ML20008D776

App 5G to Midland 1 & 2 PSAR, QC Procedure for Field Welding of Liner Plate. Includes Revisions 1-36

ML20008D776
Person / Time
Site:	Midland
Issue date:	01/13/1969
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
References
NUDOCS 8007300672
Download: ML20008D776 (8)

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s AFFENDIX 5G QUALITY CONTROL PROCEDURE FOR FIELD WELDI5G OF LEER PLATE SCCPE This procedure outlines the general require =ents for welding quality con-trol to assure that all field welding of liner plate is perfor=ed in full ec=pliance with the applicable job specifications.

GUAI.IFICATIONS KR WELDING EEPECTORS All velding inspectors who inspect velds covered by this specification are qualified by =eeting the following =ini=u= require =ents:

a. Inspectors have a thorough kncvledge of the various velding proces-ses and techniques e= ployed in field construction, and are able to de=enstrate the proper =ethods for shielded =etal-are velding, gas tungsten-are velding, gas metal-are velding, and oxyacetylene velding.

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b. Inspectors have a =ind== of two years' previous velding inspection experience, or equivalent experience and training in velding fabrication and condestructive testing.

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) c. Inspectors are required to de=cnstrate to the satisfaction of the V responsible Bechtel Metallurgical and Quality Centrol Services representative their kncvledge of the funda=entals, techniques, and application of the in-spection =ethods set forth in this standard, ie, visual =agnetic particle, liquid penetrant and radiographic icspection.

WELDING PERFORMED BY BECHTEL CONSTRUCTION PERS0ICEL WELDING PROCEDURE SPECIFICATIONS

] All velding perfomed by Bechtel construction personnel is in strict accor-dance with approved Bechtel velding procedure specifications. The appro-priate Bechtel velding procedure specifications for field velds are being i prepared, qualified and issued to the field by the Bechtel Metallurgy and Quality Control Services Depart =ent, as directed by Power Division Engineer-ing.

WEIDER QUALIFICATI0U All velders who make velds under Bechtel velding procedure specifications are qualified by perfor=ing the tests required by the applicable Bechtel Welder Performance Specification WQ-F-1 for ferrous =aterials, and WQ-ITI-l for nonferrous =aterials. These Bechtel specifica:1cns enec= pass the require-ments of Section IX of the ASME Code. No velder is per=1tted to perfo m i

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T product 10n velding until he has passed the necessary tests and has the appro-priate Welder Perfor ance Qualificatic Test Record (For= lic. WR-1) en file at jobsite. All testing of velders is under the directics of the field velding inspector.

L'EDEU PEREFMD BY EECHTEL SUSCC:TIRACTORS WElDEU FROCDURE SPECIFICATIC:IS All velding perfc=ed by 3echtel Subecutracters is in strict accordance with the applicable jcb specifications. When these specificaticus require Engi-neering appreval of welding procedures, no productica velding is pe=itted without prior approval of such precedures by Power Division Engineering.

When Engineering approval is not specified but velding is to be perfc =ed under a code er standard which requires qualified welding procedure specifi-cations, then the Subcontractor prepares and qualifies his welling precedures accordingly, prior to beginning any productice work. The field velding inspector is responsible in all cases for dete =ining that the Subcentrac-ter's velding is being perfor:ed in acecrdance with properly qualified and, as necessary, Engineering approved velding precedure specificaticus.

WELDER QUALIFICATIOt All velders and welding cperators e= ployed by Subcontracters who =ake velds under a code or standard which requires qualificatica of welders are tested 3 and qualified accordingly before beginning productice velding. Each Sub-centracter is responsible for testing and qualifying his evn velders. The Bechtel field veliing inspecter is respctsible in all cases for dete. ining that the Subcontracter's velders have passed the necessary qualificatien tests and that the Subcontractor has cc file at Jcbsite the prcper qualifica-tice test record for each qualified velder.

I:iSTRUC*IIO!!S FCR BECEEL FIELD WEDEU EISPECTORS The general instructions for Eechtel field velding inspectors which follow cover velding perfor=ed by both Bechtel Constructicc and Becntel Subcontrac-ters.

kTIDEU FROCDURE ::n,UmCATIC?iS It is the respcusibility of the field velding inspector to assure that all velding is perfc=ed in strict accordance with the apprcpriate qualified velding procedure specificatices. Specific ite=s to be checked fc11cv:

a. Dete=ine that the proper velding procedure specification has been.

selected to =atch the base =aterials being velded and the velding processes being e= ployed.

b. Per=it cnly velders properly qualified under the essential vari-ables of each velding procedure specificatice to nake velds under that procedure.

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c. Check to see that the veldin6 electrodes, bare filler rod, con-su=able insert rings, and backing rin6s all =atch that which has been specified.

d. Inspect veld joints as necessary prior to veldin6 to insure proper edge penetration, cleaning, and fit-up, e Check to see that the veldin6 =achine settings are correct and ca ll within the range of current and voltage specified.

f. Check for proper preheat and interpass te.perature,

g. Inspect the in-process velding for proper technique, cleaning between passes, and appearance of individual veld beads.

