ML20024D193

Revised Testing Procedure 10-T2, Multiple Channels,

ML20024D193
Person / Time
Site:	Limerick
Issue date:	07/06/1978
From:	PECO ENERGY CO., (FORMERLY PHILADELPHIA ELECTRIC
To:
Shared Package
ML20024D173	List: ML20024D172 ML20024D178 ML20024D193
References
10-T2, NUDOCS 8308030286
Download: ML20024D193 (8)

Text

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. CORPORATE GEllERAL ( . NAGER:_ /O'f8 6 4 d C S uh f 3 7d' f.

,' QUALITY CONTROL HANAGER- .f-[m - .

ENGIllEERING MANAGER:

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HAP.kETING. HAN AGER: MMs C@ 6

.(.l TESTING PROCEDURE 10-T2 REVISED 6/5/78 '

703974.1;

'.FORMkJ.LTIPLECHANNELS.. .

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Sp.ot Weld Qualification Hodified for Limerick -Job ' '

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' .' . A. LOT. .IS' AppROXll.idTELY .'500' (Plus of minus 100'). ~

I..,[StartofHA1tip17dhann'e1 1

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Production:[. ..

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- ,.1... '. Start .

i p ro duction'." .2Tso shear te s t ' specimen s'."f $

.; , shearetestedM A shear ' test shall also be made when . .i ~.J' ." ..c. .. -@.

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. ,;. weld.r.tiips, are' changed, and weld machine ~ settings .

E-are: changed. .They must pass.3500# shear test be-fore-lot production is resumed. Record. a cceptable- ' . ". .L ' "9:

tests .on form 10C.c Record unacceptable.. test on .. . s

' SS Form 4; SS Form '4. should go to "Hol d" wi th r' ejected

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p.iece (See'III-2). Mark. any rejected length with red and confine to. " Hold" area for Engineering advice as to

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disposition. After a lot rejection as described in .

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.I-2 below or.after welding machine repair.a restart l

of' production shall be considered as a new lot. '

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qugeRange y t With minor' dimension d.

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O to .030 5/8" 3" ~g'- *W changes shear test to-be performed in accor- ' 'i

.031 to .050 3/4" 3" O

+ dance with AWS C1.1-6 ..

.051 to .100 1" 4" .

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%" 5" ' Paragraph 504.1 '. C;.'}

.101 to .130 - .

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. 2 .* If the above tests are acceptable, produce the lot. '

'? -

.T est' 'each length of' the lot at every.7th Do weld with  ;..

a 300.Q lbs. non-destructive pull test. not pull.

.' first'op last spot on.a piece. Align test apparatus

- and center on the spot being tested. Failure of- .

this test 'is 1.ndicated by a popping sound at we)d '

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~

failure or separation of the channels. Record

• acceptable test on. Form 10C. If any piece should .

fail the non idestructive test, record on Form SS-4, G

- attach hold tag, mark that piece with red, and con- I

. fine to " hold" area for engineering disposition. .

Three such failed pieces from any lot shall cause .

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.the entire lot to be recorded on Form SS-4, have hold .

tag attached, be marked with red, and confine todispost-Engineering " hold". ,3

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, area tion may for. engineering) be either 1 disposition. reweld and retest, or 2) reject .

for use in Limerick. Any . failed pieces which They exhibit '

shall' channel separations shall.not be' rewelded. .f be rejected for.use in Limerick.

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II. _

General Requirements .

l .' Each piece shall be visually inspected for spot weld

( -

Any piece with spacing between welds longer -

- spacing.than 34" center to center shall be marked with red, ' -

- ' have hold tag attached and confine to " hold" area "

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- for engineering disposition.. Record on SS Form 4. '- ' '.l.Y[7l[.(,. '

< - The " Hold Tag Number" shall show the lot number. . . . J ' . ,_-l ,, . / c ? .

. Item description

. /v.t. Supe r . S tru t art number. will name' the . Job numberJ and, "

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the TI.' J";P,-:%tape 1

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/.f .l:be attached ibein'.;A  ; copy shall .go'to permanent:.filesd:ith. s D: A case.may third copy .shall be' attached In- rocess disposition .i..'.~ lN'.fF.'*'JJ.'.'l"'

to order file cop'y.i f .. . ?

" f..ef::l J,For:.the Limerick.

4 Job the ""wil ~ .be alther " rework"',' T s . ~j..;-T:;-. G

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. Jf.of material"'on SS Form.4 . ~ ' !."rk..: .

