ML20058C649

Rept on Weld Overlay Procedure Development for Waterbacked Nozzle-to-Safe End Welds

ML20058C649
Person / Time
Site:	Oyster Creek
Issue date:	07/31/1989
From:	Jonathan Brown, Chakravarti B, Froehlich C NUTECH, INC.
To:
Shared Package
ML20058C647	List: ML20058C645 ML20058C649 ML20058C658
References
XGU-05-211-R00, XGU-5-211-R, NUDOCS 9011020155
Download: ML20058C649 (115)

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!I XGU-05-211 iE Revision 0 l E 3=2r 2SSS l

GPU005.0211 I I REPORT ON WELD OVERLAY PROCEDURE DEVELOPMENT FOR WATERBACKED NOEZLE-TO-SAFE END WELDS

'I Prepared for:

GPU' Nuclear Corporation I

Prepared by:

NUTECH Engineers, Inc.

I Prepared by:

Reviewed by fMh bow %'/l.'

d B. Chakravarti, PhD.

7. K. Brown, P.E.

Project Engineer Staff Engineer Approved by:

Issued by:

&stant Akisto C. H. Froehlic'h, P.E.

f. R. Sheffiel4 P.E.

Engineering Manager Project-Manager I

I 4

I g

nutech

I 4

I REVISION CONTROL SHEET l

TITLE: Weld Overlay Procedure DOCUMENT TILE NUMBER:

GPUoo5.o211 Deve1opment for Waterbacked Norrie-to-S.fe End Weid.

B.

Chakravart1/ Staff Consultant NAME/ TITLE INITIALS C.

J.

Johns / Consultant I b

NAME/ TITLE INITIALS I

A

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N.Emm w1Tm3 g

ATTECTED DOC PREPARED ACCURACY CRITERIA j

ricre,i arv sv/cire cumCx ar/nire eMECK BY/DATr REMARKS go 7/7/o es7 v/7/e7 p -r/7/.,

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XGU-05-211 j nutech Revision 0

1

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TABLE OF CONTENTS m.

LIST OF FIGURES.....................................

iv

1.0 INTRODUCTION

1 2.0 EXPERIMENTAL PROCEDURE..............................

4 3.0 RESULTS AND DISCUSSION..............................

9 I

4.0 CONCLUSION

S.........................................

11 REFERENCES..........................................

13 APPENDIX A - Melding Procedure Specification (MPS)

A.0 I

and Procedure Qualification Records (PQRs) for Semi-Automated GTAM Double i

Down Technique, per Code Case N-432 APPENDIX B - WPS and PQRs for Semi-Automated B.O GTAM Double Down Technique on Waterbacked Nozzles APPENDIX C - Mockup Nozzle - Safe End Asserbly C0 Chemical and Physical Properties, Heat Treatments, and QA Test Results i

I I

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I g

1 L13T OF. FIGURES Number Title Enga 1(a)

Oyster Creek Nozzle Front View...................

14 1 (b)

Oyster Creek Discharge Nozzle Orientation........

15 2 (a)

As-Received Mockup Nozzle from B&M...............

16 2 (b)

Photograph of Nozzle - Safe End Assembly I

After Machining of Both Grooves and Dye Checking.........................................

16 3

Cross-Section of Nozzle - Safe End Assembly, I

Showing As-Received and Final Machined (Dotted Lines)

Dimensions........................

17 1

4 (a)

Mockup Nozzle with Completed Temper Beads in Overlay and Grooves for Preheated Case........

18 1

4 (b)

Mockup Nozzle Shown Mrapped with Insulation for Post Meld Hydrogen Bake Out..................

18 5

Mockup Nozzle Shows Ends Covered for

,j Waterbacked Procedure.

Front End.Shows Heater,

.E Back End Shows Mater Inlet, Thermometer, Top Vent and Mater Outlet............................

19 6

Mockup Nozzle on Completion of All Temper Bead Walding on Overlay and Two Groove Melds.....

20 7

Layout Plan for Removing Sample Blanks for Overlay and 1/2" Thickness Groove................

21 1

8 Positions of Tensile and Charpy Test Samples from the overlay and 1/2" Groove.................

22 g

9 Layout Plan for Removing Sample Blanks for

[

1-1/4" Thickness Groove..........................

23 10 Positions of Tensile and Charpy Test Samples from 1-1/4" Thickness Groove.....................

'24-I XGU-05-211

-iv-Revision 0

I 1.O INTRODUCTION Recent experience has shown that reactor pressure vessel nozzle-to-safe end welds are not immuna to intergranular stress corrosion cracking (IGSCC) in Boiling Water Reactor i

(BWR) recirculation systems.

Cracks have been observed in Inconel 182 butt welds and nozzle butter welds in nozzle-I to-safe end (N-to-SE) weldments.

In an increasing number of instances, these cracks have proceeded into tha low alloy steel (LAS) SA 500 Class 2 nozzle material, classified as P3 under Section 7X of the ASME Code.

Weld overlay represents an economically viable technique available to arrest the crack growth.in such situations and re-establish the structural integrity of the weldment.

Such overlays require special weld metal deposition techniques because the nozzle is a LAS hardonable material.

The American Society of Mechanical Engineers (ASME) Boiler I

and Pressure Vessel (BPVC) Code requirements for welding on such material are to preheat to'300'F min and'postweld heat treat (PWHT) at 1250*F min. to temper the hardened heat-affected zone (HAZ) created by welding.

I However, the ASME Code Section XI recognizes that under certain circumstances the full PWHT is impractical and allows the use of the Half-Bead Welding Technique deposited with the Shielded Metal Arc Welding (SMAW) process.

In I

this technique, the heat from the second weld layer tempers i

the HAZ of the first layer weld beads.

To assure such tempering, half of the first layer bead thickness is removed by grinding or machining before the second and subsequent layers are deposited.

Finally, a low tempera-ture (450 'F-550

• F) postweld heating is used to drive potential hydrogen away from the weld.

XGU-05-211 1

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l I

i Recently, the ASME Code has approved Code Case N-432 which allows the use of a machine Gas Tungsten Arc welding (GTAM) temper bead technique.

Here, the same tempering effect is developed by using controlled GTAM welding parameters and I

without removing one-half of the first layer bend thick-

)

ness.

In this case also, the full PMHT requirements of the P-3 material is substituted with the low temperature post-weld heating.

The Code Case N-432 is for repair of a cavity created by excavation of a defect found in a carbon or low alloy steel pressure boundary material.

Presently I

there is no guidance available in the Code on the requirements for qualifying structural weld overlays.

The

\\

I general practice has been to qualify these weld procedures i

by performing a groove weld.

Thus, structural weld overlays over nozzle to safe end welds have been qualified by taking guidance from this Code Case N-432 with regard to the welding requirements, preheat and postweld heat treet-ment, and approved by testing the base material, weld and heat affected zones of a groove welded test piece.

Thus, most nozzle-to-safe end-weld overlay repair procedures to B

date require 300'F min. preheat, the maintenance of this-300*F temperature during welding and until the start of postweld heating, and a postweld heating at 450-550'F'for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />, minimum to bake out the hydrogen from the weld (Ref.

2-3). The postweld heating is performed after three.to four layers of temper bead weld metal have been deposited.

Thereafter, the weld is completed without.any preheat.or postweld heating.

Such a weld overlay MPS is referred to-as base on the Code Case N-432 or dry-preheat WPS.

l The repair methods described above present seversi economic disadvantages.

Preheating the reactor nozzle for deposit--

ing the overlay weld and performing the hydrogen bake out-of the overlay requires the water level in the reactor to be lowered below the nozzle area until the temper bead XGU-05-211 2

Revision 0

I layers are complete.

To accomplish this, requires either I

I removal of the reactor fuel 'or at least draining of the reactor vessel's outer annulus depending on the location of the affected nozzle.

These steps can significantly extend an outage and the cost for performing overlay repairs.

It' would be very desirable to be able to perform nozzle-to-safe end weld overlay repairs without having to drain the reactor or it's outer annulus, that is, perform the welding under a waterbacked condition.

However, with the water-backing it is extremely difficult to develop and maintain =

g sufficient preheat or perform the postweld heating of the IB weld using standard resistance heating pads.

Also, as shown in Figure 1 for the Reactor Recirculation System discharge nozzles at the Oyster Creek Nuclear Generating Station, very limited space can exist within a nozzle-to--

safe end bioshield opening making it impossible-to place heating pads and machine GTAM welding equipment simultaneously around the weldment.

t This report describes the welding procedure development for-nozzle-to-safe end weld overlays without the benefit of preheating or postheating.

It is assumed the reactor will not be drained, thus the nozzles will be full of' water.

Tempering of the base metal heat-affected zone must be performed through control of the welding parameters used in the first few temper bead layers.

The objectives of this development effort were to perform such welding without any base metal cracking while meeting'the ASME Code minimum required base metal properties in the haat-affected zone.

XGU-05-211 3

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i I

i 2.O EXPERIMENTAL PROCEDURE l

Materials 1

In the experimental program to develop the welding proced - e sne:ifications, several materials were I

rocured.

In the init;al stages of the program, a common grade thick-wall carbc.. steel pipe was used.

The objective i

was to use this pipe in the initial assessment of the effectiveness of waterbacked welding on a carbon steel pipe.

The exact grade of this material is of no consequence in this case.

In addition, two SA508 Class 2 nozzles were procured from Babcock and Wilcox (B&M).

These nozzles came from the same' heat and had identical quench and temper heat treatment, and fabrication simulated post weld heat treatment.

One of these nozzles had a stainless steel safe end welled to it.

The nozzle without-the safe end was.used as a

" practice" nozzle to determine optimum welding parameters.

The nozr.le with the safe end was used for the I

mock-up assembly in the final qualification of the welding procedures.

To fabricate the nozzle-to-safe end assembly, the nozzle weld end was buttered with Inconel 182 and stress relieved at il10*F - 1150*F for one hour.

After a butt weld end preparation was machined on the heat-treated nozzle, a SA376, TP304 stainless steel safe end was welded to it using Inconel 182 filler material.

All of this work was performed by B&M at their facilities.

Figure.2a shows the nozzle-to-safe end mock-up assembly.

All material test' reports giving ladle and check analyses, physical properties as tested and heat treatments are' presented in Appendix C.

The results show that the nozzle meet the material property requirements of ASME' Code-Section III.

XGU-05-211 4

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Procedure Development The development of the nozzle-to-safe end weld overlay l

procedure was performed in three stages.

I Staae I l

In this stage, the common grade thick-walled carbon steel pipe was used to compare the results of an overlaid pipe with the previously qualified dry preheated procedure and the proposed waterbacked procedure.

The effort in this stage was purely exploratory.to evaluate the effects of various welding parameters.

A portion of this pipe was I

overlaid using the dry procedure while another portion was welded with waterbacking.

The waterbacked welding was i

performed using different welding parameters on different I

portions of the pipe.

Several test coupons were obtained on which face and side bend tests were performed.

The results of the face and side bend tests were used to prepare a set of welding parameters, together-with their variations, to be used as starting parameters for the second stage of the procedure development.

Staae II 4

Experiments were performed using the double down technique on the " practice" nozzle.

This nozzle was first welded dry

~

with preheat and then welded with,waterbacking.

In addi-tion to the weld overlay, several groove welds deposited with different parameters on backing thickness of 1/2' inch were used to provide comparison between the dry and waterbacked welding procedures.

Groove welds have been previously used to qualify weld overlay for nozzle-to-safe end welds (Refs. 2 and 3).

These experiments were 1

evaluated using face and side bends, microhardness.

XGU-05-211 5

Revision 0

i readings, charpy tests and microstructures when required.

The data obtained provided an intermediate stage validation

{

of the proposed welding parameters.

Staae III The nozzle-to-safe end assembly was machined, as shown in Figure 3, so that two (2) groove welds and the overlay weld i

could be made.

Acid etches were used to establish the butt weld interfaces of the nozzle and safe end.'

The interfaces were permanently punch marked so that tho' weld overlay could be properly positioned.

The machined surfaces, especially the grooves, were liquid-penetrant examined and-found to be indication-free (Figure 2b).

The nozzle-to-safe end assembly-was then mounted onto a vertical frame so that the nozzle axis

.l

~

I was horizontal.

This represents the 5G position, which is the expected orientation in BNR plants.

A modified GoldTrack II head was used to perform the welding utilizing the double down technique.

The GoldTrack-II welding system had remote video capability which was used to perform the weld overlsys.

All groove and overlay welding was performed under NUTECH's direction at GAPCO's Diamond Springs facility.

It was planned to compare the differences between the dry preheated welding procedure based on the Code Case N-432 and l

the waterbacked welding procedure.

Therefore, one side of the-nozzle was welded using the dry welding procedure specification (NPS) and the other side with a waterbacked WPS.

Since the heat sink effect of the waterbacked condition can be so significantly different for different backing.

thicknesses, two such welds with different backing thicknesses I

were tested.

One backing thickness was 1/2 inch and the othe-1-1/4 inches, as measured from the bottom of the groove to the inner surface of the nozzle which was in contact water (see Figure 3).

These backing thicknesses represent the range of nozzle thicknesses typically encountered in BWR units.-

XGU-05-211-6 I

Revision 0 g

/

First, welds using the dry preheated WPS were used to deposit I

an overlay (1/8 inch minimum thickness) over the nozzle-to-l safe end weld.

The 1/2 inch groove and the 1-1/4 inch groove i

were then welded.

