ML20024D104
| ML20024D104 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 07/25/1983 |
| From: | Stiner D, Stiner H Citizens Association for Sound Energy |
| To: | |
| Shared Package | |
| ML20024D101 | List: |
| References | |
| NUDOCS 8308030162 | |
| Download: ML20024D104 (12) | |
Text
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UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD In the Matter of l
APPLICATION OF TEXAS UTILITIES I I
Docket Nos. 50-445 GENERATING COMPANY, ET AL. FOR and 50-446 AN OPERATING LICENSE FOR I COMANCHE PEAK STEAM ELECTRIC I STATION UNITS #1 AND #2 (CPSES) g AFFIDAVIT OF HENRY AND DARLENE STINER 1 Q: Mr. and Mrs. Stiner, have you read a. copy of Applicants' Sumary 2 of the Record Regarding Weave and Downhill Welding, filed July 15, 1983?
3 A: (Both)Yes.
4 Q: Is there anything you would like to clarify for the record in regard 5 to Applicants' pleading?
6 A: (Both) Yes.
7 A: (Mrs. Stiner) I was certified to weld to both ASME and AWS DI.1, 8 both of which are used at Comanche Peak. ASME is used for Class 1, 2 and 3 9 hangers and supports; it's not used for Class 5. AWS Dl.1 is used for Class 10 4, 5, and 6 -- anything that's not safety-related.
11 Q: Isn't Class 5 safety-related?
12 A: (Mrs. Stiner) Procedurally, no. Logically, tbey should be considered 13 safety-related, because they are all in safety-related areas.
14 Q: Mr. Stiner, what codes did you work to at Comanche Peak?
15 A: (Mr. Stiner) I was.also certified to weld to both ASME and AWS D1.1 16 Codes. As Darlene stated, both of these Codes are used at Comanche Peak.
8308030162 830728 PDR ADOCK 05000445 Q PDR
! I 1 Q: And is it also your understanding that ASME is used for Class 1, 2, 2 and 3 hangers and supports, but not for Class 5, and that AWS Dl.1 is used 3 for Class 4, 5, and 67 4 A: (Mr. Stiner) Yes. I'd like to point out that AWS states, regarding 5 downhill welding (see copy of sections attached):
6 AWS Dl.1, 4.6.8: -
7 "The progression for all passes in vertical position welding shall be upward, except that undercut may be repaired vertically downwards 8 when preheat is in accordance with Table 4.2, but not lower than 700F (210C). However, when tubular products are welded, the progression ,
9 of vertical welding may be upwards or downwards but only in the' l direction or directions for which the welder is qualified."
10 11 AWS D1.1, 5.16.5:
12 "For the qualification of a welder the following rules shall apply:
13
. . 5.16.5. A change in the position of welding to one for which the welder is not already qualified shall require requalification."
14 15 AWS Dl.1, 5.16.7:
16 "When the plate is in the vertical position, or the pipe or tubing is in the SG or 6G position, a change in the direction of welding 17 shall require requalification."
18 Q: So downhill welding is not supposed to be used normally, but only 19 in certain specific instances?
20 A: (Mr. Stiner) That's right. And then the welder is supposed to be 21 qualified or requalified to do it.
22 Q: Is there anything further you'd like to say about downhill welding?
23 A: (Mrs. Stiner) Whenever you do a downhill weld, you don't get proper 24 penetration -- it's sort of like skiming across the top. I have made down-25 hill welds myself at Comanche Peak, under orders. Like if I came up on a I
I weld that was in a particularly hard position to get to, sometimes my foreman 2 would tell me to just go ahead and run a downhill weld over my stringer bead 3 weld.
4 Q: Were you qualified for downhill welding?
~
5 A: (Mrs. Stiner) No, I wasn't.
6 A: (Mr. Stiner) No, I wasn't. I talked about downhill welding some 7 in my testimony (CASE Exhibit 666,9/1/82,pages45-46). I don't think I 8 made it clear in my testimony, but I also have done downhill welding.
9 Q: But you hadn't been qualified to do it?
10 A: (Mr. Stiner) No, but I was told to do it anyhow.
11 Q: What specific codes and procedures did you use at Comanche Peak?
12 A: (Mrs. Stiner) WPS 11032,10046, and 11065, and CPM 6.9, plus quality 13 control procedures (it's been a while, but I believe the numbers of the ones 14 I used primarily as far as QC control procedures were QI-QAP-11.16-1 and 15 ANSI Code B31.1).
