ML20010D048

Responds to NRC Re Violations Noted in IE Insp Repts 50-456/80-12 & 50-457/80-11.Corrective Actions:Addl Info Re Main Control Board Panel Welds Provided & Encl Reliance Electric Co Welding Procedures Approved

ML20010D048
Person / Time
Site:	Braidwood
Issue date:	07/14/1981
From:	Delgeorge L COMMONWEALTH EDISON CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20010D043	List: ML20010D048
References
NUDOCS 8108210402
Download: ML20010D048 (21)

Text

-.

a Commonwealth Edison

) One First Nitional Plaza. Chicago, Illinois -

O O :~ Address Reply to: Post Office Box 767 Chicago, Illinois 60690 July 14, 1981 a

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i Mr. James 6. Keopler, Director Directorate of Inspection and l

i Enforcement - Region III U.S. Nuclear Regulatory Commission 3

799' Roosevelt Road

{

Glen Ellyn, IL 60137

Subject:

Braidwood Station Units 1 and 2 Additional Information Regarding IE Ii.spection Report Nos. 50-456/80-12

_and 50-457/80-11 Reforence (a):

May 12, 1981, letter from C. E. Norelius to Cordell Reed i

j (b):

June 5, 1981, letter fr7m J. S. Abel to J. G. Keppler l'

Dear Mr. Keppler:

l Reference (b) provided additional information requested in

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reference (a) regarding Braiowood's Main Control Board (MCB) panel welds.

The specification containing the approved weld inspectici i

criteria for the Westinghouse-supplied MCB's was unavailable at that time and is being provided now.

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The acceptance criteria for the Westinghouse MCB's was

I originally specified in Westinghouse Specification 679208, Rev. O.

Subsequent evaluation of this specification revealec that it was not entirely appropriate for MCB welds, so this specification was removed from the requirements for the project.

Welding specifications by Reliance Electric were evaluated as being i

suitable. is a copy of Reliance specifications QCP5 i

(Sect. 5.3) and WPS-6, for welding procedures and welding i

qualifications respectively.

These procedures were reviewed and apprcved by Westinghouse for the project.

Vendor surveillance 3

audits were performed by Westinghouse and included review of welding

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fabrication, criteria, etc.

Please address further questions to this office.

1 Very traly yours, ha W

L. O. DelGeorge Director of Nuclear Licensing Attachment im 2283N 9108210402 810814' PDR ADOCK 05000456 g( 11. ggg\\

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ATTACHMENT 1 Reliance Weld Procedures b

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-RELIANCEf$

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fD EL.ECTRIC COMPANY

[/fQ A??ROVID 7NINSTRUC !ONS, ??.0wURIS AND DRMCCS,_._

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i 5.2.5 Surface Prepara:1on and ?f=1sh1=g 1)

Clean Panel with safety.degreaser (? ire 2etardant;.

2)

Grind all 7anels on curside 2nd especia.'17 at any velded joints and cornars.

3) ?d2.1 all bad scratches, etc. with fd'1er, allev to dry and grind smooth.

4)

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Steam clean inside and outside virh phosphard-d g soluticu (Dura-Gard steam cleaner and phoschati=ar).

5)

Spray rvo (2) to three (3) coats of special gray

.- 1 or interior white priser on inside.

6)

Spray three (3) to five (5) coats of priser.-surfacer en outside, allev to dry and sand with 320 and 400 grit. sandpaper.

Ref417 any rec:aining surface defects with glazing putty and resand as required.

7)

Paint finish coat on outside of. panel.

"'hree (3) to six (5) costa for lacquer or two (2) coats for enarxc.1..

?inish coats to be of unifers thickness and free frm sags, runs and/or smaars.

3.3 Welding Procedures for the 7abrication of Control ?anels

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5.3.1 Scorpe This procedure defines the velded. joints used in the-fabrication of Control ?anels, and also a1d dwares the need for showing velding synbols on the fabrica:1on drawings.

When velded joints to be used are not defined herein, the fabrication drawings shall describe the joint decadin.

5.3.2 Weld % Procedure Quald*ication The welding procedure specificacious for the various setals used in the fabrica:icu of control panels are quald#1ed in accordance vi:h the latest revision of the American Welding Society's Structural Welding Code D1.1.