The first three (3) layers, which represent i

the temperbead deposits, were made to cover the groove bottom l

and the sidewalls.

Welding was done while maintaining 300*F min. preheat.

The resistance heater pads were installed on the ID surface of the nozzle.

Circumferentially placed thermocouples measured the temperature and provided input for the thermostatic control (Figure 4a).

Once all the welding with preheat was complete, the nozzle was covered with insulation (Figure 4b) and the temperature. raised to approximately 500*F and maintained for two hours to perform the bake-out.

After bake-out, the nozzle was left to cool.

The mockup nozzle welding set-up was then modified to perform the waterbacked welding.

The two (2) nozzle ends were covered by welding preformed plates and a water inlet fitting was l

attached on one end.

A pipe connected-to the inlet fitting on the inside of the nozzle transported the water to the opposite side and created circulation of the enclosed volume.

The water exited through a vent port attached at the top most point to avoid forming a vapor blanket (see Figure 5).

Since the water temperature was around 67-60*F,.below the 80*F minimum setup for the procedure, a water heating element was also installed in the nozzle assembly, close to the discharge point of the inlet water (Figure 5).

The bulk water temperature was measured by a thermometer permanently: attached to the opposite side (see Figure 5).

Water flow was maintained at approximately 0.5 GPM, which allowed the bulk water ter?erature to be around 75'F.

Due to the waterbacked condition, temperature uniformity was XGU-05-211 7

i Revision 0 3

i i

y excellent around the circumference, except for approximately two inches of the circumference at the 12 o' clock position, I

where it was about 5-7'F warmer.

I Using the WPS for the waterbacked condition, the overlay, and g

the groove welds with 1/2 inch thick backing and 1-1/4 inch B

thick backing were completed.

This procedure requires

{

i autogeneously remelting of the first layer end beads to temper the weld toe HAZ.

No problems-were encountered in making these welds.

The sidewall first bead is also autogeneously remelted before the second layer is deposited.

Figure 6 shows the nozzle after three layers df temperbeads for both the dry preheated and waterbacked techniques for-overlay and groove welds were completed.

After this-point, the rest of the j

groove on both sides of the nozzle were filled using more-i standard welding parameters for making Inconel welds.

Typically, it used higher heat input with oscillation and higher deposit rates.

A synchronous pulse mode was used to assure proper side wall tie-in.

I With the welding completed, the nozzle was cut up per the I

sample layout plans of Figuras 7 and 9.

The layout plan followed the intent of the ASME Section IX rules for taking samples for tension, side bends and charpy tests.

Since two 4

WPS'a were qualified using the same groove, tension test samples at precisely the O' and 180* azimuths were not possible to take; however, tension test samples close to 0*

and 180' azimuths were taken.

Similarly, side bend and charpy blanks were taken at 45' and-135' azimuths from one side only, and not both sides.

To assure the test results, dual sets of samples were taken.

Samples for examining microstructures and microhardness were also taken.

The positions of test -samples.

machined from the blanks are shown in Figures 8-and 10.

ly XGU-05-211 8

. Revision 0 nutech-i

l 3.0 RESULTS AND DISCUSSION l

The Welding Procedure Specifications (NPSs) together with the supporting Procedure Qualification Records (PQRs) for the dry preheated and the waterbacked cases are presented in Appendices A and B, respectively.

There are three (3) supporting PQRs for each WPS, one for the weld overlay and one each from the two groove welds.

The groove welds I-qualify the_ procedure for welding on different thicknesses for each case.

The hardness profile of the heat-affected I

zone (HAZ) for each groove weld and overlay, together with the HAZ microstructure are presented with each WPS.

I The results documented in the PQRs from the dry preheatert WPS meet the minimum requirements of the ASME Section IX I-and exceed those of ASME Section III (50 ft, lbs and 35 mil lateral expansion).

For the welding parameters selected, the HAZ shows properties only slightly degraded from the base material properties.

The hardness and microstructure correlate well, showing no hard untempered martensitic structures.

The welding parameters changed little, 3f any, g

going from the overlay to the groove welds.

Even the a

groove-weld with 1/2 inch backing was done.with only minor variation.

Generally, due to sidewall' interactions with i

the welding arc (a characteristic of groove welding only),

arc voltage is reduced to weld at the groove bottom.

This effect is small for the preheated case.

The results documented in the PQRs from the waterbacked WPS.

also meet the requirements of ASME Section IX and material I

property requirements of Section III.

The hardness measurements and microstructures show that no hard, untempered martensitic areas remain.

Although at the very l

top, near the weld lip area, some hard are were noticed.

These areas developed because of the geometric effect of the groove and the manner in which the groove-is XGU-05-211 9

Revision 0 ndah

I lI filled with higher heat input passes.

They are a groove artifact and is of no consequence to overlay welding.

The welding parameters are significantly different for the 1/2 inch and 1-1/4 inch thick backing, due to the substantial heat sink difference between the two cases.

The thickness l

of the backing material becomes the overriding parameter for this procedure.

The problem of groove geometry on arc voltage further complicates the welding.

Thus, substantial I

modifications to the welding parameters are needed to successfully weld in each case..

For the waterbacked WPS case, the base metal charpy test results from various positions in the nozzle show some variance.

This is possibly due to the nozzle having I

different forging ratios with regard to position during manufacture.

However, all charpy test results met the ASME Code required, 50 ft. lbs. energy level and 35 mils lateral-expansion at the RTNDT for the forging (40'F).

Tensile test samples from each of the weldments met the property requirements and all-side. bend samples passed with R2 opening in the heat-affected. zone.

Some opening of the' I

base metal defect. structures (removed from the HAZ) were seen in the side bend samples. -These results are impressive considering the fact that the microstructure I

near the nozzle ID surface show substantial porosity and defects.

I I

XGO-05-211 10-Revision 0 ndah

1 u

\\

'I I

1

4.0 CONCLUSION

S

.I 1.

Two (2) welding procedure specifications (WPSs) were qualified in acesidance with requirements of ASME Section'IX for performing double dewn machine GTAM weld overlays on low alloy stee3 nozzle-to-safe end I

welds.

The SA508, Class 2, norszle material was given a full cycle of fabrication-sinulated heat treatment-i and was joined with Inconel 182 slectrodes to a.SA376, Type 304 stainless steel safe end.

Each E!S is j

supported by three (3) separate PQRs; ode for the overlay, one for a 1-1/4 inch backing thickness, and one for a 1/2-inch backing thickness of the: nozzle.

In each case, it is clear that the welding can be successfully performed meeting all the requirements.of I

ASME Code Sections IX and III.

The procedures produce repeatable and consistent results.

2.

The first NPS, similar to Code Case N-432 welding-procedures developed by others, utilizes preheatz before and maintained during welding and a low' temperature postweld bake-out to drive the excess hydrogen from the weld.

To perform the. preheat and postheat, the reactor nozzle has to be dry, requiring-that the reactor water be drained below this level'.

This requires the fuel to be removed from the core or draining of the reactor vessel's outer annulus, extending both the time for performing the overlay repair and the overall outage duration.

The preheat WPS produces a HAZ, with properties only slightly reduced from the base metal properties, easily meeting and exceeding the ASME Code Section III material property requirements.

XGU-05-211 11 Revision 0

I 3.

The waterbacked overlay WPS avoids reactor drain-down problems by performing the welding without the need for any preheat or postweld heat treatment. The water temperature is limited to 80*F minimum.

The waterbacked WPS meets the material requirements of ASME Code Section-III in that the HAE meets 50 ft.

lbs., 35 mils lateral expansion when tested at 40'F, the RTNDT of the nozzle.

These results are particularly impressive as the base metal showed excessive variations _in properties due to porosity and other defects.

The microstructures showed no large

~

untempered martensitic areas / instead, an extremely-fine grained ferrite-carbide aggregate appears to form.

4.

Presently, the ASME Code provides no guidance for qualifying structural overlays.

To date, most of the nozzle-to-safe end overlay procedures have used the groove weld to qualify the NPS.

While the configura-tion of the groove has litt.% or no effect on the I

preheated WPS, the same cannot be said for the waterbacked WPS.

The parameters _ developed for the-I waterbacked WPS need to be modified to successfully complete the groove weld.

Thus, the three- (3) i separate PQRs qualified for the waterbacked WPS have significantly.different welding parameters and cover the range of thicknesses of nozzles present in typical-BWR units.

XGU-05-211 12 Revision 0

\\

1 I

1 lI REFERENCES I

1.

Repair Melding of Heavy-Section Steel Components in LWR's, volume 1, Summary Report, EPRI Report NP-3614, July 1984, prepared by Babcock & Wilcox Co.

2.

Contingency Plan for Temper Bead Weld Overlay of Safe-End l

l To Nozzle Welds, prepared by Georgia Power Company and Structural Integrity Associates, presented to NRC, December 13, 1985.

I 3.

Field Application of a Non-Postweld Heat Treat Weld Overlay to an Alloy Steel Reactor Pressure Vessel Nozzle, by

Hoffman, J.

R.; Mullins, L. E.; Millens, K. R.; and Darby, K.; presented at EPRI Seminar on Repair Melding Alternative-I for Nuclear Power Plant Components, Charlotte, NC; March 11, 1987.

4I g

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XGU-05-211 13 Revision 0 a

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OYSTER CREEK NOZZLE FRONT VIEW I

1 XGU-05-211

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OYSTER CREEK DISCHARGE NOZZLE ORIENTATION lI t

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.I XGU-05-211 15 Revision 0 nutech

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FIGURE 2 (a).

AS RECEIVED MOCKUP NOZZLE I

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END WELDED WITH INCONEL 182.

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XGU-05-211 18 Revision 0

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f 1

I 81eef-4 5-Car emirJe sessuBIEE, g*

der maprest 18 j

suese.s U mIBuurand sosM 4

t i

81NWF-2 J.

• e cessenas 7e *b..

i Reef.2 -

Figure 7:

LAYOUT PLAN FOR REMOVING SAMPLE BLANKS l

l

()

FOR OVERLAY AND 1/2" THICKNESS GROOVE l

I-O i

7 l

t

__..~.~-.._.,_ __ _ _ _m

Fre etr W F4 ##

swer 9 0 e f*

I Wa6ef0 2

6 00

...,m

\\

/

g

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88 4 WM I

l Mr 7 0.

um WedIL EkoC Fen /0C ~ loi l

WD O C_ I, L wa..o em> eA o I

& )

(88**

mer mise saar sp%..,,,r s, ai,or e

r

,,r a

, me Mdet. L8 l

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/

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b

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l

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N-

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4 meenanar semesar es m sJ c mad avtre se> anear M Figure 8:

POSITIONS OF TENSILE AND CHARPY TEST SAMPLES FROM THE OVERLAY AND 1/2" GROOVE XGU-05-211

.ggg Revision 0 22 1

s

=

P I

9WN.I p*

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ED muv K W& C + A - --

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1. 6mibcdt 9 ad8FER edcas)

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seas SNd1PTb* 640egf5 Sh N LO.8

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1 i

FIGURE 9:

LAYOUT PLAN FOR REMOVING SAMPLE BLANKS FOR 1 1/4' THICKNESS GROOVE.

I i

XGU-05-211 23 a.vi. ion 0 nutOCh

. TTMLILY 15dMM fp AJ8 V w l T*

F D & f"

\\

/

i L

( W unir #

1 I

l. Obt M 38W cf Senkt 884 FT57.

1 CMatPY SAMPdJr f) Was I

5 %f 'S &

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i b rtyi er Asery p u r 1

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FIGURE 10:

POSITIONS OF TENSILE AND CMARPY TEST SAMPLES FROM 1 1/4' THICENESS GROOVE.

XGU-05-211 24

-Revision 0 nutech 4

I I

APPENDIX A I

Welding Procedure Specification (WPS) and Procedure Qualification Records (PQRs) for Semi-Automated GTAM Double Down Technique, per Code Case N-432 I

I I

I i

I i

l i

I I

I i

XGU-05-211 A.0 I

Revision 0

I WELDING PROCEDURE SPECIFICATION j

1 (WPS)

(SEE OW-201.1, SECTION IX, ASME BolLER AND PRESSURE VESSEL CODE)

WELOING PROCEDURE SPECIFICATION NO. UPS-3/8-T-001-t!ES

mgy, O

I supporting Pom No.(s)

POR-3/8-T-001, 003, 004 WELOING PMOCE$$(g3).

GTAW tyPt(3)

Machine

== nc. %

.ais e.

I

^

SK\\TCH JOINTS (QW-402) y I

J joint oasion overlay

,,9 BACKING (YES). X (Not P>

P-T aACxiNo uATsMiAL (TYPan P-3, P-8, P-4 3

• PvLL om PARTIAL PewsTRAT1oM N/A

• or equivalent weld metal (F-No.) types

' BASE METALS (OW-403)

P-No.

O

_ ORoVP No.

1 To P-No.

3 omovP No.

3 om SPECIPICAfloN TYPE ANo GRAos N/A To SPfCiPICATioN TYPE AND GRADE N/A

.l oR CM8M. ANALYST 8 AND WECH. PROP.

N/A To CMGM. ANALYSIS AND MECH. Prop. - N/A THICKNESS RANot:

BASE METAL THICKNESS:

1/2" and creater PILLaT N/A OSPo81TED wtLD METAL; GRooV8 N/A PILLET N/A PiPt ofA. RANoe:

omoove N/A

_ PiLLay N/A oTH8R

' FILLER METALS (QW.04) 7-No.

43 oTwem N/A A-Mo.