16 A: (Mr. Stiner) As stated in my testimony (page 8), the welding procedures 17 for the C-10 and A-10 welding process codes are 11032,11065, and 10046; the 18 procedure that states that weave welding is not to be used is CPM-6.9, to the 19 best of my recollection. This is also indicated on the Weld Parameter Guides 20 issued from the rod shack to each welder when material is picked up. If you 21 go over the maximum bead width, you'd be weave welding.
22 A: .(Mrs. Stiner) 11032 is the one I used the most. It's interchangeable 23 with and often used in place of 11065. 11032 states that stringer beads only 24 shall be used. Therefore, it isn't permitted even on the cap or the root as 25 Applicants have stated can be done.
1 Q: Is the're anything else you'd like to clarify regarding weave welding?
2 A: (Mr. Stiner) Regarding weave welding and the hett input, where Mr.
3 Brandt says in his Affidavit (page 2):
4 "The purpose of limiting bead width for welds on materials requiring impact testing is to control effective heat input because excessive 5 heat input could cause broadening and subsequent embrittlement of the heat affected zone." ~
6 7 . . . when we're talking about maximum bead width, we're talking 8 about the effective heat input also. During the whole term of ipy employment 9 at Brown & Root, the only time that I was given a temperature indicating crayon 10 was in the Welding Qualification Test Center (WQTC).
11 Q: Is it a requirement at Comanche Peak that a temperature indicating .
12 crayon be used?
13 A: (Mr. Stiner) I do know it's required by some procedures. But it's 14 not a practice that is used by the structural welders at Comanche Peak.
15 In regard to Applicants' Exhibits 141N-141V, which Mr. Brandt stated 16 pennit the use of weave welding at Comanche Peak, on those procedures under 17 preheat on the Welding Procedure Specification (4th box, left-hand column),
18 the preheat temperature and interpass-temperature range is indicated. At
. 19 Comanche Peak, they don't check the. preheat temperature or the interpass 20 temperature. When I tested at the WQTC, they gave me a temperature indicating 21 crayon to check and be sure that each consecutive pass was not heating the 22 parent metal up above the interpass temperature range which was in the pro-j 23 cedure. Even on your test coupons if you rise above that interpass temperature, 24 when they do the bend test on the strips that they'll cut out of your test 25 coupon, you will fail the test because you will have created embrittlement
s 1 of the parent metal which will show cracks in the weld of the test coupon.
2 But out in the field, I have very seldom seen anyone use the temperature indicating crayons or any other kind of temperature measuring device. I never 3
4 used the crayons rqyself. Generally, because of my experience with welding, 5 I could tell when it was getting too hot if I held my hand near the metal.
6 But we were under such pressure to put up the hangers that most of the ' time 7 we didn't take time to check the temperature. Under one foreman, we had a 8 quota that we had to meet every day. I talked about some of the pressures 9 we were under in my testimony (see especially pages 18 and 19).
10 A: (Mrs.Stiner) The welders didn't have an hour or two to wait for 11 it to cool off; they had to get the weld made because they had so many to get 12 done each day. Plus the fact that they always had to worry about somebody 13 else coming along and stealing their welding machine or their lead while they 14 went to the restroom or something. At the end of the day, your foreman didn't ,
15 understand why you didn't have more hangers done. Most. of the time, the fore-16 man sent the welder to look for their machine and their lead when it was 17 stolen; they didn't have you check out another machine. You might spend 18 hours looking for a machine that nobody is going to admit was yours.
19 A: (Mr. Stiner) They created such adverse conditions for the welder 20 that he just had a limited amount of time to complete the required amount 21 of hangers. Welders shouldn't have to work under such adverse conditioris.
22 A: (Mrs.Stiner) I'd like to say something else about the weave welding.
As an example, if you took a rod and struck an arc and held it to the metal 23 24 and just kept it burning in the same spot, your metal would just fall right 25 out after a time. Also, the longer you. hold 'it there, the hotter it gets.
1 So when you weave weld, the longer it takes you to progress up the picce of 2 metal, the hotter the piece is going to be in one specific area. Therefore, 3 the parent metal would become brittle because you are not controlling your 4 heat input.
