ML20077F367
| ML20077F367 | |
| Person / Time | |
|---|---|
| Site: | Hatch  |
| Issue date: | 06/10/1983 |
| From: | Giannuzzi A, Riccardella P STRUCTURAL INTEGRITY ASSOCIATES, INC. |
| To: | |
| Shared Package | |
| ML20077F352 | List: |
| References | |
| SIR-83-001, SIR-83-001-R00, SIR-83-1, SIR-83-1-R, TAC-51407, NUDOCS 8308010348 | |
| Download: ML20077F367 (353) | |
Text
{{#Wiki_filter:_.__ _ _ . l 1 l INVESTIGATION OF CAUSE OF CRACKING IN HATCH UNIT 2 REACTOR COOLANT l SYSTEM PIPING - COMPARISON WITH UNIT 1 CRACKING EXPERIENCE l l SIR-83-001 Revision 0 June 10,1983 Prepared for Georgia Power Company by Structural Integrity Associates San Jose, California Principal Investigators: _W A. J. Giannuzzi P. C. Ric[ardella 8308010348 830712 p DR ADOCK 05000366 - PDR '3
ABSTRACT A number of areas were investigated as potential causes of the accelerated IGSCC behavior observed in stainless steel reactor coolant system piping at Hatch Unit 2 versus Unit 1. These areas included fabrication history, applied and residual stresses, and operational history of the two units (both time / stress cycles and water chemistry). A detailed review of the current inspection results at both units was also conducted. Based on this investigation, the only substantive difference found between the two units was an unusual weld prep /counterbore configuration in the Unit 2 shop welds which resulted in a stress concentrating notch or fillet within the IGSCC susceptible weld heat affected zones. This notch also coincided with most of the observed UT indications at Hatch Unit 2. Analyses were performed which indicate that the stress concentrating effect of this notch could accelerate the initiation of IGSCC in this counterbore region sufficiently to explain the observed cracking. Moreover, the presence of this counterbore can also have a confounding effect upon the ultrasonic inspection since it produces an ultrasonic reflector in itself which must be distinguished from IGSCC, It is thus concluded that the shop weld counterbore configuration at Hatch Unit 2 played a significant role in the unusually high number of UT indications observed in the recent inspection. il f j
l l TABLE OF CONTENTS PAGE 1.0 In t rod uc t ion . . . . . . . . . . . . . . . . . . . . . . . . . . . I 2.0 Cause of Cracking Investigation ...... .... . .... 2 2.1 Fabrication History . . . . . . . . . . . . . . . . . . . . 2 l 2.2 Stresses - Operational and Fabrication . . . . . . . . . 6 2.3 Reactor Water Chemistry .... ............ 17 l 2.4 Inspection Results - Comparison with Baseline Radiography .................. 19 l 3.0 Su m mary and Conclusions . . . . . . . . . . . . . . . . . . . 23 4.0 References ........................... 26 APPENDICES A. Weld Procedure Specifications for Unit 2 . . . . . . . . . . A-1 B. Weld Procedure Specifications for Unit 1. . . . . . . . . . B-1 C. Documentation of Field Storage of Unit 1 Pipe ...... C-1 D. Water Chemistry Data For Units 1 & 2 Through Mid-1982 ....................... D-1 E. Reactor Conductivity Information For Units 1 & 2 During 1982 & 1983 ............... E-1 F. IGSCC Damage Index Calculations, Unit 2 ......... F-1 G. IGSCC Damage Index Calculations, Unit 1 ......... G-1 l til s
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LIST OF TABLES 1 1 TABLE PAGE
- 1. SRI & Carbon Content Data Hatch Unit i vs. Hatch Unit 2 . . . . 27
- 2. Summary of Recirculation System Piping Carbon Content Data From Table 1. . . . . . . . . . . . . . . . . . 31 3 Stainless Steel Pipe Fabrication Information ............ 32
- 4. Nominal Stress Values in Hatch Units 1 & 2 Stainless Steel Pipe Joints (Typical) . . . . . . . . . . . . . . . . . 36
- 5. ASME Section III (NB-3600) Design Stress Indices . . . . . . . . . 36
- 6. Summary of IGSCC Stress Rule Indices for Recirculation System Piping ..................... 37 a) Original Data b) Adjusted for Counterbore Stress Concentration
- 7. Summary of Plant Operational Cycles Since Commercial Operation ......................... 38
- 8. Assumed Relationship Between Carbon Content and Damage Model Constant D* . . . . . . . . . . . . . . . . . . . . . . 39
- 9. IGSCC Damage Versus Insp.ection Result Correlation ........ 40
- 10. Comparison of Baseline Radiography to Current Ultrasonic Results for Unit 2 . . . . . . . . . . . . . . . . . . . . . . 43