ER Nicr-3 oTHem N/A spec No. (SPA SFA 5.14 Awe wo. ICLAast ER NiCr-3 size op PILLER waTAu 0.035" Dia.

,e m coa =, = m eLaCTRoot-PLux ICLAss:

N/A PLux TRADE NAug N/A CoNsvMAeLE INSERT None a saew naas wvat aiuse ovat ee anom oute se eco.oso memovau,.

oi=Haa.24.ci ceP St.1 XGU-05-211 A.1 88V 0 Revision 0

WPS-3/8-T-001-NES R3v. O Pcg3 2 of 2 L

PO$iflONS (QW-406)

POSTWILO HEAT TREATMENT (QW-407) 0 positioNtsi of omoovg SG Tauramatums mAmos 450-550 0 f

wsLoiwo PaoomassioN: up oowm _. X TiusmANos2 Hrs. min. (after 3rd lay er) position (Si of PILLET N/A GAS (QW-408) l PAEHEAT (QW. 408) 0 mmNT commoitioN tuerfumes M

pagwsAT Tsw.

uim.

300 r I

o Welding Grade iNTameAss Ta w. max.

450 P Plow mats 20-45 crH pneHaAT WAiNTs=ANcs 1/2 H r. betore welding.

Hold preheat until PWHT QAs SAca No None I

of 3rd layer is started.

TnAsuNo amiaLmNo nas cowoe: Tion None ELECTRICAL CHARACTERitTICS (OW-400)

• 100-140 Backgr.

comment Ac on oc Direct pouairy Straight 190-240 Peak

• volts (mANoel 8.2-9.8 Peak and Backgr.

Amps imAmoal E

2 e 1. ANo M n a T TM B o MAY g

IN A TAsuum Pomu slidILAR To THAT eMowN 88LowJ TuNostsN EL8CTaoot sl28 ANo Type 1/8" EWTh

"~'"

woos or mett inAmsPER Pom ouAw N/A

~"~

~"*

stacimoos wine paso speso mANog 20-69 IPM TECHNIQUE (QW-410)

I

Taimo on weave suAo Strino for layers 1-3 weave for layers 4 and above.

omiPics on cas cup aire 410, #12 initial Ano INTenPASS CLEANINo (SmusMINo. omiNoiNo. ETCJ Brushing, grinding or I

combination with new equipment or that used on S.6. only.

warwoo or sAcx oouothe None OSCILLATION (YSs1 X (Noi (PmSQJ NeoTM) 0" for ist 3 laye rs I

contact Tuse to womE oif7ANC N/A 0-3/4" for remaining layers uutfiets om siNoLa pass tpen seos Multiple uutfiets on simoLe stscfmoons Single I

inAvst setto (mANoel 3.0 - 8.5 IPM are soeed retNiNo None (Peening of repair cavities permitted when required) ofwem Water backed weldino permitted af ter PWHT of 3rd layer.

PtLLam METAL cummeNT OTHSm wtLo V0'T Tmavat i

LAvtm(Si peoM88 Aup mM8 SPGBo F

N class osa.

manos manos aAczon.

Pean

aAcnom, peak (IM*)

= na==+a.

g 1

GnW gc,3 0.035 ser.

t00 120 So5vj.2,,,. 2,,, 7.6 3,, 13.8ggg$n.

2 L20 140 230

' E.5 6.1ggf{n.

3 e00 540 5.3 D.5 1*Ikk(f"'

0 I40 530 8.2,p.6 6

3.

kk(k"'

.05 rema n layern meAmso sY:

B. chakravarti bh/1^ b^vME DATs 11/08/88 ouALIFICATioN supt.ivisom Alvitwto OY:

oATE QUALITY ABUm ANC8 AoMINiSTm Atom oiN MS3.3A41 xGU-05-211 A.2 Revision 0

iI l

lg PROCEDURE QUALIFICATION RECORD l

(PQR)

(SEE QW 201.2, SECTION IX, A8ME BOILER AND PRESBURE VESSEL CODE)

RECORD ACTUAL CONDITION 8 USED TO WELD TEST COUPON.

paoceouns ouAuricAnom mecomo wo.

POR-3/8-T-001 care 12/14/88

,,e useo com fast weLo WPS-3/8-T-001-NES ngy, A weLoiwo emocassies GTAU Types tuAnuAL AUToasAtic, seam-AUToJ Machine _

JOINT 5 (OW 402)

(oO '

I lI/"

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4 y %" } ijg P-b u

U tPon coassansanow ouEisnYTN olmossYwew arTAL TMCKNSBs wiLA se meconoso Pon eAcM piLLam earTAL on mocess weLoa SASE WETALS (QW-403) anaTemeAL spec, SA 508 POSTWELD HEAT TREATMENg(QW-407)

I TenspenaTune 450-550 F Type om omAos clana 2 n ess 2 H r s. min. after 3rd laver B

P-wo.

3 on-wo.

3 ofwsm j

To P-wo.

N/A on-mo.

N/A I

TmcKNam op B ACKING 1/2" (backing) otAnettem of Test coupon 14" OD GAS (QW-408) ofwen See fleure type op OAs om GAass Arcen coespasmom op oAs nexTune 100t oTwen 20-45 CFH Weldino Grade PILLER METALS (OW-404)

I wsLD hoeTAL ANALYSie A-No.

ER Nicr-3 size op piLLam wrTAL 0.035" Dia.

ELECTRICAL CHARACTERISTIC 8 (0W.400) plLLam wsTAL p-No.

43 cummewt Direct sea sPecipicAnow 5.14 poLam Tv Straicht Awe cLAssipicAnow ER Nicr-3 Anape.* 2 0 0 - 2 4 O Pe ak VOLTS 9. 4 9. 8P e a k *

• oTHem TumosTem eLactmoos si,2 1/8" EWTh oTwen *110 -140 Backer.

• "B. 4 -9. 8 Backcr.

PC$1 TION (OW-406) postfloN of omoove SG TliCHNIQUE (QW-410) weld Paoomassion tuPMILL. DowNMILU Down TmAyeL spaso 3. 0 -7.6 IPM are sceed oTHem stmimo on weAva seAo St rinc t layers 1-3 osciLLAnon For weave beads 0-3/4" wutTipAss om siNoLa Pass (Pen sioel Multip le PREHEAT (0W-408) o simoLe om nauLnPLe eLacTmoots Single PneHeAT TthePenATune 300 P OTHem Water Backed af ter PUMT iNTempass TempenATune 450*F max.

OTHem

• Weave; lavern a and above AG

~211 A'3

, g*y o Revision 0

7

~

Paco 2 of 2 Pom sea. POR-3 / 8 -T- 0 01 VLTIMAft utnMAft Type op WCIMEN (in.y) tIROTH TM6CENSSB AA TOTAL LoAO utstT WTnam PalLung &

MvMeen RhJ Iast LOCATioes

[

FDIT-1 N/A N/A 0.197 17,950 91,100 Parent l'etal PDIT-2 N/A N/A 0.187 16,400 t9,000 Parent !!et al 1

I OUIDED 88960 T8572 low-100)

TYPE ANo Piouse muMesa mesubT 180 Side Bend, 4T, Sample FDIS-1 Satisfactory FDIS-2 I

FDIS -3 FDIS-4 I

-.. T..T..

I speciassN MoTCM 800TgM 78s7 ledPACT I#'

NuMeam LoCAnom Type TstdR VALuas Susan tests smaAs No amaAa FDIC-1 3ase met V

40 F 178 100%

90 N/A N/A FDIC-2 151

'9%

78 FDIC-1 3[32V8n 112 100%

65 j

FDIC-2 111 100%

63 5

FDIC-1 g h HAZ 168 100%

84 FDIC-2 156 100%

82 FILLET WELD TEST (QW-180) g 5

mesutT - satisP Actony: vas N/ A,,o N/A PeNefnArioN iNTo PAmeNT tesTAL: yes N/A No U/A uAcmo - assults N/A OTHER TESTS Type or Test N/A Of Po81Y AN ALY888 N/A oTMan N/A I

Wstosm1 NAMs:

Rov Button CLoCa No, N/A STAMP No. A Turts CoNovCTeo sy: Anamet Laboratories LaconATony Tas? No, 1188.299 wt CERTIPY THAT THE STAfthe8NTS IN THIS RSCo#D ARE CCRR8CT AND TMAT TWO TSST W8LDS WERE PasPAmeo. WsLosD AND 788790 IN ACCoROANC8 WITH TM8 REQulR$MONTS OF SGCTION IX OF TMS A&M8 C008.

CERT 1PIGO SY:

MNb M

l A !I h*!II OATE QuALIFICAT1oM SUPERyttoA IORTAll, OF REcomo OP ttfTS ARE ILLUSTRATIVE ON(Y AND MAY 98 WootPitD TO CoNPOAM to THE TYPt AND NuuttR OF TESTS mg0ul#EO SY THE C008J

[GY-Y-211 A4 Revision 0

_a

W fJoovt Wf t h MAEnkfit PRDF f L E 1/?" PEfHfAffD ratt ffDiM.11 I

tammla a tama ta a DIntanen from Surfara Hat Dtatanen frna iurfaca war Toe..004 below surface 36, 38 foe. 003 below surface 36, 36 I

foe. 004 below surf ace 36 (.023" from weld)

Toe,.003 below surface 31.5 (.024" from weld)

.034. corner of itp

29. 40, 40

.034. under Itp

33. 41

.034 -.074 46.5. 44, 46.5

.034, large grains 34 174 32

.096 33 B

.!?4 25

.196 34.5 339 31

.296 34 I

tamata t tamata D

.I Blatanen frna turface Het Dtatanen fram turfaca Hat l

.004 30

.004 22 1

.104 34

.103 31

.204 30

,203 33.5

,228

) at corner 33

.253. corner 33, 30

.235

)

35

.100 f rom corner. Hor t2.

41

.100 from corner. Hort2.

26

.175 from corner. Horir.

31

.200 from corner. Nort2 24

.190 f rom corner. Horit.

31.5

.202 from corner. Horit.

28 1

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I XGU-05-211 A.5 dah Revision 0

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I BOTTOM HEAT AFFECTED EONE MICROSTRUCTURES l

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I XGU-05-0211 A.6 l

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4 I

i PROCEDURE QUALIFICATION RECORD g

(PQR) 5 (SEE OW 201J, SECTION IX, ASME SOILER AND PRESSURE VESSEL CODE) l RECORD ACTUAL CONDITIONS USED TO WELD TEST CDUPON.

Pm0CSDuet QuAWP:CATl081490040 sec. POR-3 / 8-T-001 OATE IS/tLInn wPg yngD Poe TEST weg VPS-3/8-T-001-NES may. A j

I wSLDiseo Pw0 CESS 4ts)

CTAM MACHINE TYPts teaANUAL AUTOt4ATIC. SOhm-AVTVJ JOINTS (OW 402)

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Ic.3/4 - l l

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(Pom CDeselWATICst 00ALIFICAfl0NS. TMS 088001780 WELD hef7AL TulCxNESE WILL DE m0COm000 POm SACw PiLLam heftAL OR PmOCSS WELDJ SASE METALS (QW-403)

POSTWELD MEAT TREATMENT (QW-407) enAff al AL sPg C.

SA 508 TenspenATung Ann un%

I TYPE Om omADe Clana 2 Times 2Hra Mininum. after danosit P-40.

3

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N/A on-seo.

N/A Il TwsCxNess of BACKING i1 1/4" W

DIA48tT1m 0F T587 COUPoes 1 % 1/6" OD GAS (QW-408) otusa et, r4onra TYPs of gas om GAsts Annnw II CDespos: Tion OF OAS he XTum8 innf u.1A cria.

ofwsm Sn As c'ru l

l PILLER METALS (0W-404) l wt LD hasT A L AN ALYSIS A 8eC.

ER Nicr-3 W

SIZE OF PILLim 84tTAL 0.01%" Dia-ELECTRICAL CHARACTERISTICS (QW-400)

FILLER teETAL P-40, 43 Oumm0NT Di ra e t j

SPA SPGCIPICAT1080 5.la POLAmtTVRtrafohe Awe CLAas:FiCATion ER NiCr-3 AbsPs,* 2 0 rr 2 4 ope ak,yotyyp. 4 -9. 8 Pe a k *

• i oTwan Tues4 STEN ELECTmOOs 3:331/n" ruTu OTusR __ *110-140 Dacker.

• 8. 4-9. 8 B a ckg r.

POSITION (QW-408)

POSITION OF Om00Vs SG TECHNIQUE (0W-410)

,E wem Pmooneessoas fuPw LL, oownwity Dwn TnAvst spese 3. 0 -7. 6 IPM arc speed 5

OTwSR ffaleet OR wtAvg SEAo st rina for Laver 11*

00CILLATMise0-3 /4f neh f or Weava Reads oniv.

i teWLTIPAS OR SINGLE PAM IPER 81001 Mul t inl a PREMEAT (QW-408) 3140L8 OR toutTIPLS ELaCTmoots Einale y

PA8wSAT TlesPERATung_ 300 F ofwem Water Raekad after PWWT.