1 5.3.3 Welder cualification Welding vill be done by velders who have passed cua#1-cation tests to acenrdance with the velding procedure -

specifications.

1 5.3.4 Gas Metal Arc Welding (GMAW)

Unless provided for otherwise in the proj ect progrs= plan, GMAW v111 be the process used for veld 1=g the control canel.1 of carbon steel.

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. RELJANCE ELECT'MIC CCMPANY DAT~"

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APPROVD

. _.C 5C_.2HS 2.UC"' IONS, ?ROCDURIS Alo LPXJ:5GS

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5.3.4.1 Iquipnen:

1) 7111er Model CP-250TS constant potential

'6all position welding machine with Mar=a:1c 10A control / feeder and Tweco No. 4-AN E G-Gun.

2)' Miller Model CP-250T3 constant potential all position weld 1=g machine with Dip-Matic control / feeder =ede',.v C-W4-1 and Tweco No. 4-AN ?tIG-Gun.

3) Air products MW25000 constant potential all position velding machine with vire feeder model AP25CM and E G-Gun Model AP250G45.

5.3.4.2 Wire Specifications e<~

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Spec. : AWS A5.18 2)

Size

.035 inches 5.3.4.3 Application x,.

Micro-wira Gas Metal-Arc Welding (GMAW) vill be used in all positicus for all types of joint cor-ections unlesa otherwise specified on the proj ect

- s QA Progran Plan or desdgn documents.

5.3.4.4 Welding Conditions 1)

Direct Curren: 2 averse Polar.d:7 (DC2?)

2)

Arc Volts:

20 - 25 3)

Asperes 120 - 175 4)

Gas Flov :

15 - 20 C7H

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5.3.4,5 Welding Materials Control 1)

Prior.to usc., the wire should be stored in a~

clean, dry area.,

2)

During use, care should be exercised to ayoid physical danage to the vire.

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.. R ELIANCE dam,~-

MNi 2 8 377 OL.GCTMIC CCMPANY

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AP? ROVED 7f

'57 "' dis.sC'"!ONS, ?ROCIDUPJ.S AND.DRficiGS

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5.3.5 Square Groove Su:: '4 eld 5.3.5.1 Purpose i

To join two shee:3 in a single plane.

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1. ;4 0-1/8" FRON:

2/4" MAI N

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REAR

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i 5.3.5.2 Description The sheared or ~111 edges are brought together so that the two (2) sheets form a single plane.

The joint is then ve1ded with a s1=gle psss both freut and rear cf the sheet.

'"he root op, d g shall be 1/8" or less.

The veld profile shall show a sligh:

convexity with the veld netal deposited approxi : ate 7 equally on both sicea of the joint.

5.3.5.3 Acceptance Criteria Class "A" (Ref. CC? 5.3.16.1) 0R2C

RELJANCEfS

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KiLECT'MIC CCMPANY

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APPROVD 5.

INSTRUC"' IONS, ??OCIDURIS AND DRA'i!NGS 5.3.6 Single vee Groove 3uct ~4 eld 5.3.6.1 Purpose To join two sheets in a s1=gle plane.

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5.3.6.2 Descriyt:,.on

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The sheared or =111 edges are beveled apprcx1= ate 17 30'ench.

The edges are then brought together so.

that there is a single vee op 94mg of approvi s tely 60* when the two (2) sheets f ern a single plane.

"he joint is then velded with a single pass both front and raar.

• he root op -i g shall be.1/8" or_..

less.

~he veld profile shn11 show a slight convexity.

5.3. 6.3 Acceptance criteria Class "A" (Ref. QC? 5.3.16.1)

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if5' -Disi.wcncNS, ?ROCEURIS AND DPE4n cs f.3.7

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INSTRUC 10NS, ?ROCIDURIS A5D DPJJ7INGS 5.3.8 Single Radius Groove Butt 'Jeld 5.3.8.1 Purpose To join two (2) cheets, one vtth a 908 bend of.a s4"4==

- outside radius equal to twice the thickness of the sheet and the other with a sheared or mill edge, in a single plane to forn a door border.

The thickness ~

of each is em1a1 to or less than h".

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i 5.3.8.2 Description The 900 radius bend anl the sheared or ni.11 edge are brought together to form a single plane.