5 Q: Mrs. Stiner, did you ever use a temperature indicating crayon?
6 A: (Mrs: Stiner) Only in WQTC. I've never used it other than in WQTC.
7 During my inspections, only a few times have I seen anyone using a temperature f
8 stick and that was generally pipe welders, heliarcers, and so forth. Most 9 of the time it was not on pipe supports; I don't recall ever seeing it used 10 on pipe supports.
11 Q: How can they check the effective heat zone and be sure they don't 12 get it too hot?
13 A: (Mr. Stiner) They can't. There are other heat checking devices 14 they could use, but they don't use them at Comanche Peak.
15 A:. (Mrs. Stiner) There's no way they can be sure they're not getting i
16 it too hot, because they don't use any heat checking devices at all most 17 of the time.
18 Q: How does grinding down help correct weave welding?
19 A: (Mrs.Stiner) It does not. help it at all. The weld underneath is 20 still a weave weld, which is weaker because there has been no control over 21 the. heat input.
22 Q: How could you correct weave welding then?
23 A: (Mrs. Stiner) You grind it completely down to base metal and reweld 24 it with a stringer bead. It would really be better to cut the whole thing 25 down and redo it, because you've still got dainaged parent metal.
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F 1' Q: Was that what you did Mr. Stiner?
2 A: (Mr. Stiner) No. As I testified (CASE Exhibit 666, pages 9-13, 3 33-34, and 53), I had to go.along and repair bad weave welds that other 4 welders had made most of the time, and I was told not to grind all of the base 5 metal out but just to grind off the surface and cap it so it would appear to 6 be a sound weld. In other words, it was just covered up, not corrected.
7 Q: Is there anything-else about weave welding? .
(Mrs. Stiner) Yes, there's one more thing which needs to be clarified 8 A:
9 on page 25 of my testimony, lines 2 through 8 (CASE Exhibit 667,'9/1/82).
10 On page 10 of Applicants' 7/15/83 pleading, it is stated "It is clear that 11 the ' repair' alleged by the Stiners to have been perfonned was not required 12 because of some structural weakness in the weld or welded material. Rather, 13 the repair was cosmetic, there being no structural reason for limiting weave 14 welding on materials not requiring Charpy impact testing." I thought it was 15 clear in my testimony on page 25 that the weave welds were discovered when 16 I was inspecting the hanger for torquing; the welds were in the process of 17 being made -- it was not an initial root pass or merely a cover pass for 18 cosmetic reasons, as indicated by Applicants. Later, when I returned for final 19 inspection of the torquing, I again noted the weave welds, which were still in 20 Process of being made; they were-not merely cosmetic problems, and I wrote 21 an NCR on them accordingly. As stated in my testimony, the superintendant .
22 whom I took to see the welds himself told me to have them cut the hanger down.
23 You don't cut a hanger down for " cosmetic reasons."
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I have read the foregoing 7-page ~ affidavit and it is true and correct to the best of my knowledge and belief. I am making this statement freely, without any threats, inducements, or promises of rewards. This affidavit was prepared under my personal direction, and the thoughts and words expressed herein are my own thoughts and words (with the exception of minor grammatical changes, either to correct spelling or to clarify what I meant, which did not change the intent of my thoughts).
Flenry p ner Darlene Stiner 4/ Af h9 "
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Date: July 25, 1983 STATE OF TEXAS On this, the 25th day of July,1983, personally appeared before me Henry Stiner and Darlene Stiner, known to me to be the persons whose names are subscribed to the foregoing instrument, and acknowledged to me that they executed the same for the purposes therein expresses.
Subscribed and sworn before me on the 25th day of July,1983.
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e State of Texas NotarQin an My Commission Expires: . J F f.1
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An American National Standard Approved by l I American National Standards Instituts StructuralWelding Code-3 Steel !
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Prepared by a AWS Strwtural Wckling Comminec
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s Submerged Are l>rlding I$1 i
h W e 4.5.3 4.6.3.4 $/32 in. t4.0 mmi for melds made with Permineasle atmospherto exposure of EXXI4 and los hydrogen electrodes in the verucal and pl' leur hydrogert electrodes oserhead posinons.