IMTERPAN 7thePGRATUma 4 50"F Max t

ofwsm N/A

• Weave for layers 4 and above i

D'"was.ws:

Qap e,s.2 XGU-05-211 A.7 I

ngy,

Revision 0

Page 2 o.f. 2 pept sec. P0n-3 / 8-T-o n 3 ULTiesATs WLTlasArs TYPt op

[

S M MON Wl0TM TM400885 ARSA TOTAL LDAO Vest? Stagm P AILyme a L

NW68R (nn 4neh\\

g g3

gggaygg, FD2T-1 N/A N/A n.100 16.000 84.900 Parent Metal TD2T-2 N/A N/A 0.192 17.000 AB Aon Parant Meen1 I

I G0108D SEND TESTS (QW-1901 TYPt AND Pioume Numeem Rasult 1

0 1R0 Side Rand. LT. samnle FD2S-1 Satisfactorv

" Samnle FD2E-2

". Samnle FD 7 S

'l

". Ramnia rn?R-L B

TOUGHNES TESTS (OW-170)

SPGCIMON NOTCM NOTCM TRST IMPACT

1. 1. ' I *

WUW88R LOCATION TYPs TE tap.

VALUTA BMEAR l

MILS BRgAs 40 BRSAE 0

FD2c-2 han Metal V

40 F I??

761 at N/A N/A FD2C-3 (20 100%

66 N/A w/A hl8E3 AZ 102 84%

63 w/A v/i rn'r 9 i

FD2c-3 100 87%

63 N/A w/i FD2C-2 folfo?nHA2 70 61%

56 M/A N/A FILNNLD T ST (QW-100 RESULT-SATISPAcTORY:YE8 h No C PENETRATION INTO PAmENT METAL. Yes N/A No N/A N/A asAcRo - masvLTS OTHER TESTS TYPE OF TasT N/A OGPOSIT AN ALYSis N/A OTHER N/A I

N/A l

WELD 6R1 NAME: Rev Rutton

_ CLOCK NO.

grau,uo, i Tsats 00N0ucT 0 eY: Anamet Laboratories LA80RATORY Ttst No.

1188.299 WE C8RTIPY TMAT TMS STATEM8NTS IN Twt 8 ROCORO ARE CORR 8CT AND TMAT THE 7857 wtL0s wgRg PRSPAR80, WELD 60 AND T88T80 IN AC00ROANcs '.'"'M TMS **3WIR8M8NTS Op 88CT10N IX OF TME ABME C006.

CERT 1!5tEO BY M

OATE

[

QUALIFICATION SUPERVISOR I,

10tTAIL OF ROCORD Op 788T8 Amt ILLuffRATIVE ONLY AND MAY 88 M00lpl80 70 00NPORM TO TM8 TYPt AND Nute08R OF TESTS REQutRIO 9Y THE C004J XG 211 A,3 Revision 0

I c.anovf wrth MARBkfit P.0Fftf i 1/d* PtfMfaffB EAif (FDfM-1) l

1. i

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g o,,,,,e.

imr,.e.

H.e 0,......

fre. im.f..

H.e foe..003 below surface 28 (large grains)

Toe,.003 from surface 36 toe. 003 below surf ace 33.5 (.013 from weld)

.066

38. 38 I

.003 be low surface 28 (.Ct$" from weld) 066 33 (large grains)

.025. Itp 39.5. 40.0

.066 al 33 35.0 I

.058 32

.166 36

.158 32

.266 28 256 30

.321 33 I

.358 28 I

1..nt. e

• • =al.

D Dist.ee. from turf.e.

kAt

__Dtatane. from surf.e.

H.c I

.003 from cut surface 33.5

.0!! from cut surface 33

.102 from cut surface 28

.111 from cut surface 31 l

.162, corr.or. large 28

.!!! from cut surface 31 I

bend redlus

.182. corner, large 32.5

.311 from cut surface 33 bend radius I

0.0, corner. Hort 32 0.00, corner. Horig 32

.100 from corner. Hort 28 0.100 from corner. Hort!

.200 from corner. Hort 33 0.!00 from corner. Hort 31 I

.300 from corner. Hort 33.5

.363 from corner. Hortz 33 I

l a,

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I I

BOTTOM liEAT AFFECTED EONE MICROSTRUCTURES 1 1/4' PREHEATED I

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4 i g i

PROCEDURE QUALIFICATION RECORD (PQR) j (SEE OW 201J, SECTION IX, AME BOILER AND PRESSURE VERSEL CODE)

RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON.

)

amoceovne ouAuricanon mecomo iso. P0P-3 /8-T-004 oAte 12/14/88 i

wasimeo com Tsst weLo VPE-1/B-T-001-MFC

mev, A

weLoimo amocnesses GTAW l

Tvres tuAnuAL. AuTomanc. mem-AutoJ MACHINE I

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OTMen Pfal8eo on woAve esAoStrinn for Laver 1-3_

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U II APPENDIX B WPS and I'QRs for Semi-Automated i

GTAM Double Down Technique on Waterbacked Hossles i

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WELDING PROCEDURE SPECIFICATION (WPS)

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(SEE OW-201.1, SECTION IX, ASME BOILER L

AND PRESSURE VESSEL CODE)

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WELOING PROCEDURE SPECIFICATION NO. WPS-3/8-T-002-NES

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I SUPPORTING POR NO.(8)

POR-3/8-T-002, 005, 006 WELDIN.c. PROCESS (ES) _ GTAW TYPE (8)

Machine ene. - - sa %,

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mint oasiGN _ overlay mACKiNo tYasi X

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aACximo uATemiAL (TYPei _ P-3, P-4 3, P-8

• P8 P-3 Putt on PAnTiAL PeNeTnATiom N/A L & T as reg'd by design

• or equivalent weld metal (F-No. ) types.

• BASE METALS (OW-403)

O 1

3 3

P-No.

_ omovP No.

To P-No.

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oM SP9CIP4CAftoN TYPE Aho GRAoS N/A 70 SPECIPICATioN TYPE ANo GRAog N/A on CHEM. ANALYSIS ANo MECH Prop.

N/A 70 CHEM. ANALY8sa ANo MECH. PacP. _ N/A THICENess RANGE:

Sass WSTAL THICKNESS :

1/2" and above PILLa7 N/A DEPos TEo weld utTAL: Groove N/A PiLLg7 N/A Pipe otA. manos:

omoove A11 diametera PILLET N/A oTHER -

' FILLER METALS (QW.404)

P-No.

43 g

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A-No.

ER NiCr-3 OTMan N/A SPEC. No. (sP Al SFA 5.14

-l AwB No. (CLASSI ER Nicr-3 3:25 or PILLER METALS 0.035" Diameter I

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N/A I

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7 WPS-3/8-T-002-NES Rev. 0 Pace 2 of 2 POSITIONS (QW-40ll MMBTWELO HEAT TREATMENT (OW-407) possfioN(s) or omoove SG TewsmATune mANoa _ None weLoiNo PaoomassioN: Up oowN_

X Tius mANoe N/A positiowtsi op piLLat N/A GA8 (QW-408)

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PREHEAT (OW-400)

L Pne ws AT Tew.

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70 F MaceNT compoestion tuixTvats) 100%

9 INiemPAss T8w. max. Greater than 80"T Plow mats 20-45 CFH PatwsAT MAiNTINANCg None ICONTiNuous 08I SpeCIAL wSATINo WwtRE AppucAets swouto se secomoso TRAluNo sNiELoiNo GA8 cowooltioN None ELECTRICAL CHARACTERISTICS (QW-400) cumasNT Ac on oc Diret't poLAniTv Straicht Aws inANoel_ 160-250 Pe ak

• volts (m ANos) 8. 7-9. 8 Pe ak, 8.4-9.8 Backgr.

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stacfmoot wins reso speso manos 0-69 IPM TECHNIQUE (OW-410)

TaiNo on weave seAo St rir.o for lavers 1-3, Weave for lavers 4 an d above.

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omiPica os cAs eve size # 10, a12 L

INITIAL do iNTtmPA8s cLSANINo (DRUBwl40, omiNoiNo, ETcJ Brushina, crinding or coml ination with equipment that is new or has been used on S.S. only ueT eoo or saca oouciNo. None ot: LLArioN tvas) X

<Noi ipneca twioTN10" for 1s t 3 laye rs CONTACT Tutt to womK oiSTANCE-N/A 0-3/1" for remaining 1ayers uuttiPLE om ssNGLE Paas (Pen sios Multiple uutTiPLE om siNote eLacinoons_ Single in Avat speto (MANoEl 3.0-8.5 IPM arc speed pegNiNo None (Peening of repair cavities permitted when required)

oygg, Water Backed for all layers.

!!ir.. wate r temp. = 80*F.

FILLER WETAL CURR8NT oTNER I

PmoC80s h@aspg amp R oE ygg 3 o

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manos

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1 GTAW g 0.035 str.

12074g 160 8.7 54g 5.8 8*7 5'4 5.8 5.6 22.6ggf{n.

2 140 230 160 3509.5g,g9.55.80*9 5.3,22.0ggf{n, 3

.120 7g180g.5g,g9.5g,g5.7 21.1ggf{n.

6.3 4

t.

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230 5.6 5.6

max, layers Chakravarti fN N b M f)nNi' PatPAmso eY-B.

oats 11/10/88 OVALiPlcAfioN sVPSRvisoR Rivitwto SY:

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OVALITY AMURANCE AoMINisTmATom

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m PR@CEDURE QUALIFICATION RECORD (PQR)

(8EE ow.201.2, SECTioN IX, ASME BolLER AND PRESSURE VERSEL CODE)

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RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON.

1. m0C80ume OuAUPICAMON ASCOft0 sec. Pol-3/R-T-SM OATg 19/1(/na I

WPg uBSD POR TEST W8LD WPS-3/8-T-002-NES may. A I

W8LDelee PROCS8588Si CTAu 7"rpts tenANUAL, AUT0enATIC. Whe6-AUTOJ M VitTME JQlNTS (QW-402) l foN 4

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GROOVE OtelGN Op 7987 COUPON (POA 00ee88 MAT 10ee QUAUPICAN888. TM8 08POSl780 W8LD h887A8. TMICENess WILL 68 ASCOm000 POR BACM PILLAR h88TAL OR PROCESS WOLDJ SASE METALS (QW-403)

PQtTWELD HEAT TREATMENT (QW-407) h6ATg me AL 3PgC.

SA508 TshePSRATumt Mona TYPE DA GAA06 CISES 2 Tless N/A P-40, 3

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Gr. 3 OTwem N/A l

70 P-40.

N/A on ac.

N/A TweCxhaas CF BACKING 1/2 inch 0AastTER OP 78ff coup 0se _ l4" OD GAS (QW-408)

OTMen San Finure.

TYPE OF GAS DA GA8ta Aronn CDe#08tT10N 0F GA8 kNXTung lont us1 A cenA.

OTwem 35 CFM PlLLER METALS (QW-404)

WELD heETAL AN ALY518 A-NO.

ER NiCr-3 SIZ8 op PILLam he6TAL 0.035" Dia.

g(gCTRICAL CHARACTERISTICS (QW-400)

PILL 8R hetTAL P-880.

43 Custm8NT Di rar e SP A SP8CIPICAT10N 5.14 POLAmity Se rm4.h r AWG CLAsstPICATION _ ER NiCr-3 Akers,

• 16 0-2 5 0 Peak VUL73 9.8-9.apaak**

OTwan TuNosTSN BLSCTMOOg 8:33 1/R EWTH OTwen

• 110-160 Backor.

• 8. 4-9. 8 B a ck o r.

POSITION (QW-408)

Poest:0es 0F on00ve 50 TECHNIQUE (QW 4101 WELO PROGASESION (UPMILL. DOWNMILL) Down TRAvsk 3 Peg 0 3.0-7.6 IPM are soeed OTM8R STRise8 OR WEAv8 Ogini aver 1-3 Strine.

• 00mLt.ATp0s 0-3/4" for Weave Bands.

heuLTIPAN OR 84NGLS PABB IPER 81081 Mul t inia PR8 HEAT (QW-408) gese0LS OR haubTtPL8 BL8CTR00g8 sinoin 0

Pm8 MEAT TWhePERAfume 70 F Min.

OThe8R Water Raekad for all lavera.

INT 1RPA83 78hePSRATURg Higher thar 80"F.

Minien= Water Tenn.1 80"F.

r OTwan Lavers 4 and above Weave.

D'* N XGU-05-211 B.3 Osp e,s.2 Revision 0 may o

Pagm 2 of 2

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TENSILE 758T (OW-1ED) vtTinaATs uLTIMAtt Type op MCite8%

Wl0TM TM6CrJets AA8A TOTAL LOAD West? 87R888 PAILVag a Nvueen (sq. inch) filhJ iensi L0 CAT 10N r21T-1 N/A N/A 0.199 18.100 ai nnn nme. h e al

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FWIT-2 N/A N/A 0.198 18.075 91.300 Bane Metal i

GU4080 SEND TESTS 10W1801 TYPE AND P40088 NUMetR R88 ULT 180 Side Bend. 4T. Satcrie *W15-1 Satisfactorv WIS-2 Satisfacterv W15-3 Satisfacenev a

W1S-4 smeinfmernev TOUGMNGES TESTS 10 % 1701 spec: MEN NoTcM NOTCM Test IMPACT U""

8 *

NUMSE R 60CATl0N TYPE TE MP.

VALUES gngAg wiLg gagAst 40 BARAK WIC-1 Base Meta l V

40'F 175 1001 88 N/A N/A I

150 791 78 N/A N/A W I C-2 FWIC-1 h{8SVRA2 138 100%

70 N/A '

'N/A 130 962 61 N/A N/A g

FWIC-2 l

FWlC-1 16floIn RAZ 72.5 66%

50 N/A N/A WIC-2 57 58%

40 N/A N/A PILLET WELD TEST (QW-180) mesuLT - SATisp ACTomV: Yes,H/,L.,,, No.8/,L_, PewtTnATioN INTO PAmeNT METALS yts N/ A no N/A N/A uAcmo - mesvLTs QTNER TESTS TYet of TasT N/A 08 POSIT AN ALYS18 oTMen N/A 1

N/A l

asL0amil NAWe:

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gram, uo, i T1875 00NoucT:0 sY An==.t Laboratorien LAeCaAfomY Test NO.