The joint is then velded with a singla pass both fione and rear of the sheet.

The root opening rhall be 1/8" or less.

1 5.3.8.3 Acceptance Criteria Class "A" (Ref. CC? 5.3.16.1)

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---RELIANCEyY ELECTMIC COMPANY

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DIS 2CC~ IONS, PROCIDU22S AND DRA57 DIGS 5.3.9 Double Radius Groove Butt 'Jeld 5.3.9.1 Purpose To join two (2) sheets, both with a 90* band of a

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outside radius equal to twice t.he thickness of the sheet, in a single plane.

The thicknees of each is equal to or less than V

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5.3.9.3 Description The 90' radius bends are brought together to forn 'a single plane.

The joint is then velded with a single p s.s a.

• he root opHms shall be 1/8" or less.

5.3. 9. 3 Acceptance Criteria Class "A" (Ref. QC? 5.3.16.1}

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INS!2CC'* IONS, PRC w u.d5 AND-DRAWINGS 5.3.10 Square Groove 3u:: Weld for Angle Fra=a 5.3.10.1 Purpose To join structural angles of a thickness not exceeding V.

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e 5.3.10.2 Description One leg of an angle is notched to a dep:h equal :o the leg of the other angle plus k".

First, the panel skin is put together using the corner veld shown in QCP 5.3.12.

Second, the structural angles are tacked virhin the 1:.:erior of the corners.

3.ird, the root gap of the interior but: joint is valded with a single pass making certain tha: the panel skin is tied in vich the veld.

Fourth, the fillet velds are added to the in:erior corners of the angles in accordance with :he criteria cf QG 5.3.13.

Finally, the panel ~ skin is joined to the strue: ural angles using the fille veld as shown in QG 5.3.13.

5.3.10.2 Acceptance Criteria Class "A" (Ref. QG t.3.16.1)

RELIANCE QCP c

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APPROVD 5.

LisawCTIONS, PROCDURES AND ORA'nn'GS 5.3.n Square Groove 3utt 'neld For Angle Rael s

5. 3. n.1 Purpose i

To join s mictural angles of a thickness not ex-caeding h".

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5.3.11.2 Lescription One leg of an angle is notched to a depth equal to the leg of the other angle pirm 1/8".

The two angles are fitted together to fom the corner, and both the interior and exterior but: joints are velded with a single pass.

5.3.H.3 Acceptance Criteria l

Class "A" (Ref. QCP 5.3.16.1) l l

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RELIANCE QC?

5 ELECTRIC CCMPANY B

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1. S3M APPROVED k,Mws-5.

INS 12UC 10Ns, ?ROCC URIS Arm Dan n'Gs 5.3.12 Corner 'Jeld 5.3.12.1 Purpose To join two (2) sheets of equal or unequal thickness at seme acute angle less than 120.

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5.3.12.2 Descri;.tien The sheared or =111 edges are brought together to the point where they touch when the two (2) sheets for=

the specified acute angle.

The joint is then velded with a single pass en the frent.

5. 3.1",3 Acceptance Criteria Class "3" (Raf. QCP 5.3.16.2) l I

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F1ELJANCE ELECTMIC COMPANY y$

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APPROVD 5.

DISTRUC~ IONS, ?RCCDURIS AND DRAWINGS 5.3.'3

?ille: Weld 5.3.13.1 Purpose To join the panel skin to the structural menbers; to join concealed hinges to the panel skin or structural membe.rs; to join angle frame and rack Corners.

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5.3.13.2 DeBCIL Cion P

The size (S) of the fille: veld shall be equal to or greater than the thick =ess of the tei=ner parts joined.

~he length of the fe: veld shaU. be at least four (4) tines its si=e with a min 4m m of 1".

The veld profile shall shev a flat or convez surface.

Spacing shall not exceed 8".

5.3.13.3 Acceptance Crt:erta Class "A" (Ref. QCP 5.3.16.1)

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APPROVD 5.

DETRUC IONS, PROCIDURIS AND DRA*JDK;s 5.3.14 Intermit:en: F#'7et Weld 5.3.14.1 Purpose To join unistrut to the pa.su skin; to join stiffeners to the panel skin; to join wireways to the structural members or 7anel skin; to join unistru: or brackets i

to the st ffeners or structural sember; to join d

gasket strip retainer to the door border; to join subpanels to the structu;al nembers or panel skin.