- 11. Grinding of Recirculation System Suction and Discharge Piping . . . . . . . . . . . . . . . . . . . . . . .. . . . 52
- 12. Ultrasonic Indications for Each of the Stainless Steel Pipe Systems ........................... 53 t
i 1 iv / 1 L. _ _ _ _ _ _ _ __ _ _ . _ _ . _ _
, LIST OF FIGURES FIGURE PAGE 2-1 Weld Prep Designs For IIntch Recirculation Syst e m Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2-2 Estimate of Stress Concentration Effect of Weld Counterbore ........................ 9 2-3 Application of IGSCC Damage Model (Simplified) ...... 12 2-4 IGSCC Damage Index Versus Time For Typical 12 Inch Riser Shop Weld (12BR-B-3) ...... ...... . 15 2-5 IGSCC Damage Index Versus Time For Typical 28 Inch Discharge Weld . . . . . . . . . . . . . . . . . . . . . . 16 l 4 f l M V ()
1.0 INTRODUCTION
During the recent augmented ultrasonic (UT) in-service inspections at flatch, Unit 2, (performed per NRC Inspection and Enforcement Bulletin 83-02) an unusually large number of crack-like indications were reported, particularly involving the recirculation system riser piping. Recognizing that a similar inspection performed at Hatch, Unit 1, had uncovered no reportable riser indications and only a few total reportable indications in the RHR and ring header lines, Georgia Power' Company initiated an investigation designed to g uncover any differences between the two units which could explain the disparity in the UT results. n y( Central to any investigation into the cause of stress corrosion cracking in n % structural components is a fundamental understanding of those elements which b ) togcther form the necessary and sufficient conditions to produce the cracking, i.- For BWR austenitic stainless steel piping, the intergranular stress corrosion cracking (IGSCC) phenomenon results from the interaction of piping material, fabrication processes, fabrication and operational stresses and the environments to which the structural components are subjected. Specifically, for the Hatch Units 1 and 2 investigation, the study of similarities and differences addressed the following issues:
. Fabrication History
. Stresses - Operational and Fabrication
. Reactor Water Chemistry
. Inspection Results - Comparison with Baseline Radiography.
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The investigation was structured on the premise that variations in any of the above variables sufficient to explain the dramatic UT inspection differences between the two Hatch Units must be substantial. That is, the repair of only a few welds or a malfunctioning support or restraint could not provide sufficient distinction to explain the reported UT differences, rather the differences must have been the result of a more global, general effect. This study of potential sources of such differences is described in the section below. 2.0 CAUSE OF CRACKING INVESTIGATION 2.1 Fabrication History The search of the fabrication related variables for Hatch Unit 1 and 2 recirculation system piping involved the investigation of the records submitted by the pipe vendors for the two units. This records search provided the following information: i
. Certified Material Test Reports (CMTR) for piping materials and weld filler.
. Pipe size, pipe fabrication history and wall thickness.
. Weld joint design, weld procedure specifications (WPS), heat treat-ment records and grinding and weld repair information for shop welds.
f . Fabrication records including weld joint design, weld filler, WPS,
' J grinding and repair information for field welds. yt 2 i )
1 L _ _ _ _ __ _ . _ _ _ _ _ _ - -
The search of these records indicated that the austenitic stainless steel materials used for the fabrication of Unit 1 and 2 recirculation system piping are in conformance with applicable Codes and specifications. Weld by weld carbon levels for pipe components are shown in Table 1 for each unit and summarized by line in Table 2. The pipe material used for the risers in Unit 1 (supplied by i Associated Pipe and Engineering Company) was rolled and seam welded, whereas, the Unit 2 riser piping (supplied by M. W. Kellogg) was seamless. In addition,
's the carbon level for the riser piping while conforming to the material specifications for Type 304SS, lies typically near the 0.08% carbon maximum specified for this class of material. This observation appears to be true for both units (as illustrated in Table 2).