POST-WELD HEAT TREATFEITT The field welding inspector inspects each post-veld heat treatment (ther=al stress relieving) operation to insure confor=ance with the applicable job specifications. Specific ite=s to be checked shall include the following:

a. A sufficient nu=ber and proper location of ther=occuples are selected to accurately record te=peratures.

b. The ther=ocouples are connected to temperature indicator ree nders which will provide a per=anent record of the heating rate, holding m te=perature and ti=e, and the cooling rate.

c. Teuperature charts are checked for proper heating rate, holding temperature, holding time, cooling rate, and that the proper veld identification is recorded on the chart.

VISUAL INSPECTION OF WELDS The field welding inspectors are responsible for carrying out the necessary velding surveillance to insure that all velding =eets the following require-

=ents for visual quality and general work =anship. Visual inspection is perfor=ed prior to, during, and after velding.

a. All veld beads, passes, and completed velds are free of slag, cracks, porosity, inco=plete penetration and lack of fusion.

b. Cover passes are free of coarse ripples, irregular surface, non-unifoz n bead pattern, hi 6h crown, deep ridges or valleys between beads, and blend s=cothly and gradually into the surface of the base metal.

c. Butt velds are slightly convex of unifor= hef 6ht, and have full penetration.

d. Fillet velds are of specified sice, with full throat and, unless otherwise specified, the legs are of approximately equal length.

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f e. Repair, chipping, or grinding of velds is done in such a =anner as not to gouge, groove, or reduce the base =etal thicknesses.

f. Where different base =etal thicknesses are jointed by velding, the finished joint has a taper no steeper than 1:4 batveen the thick and thin sections.

PAGIIETIC PAYiICLE I'ISPECTIO!I

a. The field welding inspector is responsible for deter =ining that all =agnetic particle inspection is properly perfor=ed,

b. When the applicable job specifications require =agnetic particle inspection of welds, the field welding inspector is responsible for deter =1ning that the proper technique is followed and that the results are properly interpreted. The field welding inspector requires the Subcontractor's responsible inspection personnel to de=enstrate their kncvledge and understanding of the applicable specifications prior to performing any production testing.

c. Special attention is given to the following ite=s for all magnetic particle inspection:

(1) Dete mine that surfaces to be inspected have been properly cleaned and are free of crevices which can produce false indications by trapping the iron powder.

_d (2) Detemine that the power source, current density, prod spacing, and application of iron powder all ec= ply with the applicable specification requirements.

(3) Per=it no arcing between the prods and veld surfaces.

(h) Interpret all linear or linearly disposed irdications as defects.

(3) Probe questionable indications by ther=al cutting, chipping, grinding, or filing to confir= the presence or absence of actual defects.

LIQL"D pENETRA!TT INSPECTION

a. The field velding inspector is responsible for detemining that all liquid penetrant inspection is properly perfor=ed.

b. When the applicable _ job specifications require liquid penetrant inspection for velds, the field welding inspector is responsible for dete m ininC that the proper technique is followed and that the results are properly interpreted. The field velding inspec- l

! tor requires the Subcontractor's responsible inspection personnel to de=enstrate their knowledge cad understanding of the applicable specifications prior to performing any production testing.

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c. Special attention is given to the folleving ite=s for all liquid penetrant inspection:

(1) Detemine that surfaces to be inspected have been properly cleaned and are free of crevices which can produce false indications by trapping the dye penetrant.

(2) Check to see that cleaner, dye penetrant, and developer are properly applied and the specified ti=e intervals for dye penetration and developing are folleved.

(3) Deter =ine that indications are properly interpreted. Defects will be identified as red stains against the white developer background. Red lines or linearly disposed red dots are indica-tive of cracks. porosity and pinhole leaks appear as local red patches or dots.

(4) Exa=ine questionable indications by a 5x or strenger hand lens, and probe by grinding or filing to confim the presence or absence of defects.

RADIOGRAPHIC INSPECTION

a. The field velding inspectors are responsible for dete=1ning that all radlegraphic inspection is properly perfor=ed.

b. When the applicable job specifications require radiographic inspec-tion of velds, the field welding inspector is responsible for

. deter =ining that proper radiographic technique is folleved and that the completed films are properly interpreted. The field welding inspector requires the Subcontractor's responsible personnel to de=onstrate their knowledge and understanding of the applicable specifications prior to beginning the radiographic inspection.

The field velding inspector shall also review each ecepleted radio-graph.

c. Special attention is given to each of the folleving items for all radiographic inspection:

(1) Check the type of fil= intensifying screens, penetra=eters, and source of radiation for confomance to the job specifica-tions.

(2) Check the relative location of fi1= penetra=eters, identifying numbers, and radiation source for each typical exposure.

(3) Review all co=pleted fi3m for quality and interpretation of defects. Check the exposed and developed film for proper density and visibility of penetra=eters. Radiographic fi1=

of unacceptable quality or with questionable indications of defects is reradiographed.

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