1188.299 W8 c8RTiPY TMAT TME STAftW8NTS IN TMl8 RSCORO ARE CORAOCT AND THAT TM8 7887 weLOS wtRE PREPAA40, wtLOGO AND 788T80 IN A000ADANCR WITH THE A80utR8MENTS OP SECTION lx OP TMt ASME CCOE.

CERT 1PiSO SY:

h DATE QUALIFICAT10es SUP9Avi304 1

106 TAIL 08 ROCOMO OF TESTS ARS ILLusTRATlvt ONLY AND MAY 08 M00tPit0 TO CONPomM TO TM8 TYPt AND NUMetR OP 78873 A30gim80 SY TM8 000tJ OtNMBL3643 XGU-05-211 B.4 Revision 0

w GRoovf Wf t B Mitbatti PRDF it t 1/?" WAf f t RAf tf D ritf (FWlu.1) l taanla &

tamala b Ottiames fena surfaca Mit Diatames fenn lurfaca Mit foe,.003 below surface 31, 31, 36 foe,.003 below surface 40, 42, 41 Toe,.003 below surface

35. $ (. 010 f roe we ld)

.034 Ilp area 39, 34, 36, 40 I

.030. Itp 42.5, 43, 39

.070 35

.075 42

.170 35

.155 37

.245 36 36 tannia e tamala o Diatame _,lena turfaca Htt Blatanen fram Rurface n2f I

.004 free edge 32

.003 from cut surface 16

.103 36

.007 L5.5

.203 34

.052 J8

.303, at corner 37

.102 34

.326 at corner 34

.t02 35 I

.302 35

.300 from corner, Hort 36

.341, corner 34

.200 from corner, Hort 35.5 s

.100 from corner, Nort 35, 36

.200 from corner, Herit 28 1

.300 from corner, Mort 34

.315 from corner, Nort 34 1

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.I PROCEDURE QUALIFICATION RECORD (PQR)

(SEE QW 201.2, SECTION IX, ASME BOILER AND PRESSURE VESSEL CODE)

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RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON.

PaoCsoume cuauPICAftoes meComo No. POR-3/8-T-005 OATE 12/19/AA was umso Pos TasT weLo WPS-3/8-T-002-NES mav.

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weLolmo PnoCassass GTAW TYPas tesANUAL. AUToMaric, sous-AVToJ MACHINE l

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h GAcovE oestGN of 7857 Coupon (Pom CoMe NAT1oM ouAUPICAT1o*es. TMS oEPostTBo WELo METAL TwlCENEM wtLL sa 20ComoED PoM EACM PILLER METAL om PMoCSM WELoJ SASE METALS (QW-403)

POSTWELD HEAT TREATMENT (QW-407)

I MAT 1mlAL SPEC. cA sna TEMPERAME NAMF l

TYPE oR GRADE c1mma ?

IIMe N/A l

P-No.

43 om-No.

ir wgm N/A To P-No.

3 QR-No.

3 I

THICENSE of BACKING 1 1/4 inchea otAMETER of TEET Coupon 15 1/R inehan GAS (QW-408) oTMen som Fionre TYPE op GAS om CASES Argan ccMposmoN of gas MixTune i nn, u.ia e --n I

ofwen as cru PILLER METALS (QW-404)

ER NiCr-3 I

weto METAL ANALYSIS A-Mo.

SIZE OF PILLER METAL 0.035" Dia ELECTRICAL CHARACTERISTICS (QW-408)

PILLAR METAL P-No.

43 CURRENT Bfroer SPA SPECIPICATloN 5.14 poLAm Ty sermi he I

Aws CLAaslPICATioN -

ER NiCr-3 AMPS.

• 16 0- 2 4 0 Pe ah'90 cts. 8. 7-9. 8 Pe ak *

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XGU-05-211 B.12 Revision 0

WFtb OVFRtAY MARDNFt1 PROFitF l

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'~'

l QUALITY ENGINEERING PROCEDURE

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nutech

MATERIAL CERTIFICATE

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[ d( i( >l lANIMK Sf00L CO.

P O SOE ItM. SCBAN10ed. PA.1SSSI - P9l Fl? S474999 PLANT LOCAftDat Ipff9CfAf8 91, WAYWLT Exit 99 CU$icate PU80 east Oute NO tessul gett N0 fvtm S8tCial C004 MAeul (tiliwcil Dalt l

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-3 XGU-05-211 B 18 Revision 0

J l

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g APPENDIX C l

l Mockup Nossle - Safe F,nd Assembly i

Chemical and Physical Properties, l

Heat Treatments, and~QA Test Results 1

L q

l XGU-05-211 C.0-Revision 0 nutech l

u

TER lABCOCK & WILC01 cmiPANY POWER GENERATION GROUP TECHNICAL PROCEDURE NUMBER 12-HT-100, Rev 5 8BCTION SUBJBCT HOUNT VEF#M POSTWELD HEAT TREATMENT OF QUALITY A88URAhCE NUCLEAR WELDMENTS-

_m agLgASE N0*

344 AEEAEi"" II#~'A #

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AFMna JV 1>sv " v 7" v

SCOPti 1.1 This Technical Procedure shall govera the postweld host treatsont of weldsents on nuclear componente made to Sectione 111 and IX of the A8ME Soiler and Pressure Vessel Code. This includos weldmeate joining ferritic pressure parte, nonpressure parte to pressure parte, cladding on ferritic estariale, and repaire in ferritic weld and bees asteriale.

I 1.2 Postweld heat treatoont shall not be required for velde jotains austenitic.

l anterials or for velde to cladding on ferritic meteriale provided that the 1

cladding to a minimum of 1/8" thick.

2.

BASE MATERIALS:

j The base materiale used in the fabrication of weldsents to be postweld heat treated in accordance with this procedure shall be those lasted under P-Humbers 1 and 3 ef Section IX of the A8ME Soiler and Pressure Vessel Code or other einilar approved materiale.

3.

METHODS OF POSTWELD HEAT TREATHElef t The veldsente shall be postweld heat treated by any of the following anthodet 3.1 Heating the complete assembly as a unit in the furnace.,

3.1.1 Prior specific approvals of Quality Assurance shall be required in the event the entire unit will not be put into the furnace at f

one time. This operation shall also require approval by Engineering.

1 4.

CLEANNESS PRIOR TO REAT TREATHENT:

Immediately prior to any heat treatments, all Inconel and etsinless steel wrought materials shall be free of oil, grease and other sulfur and chloride-bearing compounde. The remaining surfaces of the component shall be broom cleaned.

Prior to final heat treatment, all weld spatter shall be removed.

S.

TEMPERATURE HBA8UREMENTS 5.1 Thermocouples and their installation: Thermocouples shall be.in contact with the vessel surface and shall be protected against flame impingement or direct radiant heating of resistance elemente.

Iseued 9-7-72 Revisional Revised paragraphs 1.2, Revised: 11-6-78 2,4 and 8.

Added new sentence de.

Prepared by: GF/CRP and of paragraph 5.1.1.

Page 1 of 3 XGU-05-211 C.1 Revision 0

,. maa_.

1-f.

PCURR GassaATICBI GROUP 3

Tsa m1 CAL PBBCEDURR

.I g,

12-2=HT-100 Rev. 5

-l 5.1.1 Intermediate postweld heat treetsent shall be governed by readinge obtained with taermocouples attached to the anticipated hotteet and coldest pointe on each component in the furance charge. Thermo-couples are required only on a alaisua of four components in a furnace charge provided these componente are distributed to represent the entire furnace charge.

5.1.2 Final postwald heat treetaset shall be governed by readings obtained with thermocouples attached to the enticipated botteet and coldeet-pointe on each weldsent la the furnace charge.

5.1.3 Temperature calibration shall be in accordance with Quality Assurance Technical Procedure 12-2-HT-1.

5.2 Temperature cont'rols, Temperature costrel shall be accomplished with the aid i

of automatic strip chart ' recording contro11ere is conjunction with annual i

control. ' Temperature shall be recorded en strip chart recordere, or, when a L

potentiometer is employed, the operator shall asistain a log of the tempera-ture readings takaa at 15 stoute intervals.

5.3 Recorde Heat treatment cherte or temperature lose shall be antatsined in the files of the Babcock & Wilcon Compeay for three (3) years. Copies of those recorde shall be furnished to the customer.and Authorised Inspector at i

the,1r request.

i 6.

FURNACE PROCEDURE:

6.1 When weldaente are placed in the furnace, the temperature of the furnace shall not be less than the temperature of the veldaente, uor shall the-furnace temperature eaceed 600 degrees F.

6.2 During the heating and holding periode, the furnace atsoephere shall be so controlled as to avoid excessive oxidation of the surface of the vessel.

The furnace shall be of such design se to prevent direct ispingement of the flame on the vessel.

6.3 Above 800 degrees F., the rate of heating-shall not exceed 400 degrees F. per hour divided by the maxim = veld thicknese in inches, but shall not exceed 400 degrees F. per hour. The heating rates need not be less than 100 degrees F. per hour.

At all times t'ne temperature differentiale shall not exceed that; established by Engineerlag.

During the heating period, there shall not be a-variation in temperature greater than 250 degrees F. within any 15 ft. interval of length throughout the portion'of the vessel being heated.

6.4 The vessel'or vessel part shall be held within the temperature range and for the time specified in the applicable portion of Section 7.

6.5 Above 800 degrees F., cooling shall be dose in a closed furnace or cooling chamber at a rate not greatre than 400 degrees F. per hour divided by the a

Issued

.g.7 72

- Revisedi 11-6-78 Prepared by:

GF/CRF.

See Page 1 Page 2 of 3 XGU-05-211 C.2-Revision 0

~ TER BA900CK & trt140E CtBWANT POWER 05 88&T105 OSOUP TBcgRICAL Ft0CSBURR gg, 12-2-HT-100, Rev. 5

'manisya weld'thicknees. but shall not eseesd 400 degrees F. per hour.

i The

, cooling rate need not be less than 100 degrees F. per hour. - At all times the temperature differentiale shall ret exceed that establiehod by gagi-

, neering.

6.6 When pressure parts of two different p-Wumber groupe are Joined by welding, the postwald heat treatment shall be that applicable for the asterial re--

' quiring the higher postweld temperature. When nonpressure parts are welded to preeeure parte, the postweld heat treatamat temperature of the pressure-part shall control.,

6.7 During the holding period of Poetwe14 heat treatment, the assimum temperature

{

of any vessel component shall not escoed the lowest tempering temperature of i

that component.

6.8 The sulfur content of fur'nace fuele used in heat treatmente involvina inconel "I

materiale shall be limited to 30 graine,per 100 cubic feet of gas and.0.5-percent by weight for oil.

7.

P0g1VgLD UgAT TREATMBNT:

7.1 Intermediates To prevent welding or dimensional' problems, weldaente may.be given an intermediate poetveld heat treatment, if it le considered necessary by.,the welding or the manufacturing engineer. =This shall be done by heating the weldsent to a temperature of 1100 degrees F. to 1150 degrees F. and holding at that temperature for 15 minutes. Furnace procedure shall be in accordance with Paragraph 6 except the maximum rate of temperature ries'and fall need not be less than 200 degrees F. per hour. These weldsente shall receive a subseqv.at final heat' treatment et the temperature and minious time specified in Paragraph 7.2 of this Technical Procedure.

7.2 Figg},

Final poetweld heat'treatmen't is by definition the last heat treat-asnt of the component, either as an individual ~ component or part-of an assembly, prior to placing the component into service. Heat treatment shall be accomplished by heating the component to a temperature of 1100 degrees F.

to 1150 degrees F.

The minimum holding time at tempetature shall be for one hour per inch of weld thicknees up to and including 2 inches. For thicknessee exceeding 2 inches-the miniaun holding time shall be 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />, plus an addi-tional 15 minutes for each additional inch or fraction thereof of thicknesses over 2 inches. The time at temperature shall be determined by the greatest thickness of weld requiring final postwald heat treatment, which to in the furnace charge. The furnace procedure shall be in accordance with Paragraph 6.

8.

DgFINITION OF HOLD TIMg Hold time is defined as the cuamulative time at postweld heat treatment temperature, that is, total time between the last thermocouple to enter the heat-treating ten-perature range and the first thermocouple to leave the range Permanently minue the time that any thermocouple is out of the range.=

Issued:

9-7-72 Revised: 11-6-78 Prepared by: CF/CRF See Page 1 Page 3 of 3 XGU-05-211' C.3 Revision 0

i

,$1MIFICg,T E OF T EST ON PlPE MAT ERIAL N

s n o w wo m m Luv_s.,

o THE BA800CK & WlLCOX 00.

p.o. sox sein L

POWER GENERATION GROUP asoverow. rsEAS ??Oct 91 STIRLING AVE.

NW, OH 4203 ASNE QUALITY SYSTEM CERTIFICATE (WJAJFACTURkR) i o

NO. N-1261 EXPlRES 10-27-78

(,go.cos.go.,,

i9 nay 1978 C..... o,4., n..

ca.s. s i.. o,4., n..