+ 4.6JJ 3/16 in.14.8 mmi for root pass s of groose Column Column welds and for all other welds not included urder 4.6.3.1.
- A B 4.6.3.2. 4.6.3.3. and 4.63.4.
Electrude h ru twursi
. 4.6.4 The minimum siac of a root pass shall be sufn-p AS I . cient to present cracking.
i .t E70XX 4 mas Osere so lo mat 4.6.5 The masimum thickness of root panes in grouse melds shallbe 1/4 in. t6 mmi.
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- mEU"Wm st2R Hos Pau Met meUs and
- E70XX 4 mas Owr 4 to lo mas to t panes of multiple. pass fillet melds shall be 4 E30XX :mn Oser 2 so 10 mas 4.6.6.13/8 in. 49.5 mmi in the Cat posioon ee0XX 'l mas OserIio? ma, Et00XX ll: m n Oser 11: to 4 mn 4.6.6.2 $/16 in. a8 0 mme in the hontontal or oser.
i.- Ell 0XX II: mn Oser II toa mn hem positions 4.6.6.31/2 in. I12 7 mmi in the scrtical posioon
, Noers-f I. Column A Lican*s noscJ to atasphere for kviger 4.6.7 The maumum thickness of layers subsequent to pemh than ha shall be redricJ twf.we use root passes of groose and fillet melds shall be
- 2. Columa B Elecu.*s esoned to ata.i@cre for longer 4.6.7.11/8 in s) mmi for subsequent layen of melds 3 pemh than Msc estabbshed by seshns shall tie rcJried tv- mMe in the flat position k*r ia* 4.6.7.2 3/16 in 4 mmi for subsequent layers of meus 7
t mMe in the scrusal. os erhead, or honzontal posiuons
- c 4.6.8 The progression for all passes in sertical posit on 4J.4 Redrying Deetrodes. Electrodes that conform to melJing diall be upwarJ. escept that urdercut may be the protisicris of 4 5.2 sha!! subsequenti,y be redned repaired sertically Jou nsards when preheat n in acecrJ.
! no more than one time Electrodes that hase been met anee with Table 4 2. but not lower than 70* F i2l' Ci
,, shall not be used. Homeser. when subular proJwets are mcIJeit.the progrew
- " *I ""'# Id'ng may be ups atas or downsards 4 5J Manufacturce4 Certificatloa. % hen requesteJ tw the Engineer. the contractor or fabricator shall fumisit D '"'h' # * "*" *'d'"*"'I*' ' h'#h'h* IJ
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I an electrode manufacturer's cerufication that the electroJe mall meet the requirements of the clauificauon. 4.6.9 Complete joint penetration groose melJs mMe with.
..] out the use of steel backing shall hase the root gouged lcy
.g to sound metal before melding is started from the second "d' ""P' P '""'"'d 6) '
j 4.6 Procedures for Shkided J.] Metal Art Welding 4J
.s 4.4.I The mori shall be posiooned for flat posioon meld. pgg C
- '***"*"'** Submerged Arc Welding s' 44.2 The classificanon and size of electrode. are length.
! I voltage, and amperage shall be suited to the thietness of the masenal, type of groose. melding posiuons, ard
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other circumstances artending the wort. Welding current 4.7 GeneralRequirements shall be within the range recomrnended by the electrode
., ,,,,,g,,,y,,,, 4.7.1 Submerged are melding may be performed with
, h one or rnore single electrodes, one or more paralki elee.
'2 'i 44.3 The ma.timum diameter of electrodes shall be tradest orcombinauons of single ard parattelelectrodes
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s as folloms: The spacing between ares shall be such that the slag cowr ,
i 4AJ.1 $/16 in.18.0 mm) for all melds made in the oser the meld metal prcduced by a leMing arc does not j L flat pcsition. eacept root panes. cool sufficiently to present the proper utid deposit o( a l
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4.4.3.21/4 in.16.4 mm) for horianntal fillet m elds-44J.31/4 in.16.4 mm) foe root panes of fillet following electrode Submerged are mewing mith mul-ople electrodes may be used for any groost or fillet I ocids made in the flat position and groove melds mmc . eld pua.
in the flas posinon eith becting ard with a root,open-I k
( , ing of 1/4 in. or more. Il See AppendaI l
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0465 ed
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(1) Partial joint penetration groose melds shall hase 5.13 Records the designesed effectiw throat.