. '.  : to. wel d r.epair".3or ," scrap"h as'-outlined in this til' '

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' Limerick T-2 :.r'avision. '. ,. ..  ;; .

dated. ., June

):9:.. ' 5.1978.

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2'. ,Honday Fabrication testing instruments will' be tested each -

ir.orning with. an Enerpac TMS. test gaugeF 'which -

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- . .itself shall be calibrated. every six months with calibration tr'aceable to the' National Bureau of Standards. . Testing records. of testin'g. instruments '

'Six-month cali- ' , .

.shall be maintained on Form 10-E.

bration and certificates will be retained for three years; ~ also records of teisting of fabrication .- test instruments. - , . . . ::

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' J Lot.No.'s.shall be stamped out on a. flat washer,.

3.

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which shall.be wired through a hole in the end of

• one piece in each lot. All pieces.of a lot shall .

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' If the lot is ,

.be banded.together in one bundle.-too heavy to'be banded tog lot sha11'have the.-lot no, wired to it.

. 4. 'More than one lot may be re. corded on form,10C. .

5. Procedures and test results shall be recorded and -

1 kept by Super Strut for,thre'e years. ,

6... Attached are Diagrams of Test Equ.pment.

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7.- In the event of' a reweld, . treat. the first series -

of welds as if they were not there in counting

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every seventh weld. . .

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. .- JUL 1978

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03974 III. Reworking Weldad and Coated Material -- .

1. If it sh'ould become necessary to . rework previ'ously -

- . welded and coated material; .each length requalified ,

s~

- *shall be marked with blue paint inside one end of '

.. channel following acceptable testing on the non-

. destructive test equi New welds shall be . '

~

. ,, touched.-Lup w:ith

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zinc.pment.

rich paint.

. ., . .s.:::. . . ,: r P. . .Non-acceptable rework material shall be marked with -

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i n red'*as' above ,and ~ controlled into a'ihb1 ding ' area -

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. .with SS Form 4. for Engineering advice as to disposi .. . l

 ?. , .tion.

Hark Lot.No.:'.:. - . . . .. . .-

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- -3'.? Shou ~1d r'ework material be considered acceptable '.j. .

. when total non-destructive testing of the lot is . *'-

not required by/ customer such material will be - ~

marked with green paint and the footage recorded . ' ' '

. . on .SS Form .10-C.. (Not applicable to Limerick) . . .

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.: Data JU RD_

b i FORM 10C OPERATOR /PRODU TffiACilltfE QUALIFICATION T . .

...u........ 039741-( ator s Name-

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dentification#__-

-(Social Security f) - .or 10T2

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10T1 .

n accordance..with.'Proceddre Specification No. (, Ci rcl e .P.rocedure .Useci .

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.aterial..specif ca -

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.yy&i9.q'.y ,:q a...'-Destructive. Shear Test....;,y

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1- ' Allowable.  :

. Hon-Destructive *.g ..

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dentity_ .. r. ;. .. Lot .:, ;. ; .q- :.s Tdentityg"Part N: . 1 Load.' ,..

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Non-Destructive Pull Test.

ot No. Part "> F'cotage TLot No. .+ w .a

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Destructive' Shear Tea

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i Li Identities will indicate the date (i.e., Lot '

6th~ No.1-6-5-8 of May 1978): is. first lot .on ..

--m e ,.1.- ..

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If 10-T2 procedure.is us'ed. lots will. be identified with wired, stamped '

washer tag. Those which do not.' meet the'. minimums will be treated - - - -

f. 'as . J-described in.1-T2 procedure. .-

Test every 7th wel. d starting'.one .wel'd' Oi from front end - Do not pull .. .

.s. . ,

e. .

, 9 ,. .

last weld. i,;- -"'. ;. .. ,.. p. . . . -

Test conductesi by

. .. . . Lab / Shop Test No.

.. . .w . .. . _. . 22 ..* -.. ; :. .: ;_

Date Accepted (Circl@

Date . Lot: Rejected one)

Tests inspected by-

.. ( rejected,' follow SS Form 4)'

. .I.

. . ....If

.. .. . . ~

He the. undersigned.. certify that the statements in this record are - -

correct and.that the welds- were prepared and tested in accordance -

with tije requirements of Super Strut Procedure 10-T2. .

Per Authorized by - -

.(Authorized pesign,ee)

' . (QA/QC Hanager)- -

nate .