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"' I ih'" "I"I'"

384337 JT F-9216

,n o........

u,,',.,

o.o.

14"

. t.o.

.eALL sol 160 cJ.e. P.

N..

06-9216-I40-1I2 I

L...u.a CHEMICAL AN ALYul

s..l w..

c MH P

Si CR Ml Nb4Te Co N

l_

J 6456

.049 1.65.020.015.37 18.60 9.53

.01

(.01

.07

.14 ALL OPERATIONS WERE PERFORMED BY CIW & MEET THE REQUIRDtENTS OF THE LISTED MATERIAL SPECIFICATION AND SEC. til, DIV. l.

f* % j hI

o..i.,

g,,,-

MICH ANICAL PAoPERif tl

,...:t..

pg

...M.,

a,pr

E,,....

3,....

.g,7 e,93 g i-n 3

.2 3

J 6456 Trans.

86,100 45,200 51.8 68.8 OK

.505 667 Forg.Ser.#

Test Lotd Heati 30352Y 687 J 6456 30352z TEST REPORT APPROVED BY Mr. VERNON p.ATERIALS ENGliiEElilNGdyLM__14-vrW One length of pipe per heat por heat treet lot has been tested for Intergranular corrosion in accordance with practice "E" of ASTM A262-70 and found acceptable.

Pipe has been ultrasonically enemined in accordance with approved CIW Procedure PU-33, Rev. 'Al and found ecceptable@ port attached.

Hy4..e.u. I... D i na k-= '--- hu.tena4metemilu 4ma tad at *)AAA nel fne 4 ame. anA Insind accantahla.

n.. 1... = =

J925'F., held 1.50 hrs. et temp. Water Quenched.

HIsaf.I[si$f Charts attached.

sa...a.W4 s..,.

/(*

i...u r,........

6........... 4 i.......,4.

u f

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NNY J11.

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• ia ad XGU-05-211 C.4 Revision 0

I g

een 5' N xm o n w o nycs.zwc.

E. Lamb trr-4

<c

e. o. oon s2:2 asoverow. Tzzas vvoon UT-12 E ui ULTRASONIC EXAMINATION REPORT S

DATL 78 o:

Civ INSPECTDR R.Reichardt

s u StfT-TC-1A level II Babcock & Wilem CUST0tlER.

U.T. PCCEDURE.

& 33 h. A

~

PART NO.. 86-9216-140-112 SPECIFICATION: ASME SA376 TP304 SEC. III, CL.IasATERIAL.

304 S/S t,....

thru WIttTER 1974 with.20% Cobalt 30352-Y J 6456 11' 4 3/4" 4

INSTRURIENT: Ultra =aaa" m Series 10 30352-2 12' 11"

~4

'""**R leETHOD-Contact TECHfHQUr. Pulse Echo COUPLANT. Water 30353 17' 7" 12 an,,Att 1.475" OVERLAP-lot SCANNING $PEEDitaAX.1 60' I minute INDExlEC-Autemiatic feelical scan "O' C" D '

~07#.

SCANNING: Pipe rotated on rolls with search units in fixed position NOTCM (O.D.).074" r

LONGITUDINAL 800DE suarAct scA= co seasecu uw T arremence sY AnoAmo sY AwoAssoir Avio=

7 I

o h

SHEAR 3003E

$URFACE SCANNED SEARCH UNtT REFEREwet sT AeroARo ST ANDAROe2 ATeow 0.D.(2) Shear Wave Branson 2.25 MffZ cire. direction 1"x1" (2) 45*

St I.D. & O. D. N O FCst 80% on O.D. 300TCH REPORTABLE INDICATIONS ossYAuct rRoss c Rcues.

A u AL ocPTw cLocn enoscATeone Loss osr END "A" LENGTH LENGTH froes 0D POSsTsow AssPLITUDE S. R.

REesanns i

f 6 o n t(tr'UN I i.e-rNUVtv BY pit. VFRNnN i

s

,. r r. m 4i o A. n.

/

a

.a w mu a.: w. 4 LJuaM. A - ar_g-jc.f77 i

RESULT 5C REPORTABLE INDICATIONS RESOLVED ARE INCLUDED IN THIS REPORT.

ACCEPT C REJECT b NO REPORTABLE INDICATIONS AND NO REPORTA8tE LOSS OF BACK REFLECTION WERE NOTED.

THE PARTS WERE TESTED IN ACCORDANCE WITH THE ABOVE PROCEDURE AND FOUND TO BE ACCEPTABLE.

SIGNED-

$4-N f, Y

SNT *It-IA Level III

.. ~

... - ~..

. - - - - -. -... - =, - - ~ - ~. ~..

c=..,

g i a_enape :-orge umsson W

Energy Products Group x

i p.o.c..oso,w...c

....,......,...s.seaso QO ciar.=esteau esamuractuame come =,

ewone ass.ns. esso Twx s o-oes.esn Tei.ex ees. sass S.O. No.

9768 h MATERIAL TEST REPORT hb DATE Dec+" L 19 5

Purctieser m whencar i Vilcor enem w Purctimmer's Ortner No.

P.o[61559 hr=It620-00 55-10 t

O Destrituster Desiribistor's Ortser No.

res. cHaa rs Tuna

^ " " *

• seeAT on 4 oaoneo E-12, Rev.s. 2 spec,/

coca ag/

eso.

ao.

oTv.

enoover

,,, l EAT YneATase=T 1

h Feedwater Inlet Nozzle per BW Dwg. SA508-2 "per 42QIBqr 41 1,

16600F 15 F for 8 hrs.-air cool I

1 1339k7D.2 3W Spec.

4 1560cF1150F for hrs.-water quonch CE-NPS-00h, 0

1290 F 15 F for hrs.-air cool 1

ner. 2 m Tut.pecions won t-aliced cono s:

i um

.A sotuoeo o,.

r nst etr.>onry was unceurActunto unosa Code 1971 Ed f/

Held 911250F 25 F for 50 hrs. Cooling to 6000F 1

u uc ouAury sysTrus czarersc ATE Sect. III C3 9 m frimare cool.

No'ei^ni.7.77* """

thru h r

'7"{ AA A _

C9GERSICAL ANALYSl$ ASED GEClaamancas pegyERTIES O

NoT shtPO81TS ATTACMGO Foncesse teEAT

eso, aso.

C asse P

s sa Cst see eso y

u. r.

as. P.

O. P.

staaemans j

61F-Q24IAqr

. 20 76

.010

.009

.28 35

.83

.60

.02

[adle X

X P-3 dropwei ht speci-6 1

.2h 71

.011

.010

.26 32

.80 55

.01 2 heck NM Pmeedum #'s mens, four (h) no -

2

.18 72

.012

.010

.29 3h

.81 57

.01

heck UT-71-1, a v. 3 breaks per forging 3

.19 75

.015

.009

.28 33

.83 57

.01

heck dated 10/25/73 two(2)eachG180 4

.19 76

.017

.010

.28 34

.8k 57

.01

heck MP-25h3-3, nov. O, apart e+500F to qual-Mod. 2 dated ify an NMT of +h00F.

T ST REPO RT AF PROVED B" MT. VERB ON

/11/16/73

.9>

Intrt ! L.4 tinQ 8'i C 4st d a'sts m%3% /Es L" UJr wf, L/ffj y'(V.se.asse as H-27t>U-14gACT Tc Bev.

et h1 wt g tat en.e. p 6

gg gg Postos8e6 e* EAT TEST TS=

V6ELO ELoseG. 5 A. A.

Pss.SSLE aso.

eso. '

Tease.

to00-PM. sees an 2-2

e. M. N.

SenestGY ffe-It.J LATG8tA4. 9 RP. lan *)

1E SHEA88 0

g 61F-1 Q2GIAgr R.T. 0 89 262 67 716 26.0 70.8 208-213-223

.085.097.090 100-100-100 w A0"r 180*

93 5h5 70.225-2h.o -

7o.7 210-217-192

.o89.102.093 100-100-100 w 40cF 0

103-107-111

,078.W7.083 100-100-100 W +1000F 180' 110-99-112

.082.077.000 100-100-100 W +100 F

-2 00 88.660 66 950 25 5 73.h 233-240-240

.084.068.094 100-100-100 w AO F 180*

86 788 65.057 27.o 75.2 2ho-2ho-2bo

.090.090.086 100-100-100 W+h00F

' 0" M */ 76-99-107

.076.069.078 100-100-100 W +1000F 1800 T102-110-111

.079.083.075 100-100-100 W +100'F

" Major direction of wo*inar is =v1=1."

R2 SIEET 1 of 2 d

7/.*"*" 'I."'.' **.O.Yec E *""'

i

g j j e tessape rorge unvasion

.}

Eriergy Products Group

..O....

3.. w...c.....,......,s...a.iss.O

.g x QuLremESTEsus massurACTUftsesO Comernasy

,HOM E 2 3 5-703 0 See Twx Ste-es3-0372 TELEX 003-5493 50 s,o, no, m;g Js MATERIAL TEST REPORT DATE Deca"her 2.

19 74 O e D[

krchaser

• rhe h hnnck N Vilcox CnsenA w Purchaser's Ortser b.

P.o. 6'14G94CR Contract 620-0010-55-10 Destributor Destritiusor's Ortser N.

FCE.CMa.TS TEM teEAT OR FOftGaase MO.

OTV.

eftODUCT

- 9,5C.

COOS NO.

80 0.

DeE AT TftE ATtaENT vgS 88 0 MATERIAL BNCLUOcD ON THIS TEST

.-~*07 WAS e4A9el,FACTUrtED UNDER IO 1E C'JALITY SYSTEMS CERT 8etCATE te4ATER ALSD MO. MM EXP9stES OCTOSER 28 1977.

C3assancat Aggatyggs aga) ageOsammaras pagpggTtgS 8e07 sterORTs J

ATTACMEO FOAG8884 DetAT

=0.

NO.

e

==

e se c=

ne esO

u. T.

O. e.

.A..

" ' "*"* ** 8aa

• avi=1 m sting

' II* ale.

eE"'III.

esIIL.

O "

"s"-.

l-

• • "*O."*

=O.

e. a. m.

ene'aev e.. mas i.ATenaa. e xe. a. s u s ean 51F-3 Q24LBqr R.T. o" 92.619 70 518 26.0 73 7 N(206-192-203

.o87.100.090 100-100-100 w goof 180*

92.836 70.747 24.0 73 1 180-182-191

.093.093.096 100-100-100 w 40 F 0

00 Q,( 121-120-100

.090.080.076 100-100-100 m ioooF

.1800 112-110

.079.086.079~

1 % 100-100 m 1oooF 113 K20f' 70904090'.098

~100-100-100 w40 F

-4 0

93.h38 70.k70 2h.5 73 1

'92-180 91 780 69.k20..

26.0 73 4 197-223-184

.109.089.092~

100-100-100 w 400F 0*

116-122-103-

,080.083.081 100-100-100 m 1oooF W'(t06-9h-118

,082.075.086 100-100-100 mioooF,

0 180

[I

' TEST REPORT AFo30'!ED BY MT. VERNON smis r 2 Or 2 f.'IATEKIA!_S ENGiXEER!NGdM e = = /r-s-7r

_ m,

,e

If I/ Lt."apW r OrgG Olvision y

[ Energy Prrdusts Grsup ow.=esta= warun. e co L

.........e......n...............t.,....

PHONE all.193*lS44 TWX 5t. 643 0373 TELEX.4364:3 I

ULTRASONIC INSPECTION RECORD Report Dete T)=^.=h., 1L io7 <

735595cR l

Cente cl He.620-0010-CC.1 Mill Order He.

61P g,0, H,,

h68.h Heet He.

Q2QL8QT p, He 1.2.3.h item He..

1

)

P,eced.,e He, UT-71-1. Rev. 3 Identificellen el piece (s) Feedwater Iz0s t Nossle per BW Dwg. 133947D-2 INSTRUMEN[U$ED TRAN$DUCER g,, ${Ig,,

F g g CY go gE COUPLANT Erautkramer USIP-11 Aerotech 1"

2.25 MHz long'l' 011 Forginge were ultrasonically tested in accordance with the above procedure and were Results found to be acceptable with no reportable or rejectable indications.

E'(r n

.f$d f.. Til E:b ' fl

')

!V -l c;f.s

,.. (3 1II ;-)

-- ir1

• ~~) C CO g

M NN

o 2

/

2' bd).wa.)

% Witnessed by inspected by Date el Eneminellen 1<>/ t/? q XGU-05-211 C.8 Revision 0 l

\\

LcnCpe Fcrga Division r

Energy Products Group eae.weersan==wacrun cow =v l

l p.o. e e. e s o, we.i c m..i.e. p.n a.riv.ni. s e s s o l

PHONE 286 7 3.l64.

TWX 984 443 0378 TELEX 0435463 l

MAGNETIC PARTICLE INSPECTION RECORD 635595cn neport Date December 3.1975 loos X oener contract No.620-0030-55-10 AUll Order He.

61F

g. o, y,

2768-h

\\

Heet No.

Q2Q.L8QT pc. No.

1.2.3.h hem No.

1 tracedure No, MP-25L3-3. Rev. O. Mod. 2 Identincetion of piece (s)

Feedwater Inlet Nossle per BbW Dws.1339h7D-2 MACHINE U$to Sonofluz AH-15

__ aoo spAoHo 6"

Amps 125 aspe./in.