l Q) Fdlet welds shall haw fusion to the runt of the Records of the test results shall be kept by the manu-J joint.but moi necessarily beyond.
acturey w conwim and shah be asailaW to show On Minimum leg siae shall meet the specified fillet autherized to eaamine them.
gg (4)The partial joint penetration smow melds and fillet welds shall:
'w- (a) Haw no cracks. 5.14 Retests (b) How tierough fusion between adjacent layers of i . weld metals end between weld metal and baw metal. N an) ne specimen of all those tested fails to meet the
- (c) Have weld profiles conforming to intended de-
, ? L'st t'9u'ftmentS 8*o ret 8sts for that partcular type of tail.but with none of the sariatens prohibited in 3 6.
teu specimen may be performed = ah specirnens cut from
.! (d) Have se undercut eacceding the salues permit- the saa pr cedure quahfication material. The resuhs of j eed is 9.25.1.5. . both test specimens must rneet the test requirements For l ,
', $.12.4 AB.Wdd-Metal Tenslen Test telectreales and material owr I 112 in. Og,I mmi thick failure of a spec-l electregas). The mechancal properties shall be no lew imen shall require testing of all specimens of the sarne than those specified in 4.16. ty pe from rmo additonal locations m the test matersal
{; 5.12.5 N=d=*setive Testing. Fac acceptable quahfi-catme. the weld, as revealed by radiographic or ultra-sonic testing shall conform to the requirernents of 16.15.
9.25.oc10.I7 =hkhewtis apphcable. ,
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5.12.6 Visual taspection-Pipe and Thbing. For anept-
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/ able quahfication. a pipe utid, when inspected snually.
9 shall conform to the following requirernents: ,
(1) The weld shall be free of tracks. gg Q) All craters shall be filled to the full crow secten of the nu. Welder Quahjication 0)The face of the s. eld shall be at least flush math m the outside surface of the pipe, and the meld shall merge
- mwwMy =ith the base metal. Undercut shall not eacced 5.15 General 1/64 in. 40.4 mml. Weld remforcernent shall not eweed
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- N The quehfication tests described in Part C are specially deused tests to determine the utider's abihty to produce
- Pipe m ali thdacu. Reinfor6cment. mn.
sound utids. The quahicaten tests are tot maended to be used as a guide for meldirq during a:tual construc-i
""" '" ** ton. The latter shall be performed in accordance mah l '.,
3,32 2a the requirements of the procedure specifwaton.
3/8(9 Siorleu Owr 3/5 to 34 819.0nrict. Ils 12
- Owr 34 3*l6 a4 5.16 Umhation of Vadables
- A (4) The root of the meld shall be inspected and there For the quahfication of a melder the folloaing rules shall be no evidence of cracks, incomplete fusion, or inadequase joint penetraten. A concave root surface is shall apply
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permitted within the limits shown below, prouded the 5.16.1 Qualification established u nh any one of the j
total weld thickness is equal to or greater than that of the stects permitted by this Code shall be considered as 9 # " '
d) maximum root surface concavity shall be '
5.16.2 A welder shall be quahried for each process used.
lh6 in. (1.6 mm) and the trsanimum rnett thru shall be l
W in. 42 mm). 5.16.3 A welder qualified for shielded rnetal arc webns with an electrode identified in the folbwing tr.ble shall be 5 5.12.7 Visual leapecties-Pl.ste. For acceptable quah.
ficatlee, the welded test plate. when inspected visuahy, conaidered quahried to weld or tact wtld with any other e
shall coeform to the requirements for visual inspection electrode in the same group &stgnanon and wah any electrode lisaed in a numencally k>mer group designation.
. la 9.23.1.
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F2 EX X to. EX X i t EX X 12. EX X 11. EX X 14 tangular tubing equal to or leu than the thrincu of the I Fl EX X20. EX X24. E.X X27. EXX 2g test plate welded If the test p(me es I in. (25 4 mm) or ,
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' h tzNr stand kw the warmes irnegth k=ch feu ro. 80.n #00..
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~wekiing of plate and pape, as shown in Tabee 5.23.
- and W W W snetM 5.17.4 The cider who makes a compicte pers pene.