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l 5.3.14.2 Desc:1p:1on The size (S) of the f'7'et veld shall be ecual to or greater than the thickness of the thtnar' parts joined.

The length -of the f'11 et veld shall be at least four '4) times its s'2e with a md 'wr of 1".

The veld profile shall show a flat or conve:t -

surface.

Spacing stall cet exceed 24".

5.3.14.3 Acceptance Criteria Class "A" (Ref. QC? 5.3.16.1)

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DISTRUCCONS, PROCEDURES AND DRAWINGS

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5.3.15 Plug Weld 5.3.15.1 Purpose To join continuous hinges to the door border or s m etural me=bers; to join wireways to the s m e-tu al me:nbers or panel : kin; to join u=1stru: or brackets to the stiffeaers or structural members; to join subpanels :o the structural members or panea skin.

5.3.15.2 Descriptien The diameter of the hole in :he' interior 1:en :o be mounted shall be a d"d m s1=e of 5/16"'plus the thickness of the =ecal ite:s.

The holes un placed against the par: to which the item is to be attached,.and 1: As then welded in the hole.

i 5.3.15.3 Acceptance Criteria i

Class "C" (Ref.,QCP'5.3.16.3)

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EL.EC-TRIC COMPANY DATI l

MAR 3 1 373

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APPROVED t

5.

INSTRUC ICNS, ?RCCEDURIS AND DRAWINGS 5.3.16 Criteria 7er Acceptable Welds 3.3.16.1 Class A

1) Welds shall have no, risible cracks.

2)

"he sun of diameters of pinholes sha11 not exceed 3/8" in any 6" length of weld.

3)

The rear veld of square g:: cove, single vee, and double vee groove connections hhall have no more than 12" of overlap in any 72" length of weld.

4)

Undercut shall not exceed 1/32" in depth or width.

5.3.16.2 Class 3

1) Welds shall have no visible cracks.

2)

Un' der cut shall not exceed 1/32" in depth or width.

3)

After grinding, when the sum of ru n~*ters of 71nholes exceeds 3/8" in any 6" length

.of veld, conectdve action is required.

4)

After grinding, when:the sum of the lengths of the non-convez welds exceed 1h:" in an7 12" length of weld, conective action is required.

533.16.3 Class C

1) Weld shall have no visible cracks.

2)

The sum of diameters of pinholes shAP not exceed 3/16".

3)

The veld profile shall be flat or slightly convez.

l 5.3.17 Conection Require =ents For Nonconfor=ing Welds 1)

Excessive overlap on the rear veld of square groove and double vee groove connections shall be co nected by removing enough veld netal to 'show that the connection is properly fused.

2)

Excessive conceivity of weld, undersize welds, and under-i cutting shall be co nected by cleaning the wald and depositing additional weld metal.

3)

Cracks and pinholes shall be repaired by re=cring the i

defective portion of the veld and : hen revelding the

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RELIANC2!D El ECTRIC CCMPANY OS 3'

MPRO M

,, 7,7,7 WELDING PROCEDURE SPECIFICATION NUMBER 6 a.

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RELIANCE lD ELECTRIC CCMPANY US

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..w REV' NC' hh] 7[ff APPROVED WELDING PROCEDURE SPECIFICATION NUM3Et, 6 1.0 Scope l.1 This procedure specification covers the Manual Ga.s Metal Arc Welding (GMAW) of carbon steels used in the fabrication of control panels and racks.

It conforms to the intent of AWS D1.1 Rev. C-i:;f,,

_g.pt.;

2.0f Base Metals And Applicab'.a Specifications

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3.1 Low carbon steels covered under the specifications ASTA-A36, -A283 and -A569.

2.2 The procedure is qualified for a maximum of 3/4 inches.

3.0 Positions Of Welding 3.1 Qualification in the 3G (vertical) position down-hill progression, qualifies the procedure for the vertical position groove welding of plate.

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also qualifies the weldir fer *he

'lat,' horizontal and vertical pocitiqs fillet welding of plate.

3.2 Qualification in the 4G (overh ead) position qualifies the procedure for the overhead position groove welding of plate. It also qualifies the welder for flat, horizontal, and overhoad position fillet welding o f plate.