0. C.

p REsutis_ Forminas were marnette particle tested in accordance with the above procedure and were found to be acceptable with no reportable or rejectable indications.

i 4

v' m 5; m i

m

.O

'1 D !f}

rus a t

D;! Ul 1

F,isj Ci9 fj in U

Li LI3 l

g Q

.d

\\

i y s m i

N h M i

2 k )' 2 I.-

\\Wis..sied by

'd.

Ny

l.......,,

l D.te el En.minellen 12/2/75 & 12/3/75

~

l l

XGU-05-211 C.9 l

Revision.0

• 8

~~TIUNTINGTON ALLOYS, INC.

. 7 [$sAsiseg M [4 i

-***'s"

,x e

p.

N ceo.. =es,vi.r ma is,,.

TEST REPORT eo BAI GRVELA W O!DD-OY AIJE AFTE.R.J. EEASY M y

A f,mrs CHAaCE OWDER NO PRIME CONTRACT NUMBER c"

DM Inist rutuuntsPuruf DIY oC E

BAB(Da a WIDIE (D P O EtE 331 317254 5.

opt NUMBER E

BARBERIDE OEM AA9ng DA T E. lO 17 75+aca 1

<= 1 I

A.xOnoE.NO.

S

-.-.-.-.m.-._..

o.,o R.....fxl

-.u--.-~.---

=, - - -.

--Nmt.

~.<=

. - ~ ~ - -

u...v,,, o,

- ecasisos n: Ear C'Mst l = i' 3'l [~

'nr a

AEDGE BOIIBt 3, pos:cunis vamosa uma IFF masam M,d 2 PA EF C.JIWA*QJ 51A35 oUAany Connoot escasta=Nr N<

EBICRPE-3 (M5urfm WAIVED) AERIE m'n'TfDt 3 - 19T1 EDTTIDE - 1973 WIBIEll anrsnna STATE OF 4E3T VIRGINIA COU'iTY O?

EKCEPT SUB SECTEON BA 3700 WAIVED.

CABEI.I.

SU2SCRISED AUD S'.03:4 TO BEFO3E VC TiiI~$AY 0?

.n ence

.o o.

.. = s mo 4

j mmmer gEgBDs RIDeumm.3fR.aTg 1975 MY C3321' 103 52 G

'g

-l-156" X 14.000

I:07. 8, 133, I

worxn dosional

!!OTA'tY 30 IC y

.. -o

(

s s.

cu

a. o.

o

=

co

.o = 14 i.

.. s

,sf o.

g g

?

l l

l 00l05 f

l I

I coa'et ao 00113 j

CB OL j61 TA 00j0l 0 j50 i

9 37 0l06 06 j68 08je2 l008 00je6 00l10 67j52 14:69 l

0 l47

e mmn:281HE BREEL aun.masa 3BR1 DEI @

i ---.n rs. _ =.. m vesse.

een.. sew N

eDOW rat.

owen.c.

,,,,g, g i

gas,

• .t.

O

.8=

g 33* #

y

g.

• est.a

.OUAN,f,Y Mf AI $80

_.. _j._... _ _

~

g..

_. _g REMARKS AND RESULT 5 OF FURTHER EXAMINATION: PeOTE: Net a) UNLESS OTHERwtSE 5 Howes.NI INCLUDE 5 A SamAtt AnaOUNT OF COeAtr.

F'550eES WEeE naEA5ueED AseO 00 NOT EXCEED CAST AseO HElfX COnartY SPEOF8 CATION (genti$ EITHER eN Muan8E8 On SaZE.

uttDeNG Cue #ENT -

AAAPS VOLTS -

wtfM SPEOFICAftCos mEOuseEAAEfef5.

4 WELD TESTS s' 7e.c.e7. E.e's5s Ys.'s7 E VISUAL ANO OtMEN580NAL EXAM 8 NATION-OK

~

a e

eA

,f,,w,.,,

?. TATER!At A5 SHtPPED FAOa4 HUMffMGTON PLANT FREE FROAA CONTAANNATION ST HG. RA AND ALPHA SOUSCE.

t

- - = - - - -

~

"I

-_m.

u-m

' Hil.-Eo0033200/3C(SilI PS).

(10-69)' INCO CLEVELAND

.CHG. T0

~

INCn ORDER # CERTIFICATION OF OllALITY CONI'ORMANCE TESTS E51609Il CHC. ORDER #

Hanufacturer or HU:ITillGTrH ALLOY PRODUCTS OlV. II:SPECTION. INCO Distributpr Tilt it!TEnPATIONAl IllCitEl CO lHCCustomer 's Name B&W BARBERTON 0HIO Address HUMTit!GTON U. 'VA.

25'720 Customer's Order No.

1179tli.ct Date-01/07/M Cnre Wire Hea,e No. HT1858MO

)

)

Specification MIL-E-no'27200/1C piEm 1 Lnt Identification HIL-E-00222t10E OTO 7-23-70 INT CHG 1 OTO 9 21 72 CLAS$ 2 Para.

4.4.2.1 d

. Type MIL. 8H12 (WEIGHT 2730#)

Hechanica l Test.

As /

Heat g

Diameter & Length'.156" x 14.000"

~

Welded Treat

'Yleid StrenAth L

Inspection Level A

(0.2% of fset methnd) ' 53500 t No.

4W

+

Tensile Strength 92500 g

, Chemical Analysis (Complete)

Tiongatinn (%)

46 _

teduction in Area 39 k %ickel (including cobalt) 67.52

'O'

,lardness- (Average) t!/A y

Copper 0.10 Titanium 0.47 Bend Test j

~ %nganese 6.66 Aluminum N/A Side end

1. 1- 0 #2. 0

1. b 0

1. ron 8.42 tolumbium 1.61' Transverse 1

$ h ASilicon 0. I+1+

tobalt 0.0)

Face Bend,

N/A Creeve WaM Test

! h

.=h, t,,,,,

0. 0'i.

vid i.a tn,,,

0.01 N

Test-No.

3 8a Chemica1 P k 5 iulphur 0.008' Holybdenum /A 12 0 nmperage 120 gjg=

XChromium 14.69 Phosphorus N/A g@h Motal Other Elemente

< 0.5 0 pass and' Layer Sequence il/A g

(When required to be reportec gg Chemistry was taken from:

-X Chem Pad O NO. 959001 N/A Croove Weld 10g.X-ray Results TEST #3-0.K.

Grinding during 8a Test Plate Preparation Operation Error 5

Concentricity (%)

.005 8 a:

(Layer [s))

N/A I MATERI AL AS SHIPPED FROM HUNTINGTON PLANT FREE FROM CONTAMINATIO RA A SOUT Ig We hereby certify that the above material has been tested accor with the listed ecification and is in nformance w th all requirement 3,

4g MATERIAL WAS E TAL TED IN ACCORDANCE WITH

' g k HAPO QCP 0066 REY 0 OTO 11-03-65 g

RESULTS WERC SATISFACTORY.

Figure 3 - Certification of. Quality Conformance Tests g

j Notes to Figure 3:

Igl 1.

Items not appihabic to the. type e'lectrode involved or exempre b

by the procurement document shall be marked N/A.

2.

Thi's form is applicabic to the quality confnrmance ~ tests-regol 1;;

for cach lot.

A copy of the quality conformance test certification for lot shall be forwarded with each shipment regardicas of the identificat of the wet mixes of covering mixture represented.in this shipment.

-a s m r urt.r.nn???nnr.,

XGU-05-211 C.11 Revision 0 1

w w

w

,M s-3 7>E sagtoca e estCox CouPassy NN PoetA CEesEna7eone Caoup Q@

wr. n==en. Issoiassa m o' REC 090 0F FILLER WIRE QUALIFICATION TEST EL-318 rest e 0.C. TECNes SCAL mE w.

wELo ss'sG CN PeoCmset no.

enoCEss py car ed',T,E',cuY4O rateo suo.

WEeon

@d

. sear ce Lov ssp.

sra srEC.

CLAssar:

12-2-U0I-IIIC 0

Shielded 317934CL

' 12-2-Wof-Tsti o

MeCal.

5.11 ENiCrFe-3 5/32 610-0234 567-355 HuntingCon A11 )ys 4537 I?-2-unr-r:1i n

Arc rius SFA SPEC.

CLAsSIFsCATIOss "hfI rh TamCT FOLeo eso.

wEascoe Canot Lor eso, L

WELDING PARAksETERS AasPEAACE wetYaCE

Taawa, esat FEED CoseTACT TO

$8ssELDesec CAS g

LOCAfs0H SPEED is M MEOtsNS uGRE t ems OCSP '

Ocee AC OCSP OCer aC y,,e

'q,y st Posefsas Undiluted Pad 130 21 Flat ra t,ir 130 23 rime O

CHEnelCAL AssALysis b

tocATsos tao no.

C 4An l P S

S3 Cr NI see Ce Ch Te Co N

Ti Fe Other Undiluted Pad--

Vendor

.04 6.665.01

. nn!

.AA 1A A< A7 o

.13

.10 1.61

.01

.03

.47 s.42

< so Jndiluted Pad 33184

.039 7.3

.017

. ni :

.ss is n AA n is

.14 1.66

.03

.06

.41 g,7 Joine 31779-

_nto 7t ni?

ni-

_ra 15.0 65.9

.11 1A 1 An

.05

.07

_ss g_a y

At Jndiliated Fad -

33184

.06

.05 Joint 33229

.06

.06 APPt.1 CATION APPftOVED

~

~

rERCITE ANALYSIS

~'

L..

att.Deseg SENDEss?

W Femme rf %We

.0E-,-

-- s =

E-Copts --

CcDE t.C.,s.s s.o. -

g,,,

r,s, l

eE HEREEY CERTIFY THAT THE r,s,

,,, g, I

MVSNsPS N 8988 A80VE ts57EO asATEstas. HAS

. GEEss TESTED see AC-M WsTN Tset AeOwt ts57FO A L*

SPECtF sCAfsOsst$3 AssO iS sN W Cope Cass*L-IS1J

. CaseronesamCE es tu Att Y Ai 1 APPt.sCaett mE0ulatasEssTS.

THE TE57 OATA e$ CORGECTLY AM CEEIE FWSet..

SEPomTED U$ssac anaCNesuES AssO INSTALAIENTAf sCes 98 7H II1C I! IJ AwAetAett mEComes or CcwTasCr aso.

6 IAIJ PEascosc CattenAviose.

(ni n-n?1& srve -)

/A.ae. 3 P

' /JL."3 E-7F APPtICATeesssis: APeeOwO esesrear e ft 7*

O $^ j "

zl 3l Al wtn see.

& = M -

_ l- _

m,=-

All Poeitions

,,,,.t,g,,,,,

77j yw jjf_ g_ag PL 2 P9%dY'I?

1

~- -~' ~

. - - -. _ -- - - - ~ --- ' ~ ' ' -

--~ -----

_,, ~-

-...m.

eos,3s3P-3

..m.

RECORD OF MECHANICAL TEST RESULTS m ' =0.

t1.-318 I

POST WELD HEAT TpEATMENT 1100-1150 e,, o.

50 wouas l

, r r on waves 15

'r Pra nous natt or cootiNn to 800

't i

ASTM E206 DROP WEIGITS $PECIMEN 17PE P.3 true.

attutts !I etwP.

etsiitts i truP.

atsutts trup.

atsut ts I ther 'r t.

Il i

i ASTM rn TENSILE PROPFRTitS ItSI SPECitetN U(tlMAf(

YitLO PT. PSI stLONG.

t Atc. OF j

LOCATION ttMPthatunft'FI sift (th.l Sta. Psi

.it Ortstt t' GASE LENSTM AktA

.toint 1/2T Ambient

.500 113,000 H,500 35.0-36.5 4

SA.370 CH ARPY V. NOTCH IMP ACT TEST 240 FT./LB. ENERGY L 0AD SPECIMEN TYPE A YtMP.

FT,/Lg5 Lat (IP t $.d AR f t34P.

F1./L98.

LAT. ERP.

t SedAA TEAF.

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peggt 7,lBIERAT305 089W TgmIRlCAL PRDCEBURE I

_ _ _ _ ER 12-2'WP-5. Rev. 3 NE 8 E110N GENERAL PROCEDUk2 POR MANUAL METAL MOUNT VERN0ll ANC WELDilIG FOR CCWlERCIAL NUCLEAR OR WsLDING TECHN014CY, SPECLAL APPLICATIONS AFFROVED JY Ed AL > d-Jfh DAtt s,l/hsAu 1.

SCOPEt This Technical Procedure shall govera the aseval metal are welding of Carbon, Low-Alloy, Nickel-Chromium-tron, and Statalees Steele in accordance with the ASME Boiler and Pressure Vessel Code. This Technical procedure is supplemented by a Wold Data Sheet.

2.

BASE MATERIAL P pFARAT10ftt 2.1 Joint preparettaa shall be prepared by mechantest methode or thermal

[

cutting in accordance with Technical Procedure it-2-WP-3.

2.2 The weld' preparation and adjotains base antal for a minimum distance of 1" fron the welding groeve shall be kept iroe of oil, areese, dirt, moisture, and other materiale that would affect the integrity of the weld. Jointe that will not be welded immediately shall be adequately protected to prevent contamination.

2.3 Weld preparatione shall be inspected by the angnetic particle or liquid penetrant methode se required by Section 111 of the ASMR Boiler and Fressure Vessel Code. Visual Inspection shall be performed ta accordance

[

with Technical Procedure 12-2-WQ1-3.

2.4 Sackina Stripe. Backina Rinas. and 8sacer Blocket 2.4.1 Materials for backing stripe, backing rings, ans' opacer blocks shall be compatible with the base anterial.