LM.4 A stWet quahfied with an apprmed ekctrode taten groost etid pipe procedure quahfication test.
.c and shebei rnedium corrdunaton shall be cortsdered *nhwt backing scip, that ncets the requirements n I gnhfied to weW or tact weW sh any other approved ebctrode and shebng medium combination for the themby quahried fw that prenu. His quh6cmion mill i
- f. include the test position for pipe hasing a eaff thriness I practu used ta the quahicataan neu equal to or leu than the wall thekness of the seu p9e f .
S.15.5 A change in the posrta of weang to one for welded If the test pipe welded a 6 in. (152 mm) Sch 80 y
.g whsch the oeWet rs not already quah6cd shall require or in (203 mm) Sch.120 pipe. he mill be quhried for Qy segaakricum all thekneues Ths =tider is also quahried for fillet "
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- 85 Sh '" 'n Tabk 5 23 If the l 5.21.6 A chage from one diameter .all ppe grmping diameter of the pb. sue pipe of tubing used in quh6
@0 sho=3 ra Table 5 26 I to another shall require rtquah. eation es 4 in (102 mm)or len. the qah6 cation u hmited ;
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% to diameten 3/4 in (19 mms through 4 in (102 cnrni. * +
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S.2f 7 W3 the pLw: n in the wrtical posrtion. or the incluuw. If the diameter of pb.nze pipe is owr 4 in (102 mm), the quahncation is hmited so a minimum y pre or subing n in the SG oc 6G poution. a change in e tic 6tectmn o( mekiing shall etquire requah6catio9 d.arneter of greaser than 1/2 test diameter or 4 in (102
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5.25.2 The orniuson of backing matettal in.completc
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w pen penetrtsam melds melded from one sa$e shall re. specr6cd in Tabk 5 26 I g qwe requaLfication.
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5.17 Qu:sficationTbsts Required jI,. 5.18 Groove Weld Plate Qualifkstion
. ..S 5.n. The =euer quiiricaton iem for manui and Test for Piste o(Unlimited
, seminunoma:ic webeg shall be as follows. Thickness 1.!7.L1 Groove meld quahficacian test for plate of
/ sefammed thriness The pint detail shall be as follows I in (15 4 mmi >
5.r7.L2 Genow
- tid quah6caton icu for plate of plate, ungle V.groon. 45 deg included angie. U4 in thicinesa (6 4 mmi root opening
- nh backing (see Fig 5.18 Al . !
} S.!7.l.3 Fillet =eu quahficata tests for fillet *cus For horimntal poution quah6 cat.on. the point detail 4 4 may at the corttractor's ceion. te as fotbos ungk. j J
- ,. (1) For meus is points haung a dihedral angk Wof bestl groom 45 deg g oow egk,14 in rom ops ning 2 75 des or len, quahfication tests shall be as required by with backing asee Fig 518B: B ad mg met te at k ast v i 5.13 ce 519 Such quahficaion = di be sahd for filkt 3 8 in (9 5 mm) by 3 in C6 2 mmi if radiographic M
, weWs h.ning arigles greater than 75 deg tening a used without re nove! of backing it rnuu be a C) For =cids in fornts haung a dihedral angle M 3 e leau 3 8 in % l in (25 4 m ni for wanca] wing 4 '
g: ester than 75 d g and not escceding 135 deg. tests shall or for ndiog@g testeg af.er the backing n renowd /
f . bn as sequ"ed by 5 22. Opuon 1 or Optam 2-contractori Minimum length of *elding groost shall be 5 in
@" (127 mm) ,
5.r7.2 The p9e w tu5ng quahricat=3n tesu fw man at f., e i
and semtau:omae *ctdiris shall be u folic = s 1ma
', " s.17.2.1 Groow wu qahricaoon itu rw 5., pe 5.19 Groove Weld Plate Qualifka*!on c=f.!7 a a;=re m rectaar a ameng r'c'.1.2 Groow weld quahficma seu for T. K . or Test for Plate of Limited M"MJ h
l Y. corr:setem on pipe or aqua e or recungular t Ang 5.17.2.3 Getum *vu quahricaten test for butt pinta C
os equare or rectangs!u tubing testad on fim plate The point deta1 Aa:1 be u follows 3'8 in (9 5 mm)
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