3.3 The welder making the procedure qualification _ test successfully is thereby qualified for the process and test positions for plate and square or rectangular tubing of thickness equal to or less than rhe thick-ness of the tert plate welded.

4.0 Filler Metal 4.1 Filler metal specification is AWS A-5.18 with classification Z70S-6.

4.2 The wire size is

.035.

4.3 Prior to use, the wire should be stored in a clean, dry area.

4.4 During ure, care should be exercis3d to avoid physical damage to the wire.

5.0 Shielding Gas 5.1 The gas shall be commercially pure welding grade CO 2-Gas flow rate shall be 15-20CFH.

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'JELDI N G PROCEDURE SPECIFICATION NUMBER 6 6.0 Technique 6.1 Arc strikes outside of the area of pe:manent welds should be avoided on any bas e metal.

Cracks or blemishes resulting from are strikes shall be ground smooth and checked for soundness.

6.2 Before welding over previously deposited metal, all slag,shall be removed and the weld and adjacent hase metal shall be brushed clean.

6.3 Groove welds shall be terminated at the ends of a joint in a manner that will ensure sound welds.

6.4 Caulking of wulds shall not be permitted.

6.5 The maximum size of a fillet weld made in or.e pans shall be:

1/2 in. for the flat and vertical position, 3/8 in. for,the horizontal position, 5/105/16 in. for the overhead position 6.6 The thickness of weld layers, except root and surface layers, shall not excaed k inch.

The split-layer technique shall be used in making all multiple-pass

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velas when the width o?-the layer exceed 5/8 inch.

6.7 Complete j oint penetration groove welds made without the use of backing shall have the root of the initial weld couged, chipped.or otherwise removed to sound metal before welding is started from the second side.

7.0 Criteria For Acceptable Welds 7.1 Plug Weld 7.1.1 Welds shall have no visible cracks.

7.1.2 The sum of diameters of pinholes shall not exceed 3/16 inch.

7.1.3 The weld prcfile shall be flut or slightly Convex.

7.2 Corner Weld 7.2.1 Welds shall have no visible cracks.

7.2.2 Undercut shall not exceed 1/32 inch in depth or width.

7.2.3 After grinding, the sum of diameters of pin-holes shall not exceed 3/8 inch in any 6 inch length of weld.

7.2.4 After grinding, the sum of the lengths of non-convex welds shall not exceed 1\\ inches in any 12 inch length of wa.1d.

-- 7.1.6 I

RELEANC2!T wPs 6

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APPROVED

,g WELDING PROCEDURE SPECIFICATION NUMBER 6 7.3 All Other Welds 7.3.1 Welds shall have no visible cracks.

7.3.2 The sum of diameters of pinholes shall not exceed 3/8 inch in any 6 inch length of weld.

7.3.3 The rear veld o f square, single vee anc double vee groove connections shall have no more than 12 inches of overlap i_. any 72 inch length of weld.

7.3.4 Undercut shall not exceed 1/32 inch in depth or width.

8.0 Corrections 8.1 Excessive overlap on the rear weld of square, single vee and double vee groove connections shall be cor-rected by removing enough weld metal to show that the connection is properly fused.

8.2 Excessive concavity of welds, undersize welds, and u tTdercutting shall be cc.rgscted by cleaning the weld and depositing additional weld metal.

8.3 Cracks-and pirboles shall be repaired by removing the de-fective portion of the weld and then rewelding the joint.

9.0 Peening 9.1 Peening may be used on intermed' ate weld layers for i

control of shrinkage stressss to prevent cracking.

No peening shall be done on the root or surface layer of the weld or in the base metal at the edges of the weld.

10.0 Electrical Characteristics 10.1 Direct Current Reverse Folarity Arc Volts:

20-25 Amperes:

120-175 11.0 Preheat And Interpass Temperatare 11.1 When the base metal temperature is below 320F,, pre-heat the base metal to at least 700F. and maintain this minimum temperature during welding.

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RELIA NCE! it.2 ELECTRIC COMPANY UA APPROVED 7_7,7_4_

WELDING PROCEDURE SPECIFICATION NUMBER 6 12.0

' Joint Detail For Procedure Qualification 12.1

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