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SS Form 10C Page 1 of 1

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DISCREPANT REPORT AND CORRECTIVE ACTION 3,6 .: 6. -

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SS JOB NO. . -

- CONTRACT- N0. -

DMG NO. '

J0MER .

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RtJECT' TAG NO.'.e@- ' '

HOLD TAG NO.

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1TEH DESCRIPTION

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OF ILURE 'CDEFECT OTOLERANCE O oAsAce . .

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IN PROCESS (DESCRIBE DISPOSITION OF MATERIAL).. , . -

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l CORRECTIVE ACTION t * -

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RESPONSIBLE DEPT' . PURCHASING- -QC - *

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Job 0031 Limerick Units 1 and 2

' 03278 Cold-formed Back to Back Channels (struts) for Electrical Supports i ,

Interim Acceptance Criteria for Replacement Material. The following acceptance criteria shall be used pending final acceptance criteria i by Spec. E-140 6 Revision.

A. Replacement Material on hand at the Super Strut Goshen, Ind.

Plan t ( APPR. 7000 ft.)

1. Struts shall be hot-dip galvanized af ter shop welding, or pre-galvanized channels welded by the 4-tip automatic Teledyne-Peer machine at the Superstrut Goshen, Ind. Plant.

2. For each back to back channel type, the 3,000 lb. pull test lining up on a single spot weld shal.1 be applied at the following rate:

Rate of Testing ,

(1) Frequency of Spacing of Sequence No. pieces Pieces Tested tensile Tests 1 1-100 Every piece 18" O.C.

2 101-200 every alternate 18" O.C. -

piece GD 3 201-up every piece 3 welds

() If any one weld fails in any piece, the entire length shall be rejected and the above testing sequence shall be restarted be-ginning with the piece following the reject. All previously tested sample found satisfactory are acceptable.

l Q) One weld shall be located at each end and one near the mid-1.dngth of the piece.

Indications of weld failure during testing shall be a loud popping no.ise under load and/or physical separation between the channel sections at the weld. -

3. Tension - Shear tests shall be performed in accordance with AWS C1.1-66 paragraph 504.,1, Test No. 1 with minor exception -

to the dimensions of the specimens. The test specimens shall be cut from the ends of channels used for the pull tests.

One specimen shall be obtained from the first channel and every 20th channel thereafter from the designated shipping lot. No less than two test specimens shall be tested per lot. The ultimate shear capacity of a single spot weld shall be not less than 3,500 lb. If the first 20 tests pass this i

l T-355a i

1978 g{ggggg MarchPago 220, L. .

of 2

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• A-lord, such tooting may be terminated. If any.ono specimen fails at a lesser load two retests from that piece are permitted; the retesta must be successful. Otherwise, the entire replacement lot initially designated for shipment shall be held pending Bechtel project engineering disposition.

Bechtel will accept delivery of any channels from which specimens had been cut and successfully tested.

4. Specimen for direct tension test for information only shall be cut from the same length as for the shear test specimen such specimen shall be at least 3 inches long with one spot weld at the center and shall bo pull-tested to destruction.

5. All testing equipment shall be calibrated and certified within the last 6 months. Calibration shall be traceable to the National Bureau of Standards. Super Strut Super to propose calibration accuracy for Bechtel SFHO approval. Strut shall also prepare procedures for tests in par. 2, 3, & 4 i for prior Bechtel SFHO approval. l

6. Each piece shall be visually inspected for spot weld spacing.

Any piece with any spacing larger than 3 1/4" shall be re-jected. .

7. The testing and inspection shall be performed by Super Strut, Inc. and witnessed by Bechtel personnel,.

8. All pieces actually pull tested and with shear test samples cut and found acceptable shall be uniquely identified and -

marked. All pieces not tested but acceptable for shipment shall be likewise uniquely identified and marked. All rejected pieces shall also be uniquely marked.

9. Ultimate Strength values of the shear tension test and the direct tension test and all tests not meeting acceptance criteria, shall be submitted for information to Bechtel Field before shipment.

i

) B. Replacement Material by Returning Super Strut Back to Back Channels at Limerick Site to Super Strut Goshen, Ind. Plant, for Rewelding

1. Reweld channels at 3" on centers as in Item A(1) above.

2. Such repaired material will be considered as a new channel type independent of the classification in Item A.

3. All sampling , testing and marking shall be in accordance '

with Item A(2) through A(9) above.

. 355a i

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