3.

WELpING CHARACTERISTICSt Welding parameters and electrode type shall be in accordance with the weld data sheet for the base asterial to be welded. Welding shall be performed using alternating estrent or direct current, reverse polarity at 19 to 26 volte.

The range of travel speed shall be 3-9 1.p.m. for 3/32 and 1/g", 3 1/2-11 1.p.m.

for 5/32", 3 1/2-14 1.p.m. for 3/16", and 5-12 1.p.m. for 1/4" electrodes.

4.

WELDING TECHN!QUEt The welder shall malatain a short are. A slight weave any be used. The width of weave shall be limited to that which produces a sound weld of good appearance.

At no time shall the are be directed into solidified slag. When welding ta positions other than flat, the welding progression shall be uphill.

Issued:

3-17-71 Revised 11-12-7 L Prepared byt CHK Complete Revision Page 1 of 2 XGU-05-211 C.16 Revision 0

gas taggots 6 WILCOE CO W W pgWER SWIERAtleel SWP TEMBlCAL PROCWWEB ggggg 12-2-VF-5, Rev. 3 J

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. 4.2, Af tereech bead of weld'estal to deposited all slag shall be removed from the surface of the weld. The welder shall visually emasine each bead. Special attention shell be esercised et starte and stops. All defecte such as tracks, blowholes, porosity, undercute and overlap shall be removed by chipping, grindtag, or air-ere. Weld spotter and eside sh:11 be removed from the side-ws11e of the groove.

I 4.3 When wire breehoe are need on statalese steels and alckel-chroelue-tron alloys, the y shall be statalees steel, 5.

TMERMAL TRAATNElft Proheat, interpass toeperatures, and postweld beat treettag shall be in accor-dance with the applicebe approved Technical Procedure.

6.

QUALIFICATIO91 0F PROCEDURES All weldere and procedures shall be qualified la accordance with the ASME Botter and Precevre vessel Code, Section 11, til, and contract requiremente.

leeued: 3-17-71 Revinna, i i i,_u Prepared by: CHK See Page 1 Page 2 of 2 XGU-05-211 C.17 Revision 0

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145 Martsnvale Lane San Jose, CA 95119 Telex (

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CA 95119 Cperating Subeldlerleet Phone:(404) 6294800 Tenox (RCA):278971 NUTC UR Fax:(408)2814186 NUTECH Engineere Attente 1301 Hghtower Trail, Suite 205 NUTECH International Madrid Atlanta, GA 30350 Otense,64 Phone:(404) 642-8215 4th Fbor Fax:(404) 6424213 Madrd28020, Spain Phone: 0113412746604/-5600 NUTECH Engineers Betheode Telex:46642 FATS Three Bethesda Moto Centu, Suite 430 Fax:011-341279 3500 Bothesda, MD 20814 l.

Phone:(301) 6521610 NUTECH internetlonel Rome g

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NUTECH. Intornetional Seoul Fax:(312)7894343 2044 WDong Kangnam Ku Seo'.d 135-010, Koree NUTECH Engineere Minneapolle phone: Ot t,82-2 547 5887 3055 Annapolie Lane Telex:K28143 NUTEKSL Plymouth, MN 55447 Fax: 011822-549-7915.

Phone:(612) 5504400 Fax:(612) 559 2207 -

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CONTINGENCY PLAN FOR l

I REPAIR WELD!ilG OF i

N0ZZLE-TO-SAFE END WELDS GEORGI A P011ER CO."PANY PLANT HATCH DECEMBER 13,1985 I

e INTRODUCTION

- L. GUCWA i

0 DEVELOPMENT PROGRAM

- W. CHILDS 8

DEVELOPMENT DETAILS METALLURGICAL / MOCK UP

- P. NORRIS ANALYTICAL DETAILS

- P. RICCARDELLA I

l i

0 CONCLUSION

- L.T. GUCWA 4

l

. i

- [

CONTINGENCY PLAN FOR TEMPER BEAD WELD OVERLAY OF SAFE-END TO N0ZZLE WELDS l

i PREPARED BY i

GEORGIA POWER COMPANY i

AND STRUCTURAL INTEGRITY ASSOCIATES 1

I PARTlALLY FUNDED BY i

ELECTRIC POWER RESEARCH INSTITUTE 1

l l

i i

l DECEMBER 13, 1985 l

l

INTRODUCTION

/

l CONTINGENCY PLANNING FOR REPAIR OF POTENTIAL IGSCC I

FLAWS IN SAFE-END TO INLET N0ZZLE WELDS TRADITIONALLY, TWO ALTERNATIVES FOR REPAIR 1

REPA!R/ REPLACE AND PWHT TEMPER BEAD REPAIR USING SMAW j

CURRENT PROGRAM FG':USED ON DEVELOPMENT OF A.

7 THIRD ALTERNATIVE:

TEMPER BEAD, INCONEL 82 WELD OVERLAY REPAIR USING MACHINE GTAW PROGRAM PARTIALLY FUNDED BY EPRI FOR GENERIC

~

USE - EPRI REPORT WILL BE ISSUED.

t

COMPARISON OF ALTERNATIVES l

\\

PWHT:

COSTLY AND DIFFICULT PROCESS TO IMPLEMENT ON OPERATING PLANT VESSEL LONG OUTAGE, HIGH EXPOSURE POTENTIAL FOR INTRODUCING HIGH RESIDUAL STRESSES ELSEWHERE IN VESSEL IF IMPROPERLY DONE APPLICABLE PRIMARILY TO REPLACEMENT PROGRAM EXPERIENCE OF OTHER UTILITIES SUPPORTS AB0VE TEMPER BEAD REPAIR USING SMAW:

\\

PERFORMED LOCALLY AT PILGRIM DURING N2 SAFE-END REPLACEMENT l

ASME SECTION XI PROCEDURE CURRENTLY IN PLACE DIFFICULT PROCESS TO CONTROL SINCE MANUAL PROCESS ALMOST EXCLUSIVELY USED WITH REPLACEMENT MANUAL SMAW OVERLAY WOULD HAVE HIGH MAN-REM IMPACT AT SAFE-END LOCATION i

4 I

i t

l COMPARISON OF ALTERNATIVES (CONTINUED) i l

)

l TEMPER BEAD / WELD OVERLAY USING GTAW:

l PARAMETERS DEVELOPED BY B & W IN EPRI PROGRAM TO GIVE PROPER TEMPERINb 1

RECENTLY APPROVED SECTION XI CODE CASE INCORPORATES THELE RESULTS PROPOSED OVERLAY PROCEDURE MEETS INTENT OF CODE l-CASE (TEMPERED P3 MATERIAL)

CAN BE SHOWN EFFECTIVE FOR AT LEAST ONE FUEL CYCLE (PROBABLY SEVERAL)

ALLOWS PLANNING OF ORDERLY PIPE REPLACEMENT l

IF NECESSARY l

MINIMUM IMPACT ON OUTAGE LENGTH i

M w

METALLURGICAL TEST!f!G l

• ERFORMED TO OVALIFY PROPOSED OVERLAY PROCEDURE i

0 FABRICATED MOCKUP F0P. DROCEDUP.E QUALIFICATION

- OBTAINED B 4 il fl0ZZLE (FP.0M CAllCELLED PLANT)

~ bk!

h0'i$h,'Dfbfhfl 0

PERF0PJ11NG PROCEDURE OVAllFICATION TESTS IN ACCORDANCE WITH CODE CASE

-INPACTTESTING(C.E.'-ENATTN00GA)

- NICP0HARDflESS TRAVEP.SES (J. A. JONES)

- TENSILE TESTING (C.E.-CHATTANOOGA)

- BEND BARS (GEORGIA P09ER) i 0

PROGRN1 TO DATE DEMONSTRATES THAT GPC PROCEDURE AND RESULTS ARE C0llSISTElli WITH EPRl/B 8 W PROGRAM

- SATISFACTORY TEMDERING OF HAZ e

s n

9

,-.,,--nv

,e

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1 i

1.

N0ZZLE TO SAFEND HELD-IMCOMEL BUTTER r.d BUTT WELD t

2-is.

THREE LAYER TE9PER BEAD WELD i

5-6.

OVERLAY AND G8100VE COMPLETED WITH WATER BACKING

)

1 A.

LOCATION OF MICR0HARDMESS SURVEY l

t i

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_ AREA IN l

BEND R.

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I N0ZZLE/SAFEND OVERLAY WELD PROCEDURE OVAL!FICATION i

SEQUENCE OF OPERATION (OVERLAY MOCK-UP AND GR0031)).

l TEMPER BEAD (NOTE 1) 1.

PREHEAT TO 350*F-HOLD 1/2 HOUR j

2.

DEPOSIT FIRST TEMPER BEAD LAYER (AS SHOWil ON SKETCH) 3.

DEPOSIT SECOND TEMPER BEAD LAYER 4.

DEPOSIT THIRD TEMPER BEAD LAYER REPEAT STEPS 2 THROUGH 4 FOR THREE AREAS AS SHOWN Ort SKETCH 5.

HOLD PREHEAT TO POSTHEAT 6.

POSTHEAT 450-500'F FOR 3 HOURS-SLOW COOL 7.

FILL MOCK UP WITH WATER, FLOW APPROX 3 GPM

~

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NOTE 1 - N0g(eiGH g},e,gELUTTER gN N0ZZLE E AND 2

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WELDING PARAMETERS t

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Modified Procedure F from EPRI NP-3614. Volume 2. July, 1984 l

1 Layer 1 Layer 2 Layer 3 Layer 4 Layer 5+

~

Current (A) 180 200 220 180 200 i

voltage (V) 11 11 11 11 11 Wire feed (ipm) 39 59 65 39 59 I

Travel (ipm) 8.5 7

6 8.5 7

Bead Overlap (%)

50 50 50 50 50 Preheat (0F) 300 300 300 300 300 Max. Interpass (OF) 500 500 500 500 500 Jules/in 14,000 18,900 14,200 14,000 18,900 (WaterBacked) t Wire Diameter -- 0.035 Inch Shielding Gas - AR 18 CFH Electrode

-- 2% Thoria Tungsten; S/32 Inch Diameter; 2-1/2-inchTotalStick-out(WithLon9 GasCup);

Tip:

22.50 Included Angle l

NOTES:

1.

N0 LAYER S PARAMETERS ON STAINLESS STEEL SIDE OF WELD 2.

PREHkAT (250-3500F) ON FIRST 3 LAYERS AND POST WELD BAKlNG (450-5500F) AFTERWARDS 3.

PlPE FILLED WITH WATER AFTER FIRST 3 LAYERS 4

P-e

...,... -,. _. ~,,,.,...

CHARPY "V TEST RESULTS 40'F l

l

[V (J-LB gg' GEAR fT g EXPANS!0tl I

B 88 70%

66 MILS l

C 69 50%

51 MILS l

l SNgTSUITABEFORNhE$

BEVEL FyhfFFkt h {g Y

S10ll NE BEND TEST NOTE - 7 i

MbL W

B $

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L NG TUD NAL BIEllD TEST, TENSILE TEST RESULTS:

B H FA D

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I

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100 y l 315 302 300 302 190 l

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i l

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l r

RESIDUAL STRESS ANALYSIS SIMULATED BUTT WELD RESIDUAL STRESSES IN WELDS-2 l

f FINITE ELEMENT MODEL TEMPER BEAD OVERLAY PROCESS PRODUCES COMPRESSIVE l

I STRESSES FOR SIGNIFICANT PORTION OF PIPE WALL CRACK GROWTH ANALYSIS f.ORRELATION BASED UPON LIMITED EPRI DATA FOR 4

CREVICED INCONEL SAMPLES IN AGGRESSIVE ENVIRONMENT DA/DT

• 1.08 x 10-8 K.26 l

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CRACK GROWTH RESULTS SHOW AT LEAST ONE FUEL CYCLE OF REPAIR LIFE e

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Dietece from Inner Surface (sn.)

OUTT KLD LAVUt 8 BUTT WELO LAYER 6 i

FINITE ELEENT RESULTS - RESIDUAL STRESSES AFTER BdTT WELD l

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Dietamco from lener-Surfoce ( s n. 7 OVER.AY SEG8ENT 34 I

DVERt.AY SECaeENT 34 FINITE ELEMENT RESULTS - RESIDunt STRESSES AFTER KLO OVERLAY i

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RESULTS/ CONCLUSIONS i

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. A CONTINGENCY REPAIR PROCEDURE IS BEli4G DEVELOPED AND-QUALI-FIED FOR INCONEL-82 WELD OVERLAY REPAIR OF N0ZZLE TO SAFE-END WELDS.

. PROCEDURE USES GTAW TEMPER BEAD PROCESS SIMILAR TO THAT DE-VELOPED UNDER EPRI SPONSORED PROGRAM AND RECENTLY APPROVED SECTION XI CODE CASE.

i

. METALLURGICAL TESTING SHOWS THAT HEAT AFFECTED ZONE IS TEMPERED WITHOUT PWHT, AND IS CONSISTENT WITH THE RESULTS OF AD0VE EPRI PROGPAM/ CODE CASE,

. ANALYSIS SHOWS THAT:

I

- RESIDUAL STRESSES ARE HIGHLY FAVORABLE. (SIMILAR TO CONVENT 10NAL OVERLAYS)-

- CRACK GROWTH IN INCONEL-82 OVERLAY MATERIAL ACCEPTABLE FOR AT LEAST ONE FUEL, CYCLE UNDER WORST CASE ASSUMP-TIONS.

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