I WELD SIZE CALLED FOR . HELD SIZE HEASURED i REMARKS-
/ 1 1/4" fillet - all around. l alz. or vela in obtua ans1.
3/16" and 1/4"(50/Sb) fillet. Indeterminate. 2 1/4" f111et - all around. 1/4t" fillet welded all around. Center weld as installed. 3 1/4" fillet - all around. 1/4+" fillet welded all around. Top weld as in. eta 11ed. 8 l l l (See calculations page 37 pppendix III) l 1 66 .
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HANGER # l HEiC-136-H1 SKETCHf 1- 06-(.-J$. ,. SHOP l
;- s -
~
WELD # ' WELD SIZE CALLED FOR ; HELD SIZE MEASURED REMARKS
! 3/16" fillet - 10% length South stanchion as installed.
/1 l l/4" fillet -'All around. I .
I 1/4" fillet Bottom leg- 90% up to leng(th40%) 3/8" -
/2 1/4" fillet - All around, 3/16" fillet - 10% length South stanchion as installed.
1/4" fillet - 90% length Bottom leg up to 3/8" (40%)
. [3 1/4" fillet - All around. 3/16" fillet - Random scattered 5%. Welds associated with clamp assembly.
1/4" + fillet - Remaining 95%
)4 1/4" fillet - All around. 3/16" fillet - Random scattered 5%. Welds associated with clamp assembly.
1/4" + fillet - Remaining 95%.
/ 5' 1/4" fillet - All around. 3/16" fillet - Random scattered 5%. Welds associated with clamp assembly.
1/4" + fillet - Renalning 95%.
/6 1/4" fillet - All around. 3/16" fillet - Random scattered 5%. Welds associated with. clamp assembly.
1/4" + fillet - Remaining 95%.
/7 1/4" fillet - All around. 3/15" fillet - Random scattered 5%. Welds associated with clamp assenbly.
' 1/4" tfillet - Remaining 95%.
/8 1/4" fillet - All around. 3/16" fillet - Random scattered 5%. ' Welds associated with clamp assembly.
1/4" + fillet - Remaining 95%. ,
/9 , 1/4" fillet - All around. 3/16" fillet - Random scattered 5%. , Welds associated with clamp assembly.
. i . 1/4" + fille.t - Remaining 951. ,
/ 10 1 1/4" fillet - All around. 3/16" fillet - Random scattered 5%. ; Welds associated with claag assembly.
1/4" + fillet - Remaining 95%.
. .i .
(See calculations page 38 Appendix III) ',
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}iANGERf2ilBC 145-H2 SKETCil'# 2 617-9-10 i l
. .. i. j .. .;. .. I WELD # . WELD SIZE CALLED FOR HELD S12E HEASURED REMARKS
[1 l 1/4" f!)10$ - all around. 3/16" fillet generally except Pipe to plate per detail. j 50% of the upper most weld (#6) i is 1/8" fillet [2 1/4" fillet - 611 around, fillet alI around. Pipe to clamp weld. 151 - 3/16" fillet 85% - 1/4" fillet '
/' 3 1/4" fillet ~ all around. .
Fillet all around. Pipe to clamp weld. 15% - 3/16" fillet . 85% - 1/4" fillet
/4 1/4" fillet - all armund, 3/16" fillet generally except Pipe to plate per detail.
50% of the upper most weld (#6) is 1/8" fillet *
/ 5 1/4" f111et - all around. Fillet all around. Pipe to clamp weld.
15% - 3/16" fillet 85% - 1/4" fillet I 6 1/4" fillet - all around. 3/16" fillet generally except Pipe to plate per detail. 50% of the upper most weld.(#6) ' is 1/8" fillet
/7 > 1/4" fillet - all around. Fillet all around. .' Pipe to clamp weld. ~
15% - 3/16" fillet - 85% - 1/4" fillet *
/8 .' 1/4" fillet - al around, t -
l Pipe to plate per detail.
- l. 3/16" 50% of fillet generally the upper most weldexcep(#6):
is 1/8" fillet. ie
. l' .
i (See calculations page 40 hPpendix III) j 29 ,
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/
e 4 APPENDIX III LIST OF STRESS CALCUIATIONS i I s
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UL-M /ndQga,ation "" "" "#' " BECHTEL EWR. CORP. 5"55 " "* "; " " "
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, 4 M ' sie 1.s = g 4.cs $ tt,_
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/i d kG wer o e. <
l 54op WELD *4.
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O s s e 0 e G G i 1 APPENDIX IV - DETERMINING FORCE ON WELD O e
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Joint Design and Production * . Deterrnining Force on Weld n.-- . standard treating de sign the weld
- formula as a line Type of Loading stre s - force
!b s /in2 !b s /in PRIMARY WELDS ;
transmi entire load at :*.is point l P I
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4 l APPENDIX V , PROPERTIES OF WELD TREATED AS LINE 4 e e
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Determining -Weld Size
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