A significant distinction between the two units was observed in the examination of the weld joint designs for the shop butt welds in the riser piping. For Unit 1, the weld prep design for the shop welded pipe to elbow weld is given in Figure 2-la. Here the counterbore is machined a minimum of 0.5 inch from the edge of the land, the taper to the original pipe wall is gentle (10% maximum) and the counterbore radius is 1/8-inch minimum. In addition, the land thickness is 1/16"
+ 1/64". On the other hand, the records for the joint design for the Unit 2 shop welds, presented in Figure 2-lb, show no minimum counterbore length, no minimum taper angle and no minimum counterbore radius. The extended land thickness is 0.045" + 0.010", about two-thirds of the thickness of the Unit 1 joint design. A comparable WPS for a gas tungsten arc (GTAW), shielded metal arc (SMAW) design for Unit 2 shop welds (the end cap to manifold welds are examples) presents a similar joint detail (shown in Figure 2-Ic). From Figure 2-Ic, the counterbore length is typically 3/8". In addition, no taper or counterbore radius is specified for this joint design. The significance of this observation is -
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l ( FIGURE 2-1 WELD PREP DESIGNS FOR liATCll RECIRCULATION SYSTEM PIPING 12h* J
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f Min. a) Weld Prep For Unit 1 Shop Welds b) Weld Prep For Unit 2 Shop Welds (SAW) (SAW) (Riser Discharge Pipe) 10* 1" 5* 221* Y h 3" 4 "R l
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. L [s T"". / j" y 14y _;._, f c) Weld Prep For Unit 2 Shop Welds d) Weld Prep For Unit 1 & 2 Field Welds (GTAW, SMAW) (End Caps) d 4
l that the stress concentrator associated with a shop counterbore may very likely occur in the weld heat affected zone (IIAZ) in the Unit 2 shop welds, whereas, for the Unit I shop welds, a longer counterbore with a gentle taper to the
- original pipe wall was used and will generally be found outside of the weld IIAZ.
Another significant item when relating shop to field welded riser piping is the difference between the welding procedures. For both Units 1 and 2, the shop welding was performed for the 12-inch and 28-inch piping using a combined GTAW, SMAW, submerged are (SAW) process, whereas all the field welds were fabricated using combined GTAW, SMAW or only SMAW. (This fact is illustrated in Appendix A and in Appendix B where the WPSs are presented.) The SAW shop procedure produces a moderate heat input weld with potentially long times for cooling due to the thermally insulating nature of the cover slag. This slow cooling between the welding layers produces the opportunity for additional weld induced sensitization of the piping as well as a probable difference in weld residual stress compared to the GTAW and SMAW processes. In addition, the field weld procedures for both Units 1 & 2 use a weld prep design similar to the shop prep design for Unit I as shown in Figure 2-Id (see Appendix A WPS 15GE and 16GE for additional detail). The pipe size and wall thickness information for both units provided no strong distinctions. The pipe sizes were nominally the same for both units. The greatest single difference between the two units was the fact that the 12-inch, Schedule 80 pipe for Unit 1 is rolled and seam welded and for Unit 2 it is seamless. In general, the minimum wall thicknesses for Unit 2 were slightly greater than for Unit 1, of the order of 5% to 10% 5 I '
- Although some repairs were required for both units, particularly in the ring header and large diameter piping, no remarkable differences were observed between the units in the records search. The baseline radiographs were re-examined for the recirculation system piping in Unit 2. These data are discussed at length in Section 2.4 of this report.
A search of the records was performed to determine if the field storage of the Unit 2 piping influenced the extent of cracking in this plant. The records revealed that the Unit 1 piping was stored outside in the open (Appendix C). No evidence of open outside storage was found for Unit 2. However, discussion with Georgia Power plant personnel suggests that the Unit 2 piping had been stored in a similar manner to the Unit 1 piping. 2.2 Stresses 2.2.1 Nominal Stress The stresses which are considered to be significant contributors to BWR stainless steel pipe cracking are those due to internal pressure, dead weight, thermal expansion, and welding residual effects. Table 4 provides an estimate of the range of magnitudes of these stress components at Hatch Units 1 and 2. The magnitudes for the two plants are similar, and are nominally the same as those found in other operating BWRs. Other sources of stresses exist, notably seismic, thermal transients, flow induced vibrations and field fitup. These are not generally considered to be significant contributors to BWR pipe cracking. Seismic stresses are very infrequent, and
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have not yet occurred in any of the plants in which cracking has been observed. Thermal transients and flow induced vibrations are of very low magnitude in the piping systems of interest, and fitup stresses are believed to be conservatively , bounded by the above welding residual stress estimates. 2.2.2 Stress Concentration Effects The above nominal stresses are concentrated in the piping weld heat affected zones, which are susceptible to IGSCC, by general and local geometric effects. General effects are those due to the proximity of the welds to elbows, tees and other large scale geometric irregularities in the piping. These effects are conservatively addressed by the stress index table (NB-3600) of the Design Code for the piping, ASME Section III. Table 6 provides an approximate range of the design stress concentration factors for these effects, and illustrates how they are applied to the various nominal stress terms. Once again these values are essentially the same for Hatch Units 1 and 2 and typical of other BWRs. A A significant discovery was made, however, in the review of plant fabrication and inspection records discussed above, which infers a difference in local stress concentration between Hatch Units 1 and 2. The weld counterbores on the shop welds on Unit 2 were machined shorter than most BWRs, such that a significant local discontinuity occurs in the weld heat affected zone. These were observed in the weld radiographs at precisely the location where the majority of the cracking has been observed. Furthermore, this condition only occurs in the shop welds for Unit 2. 7 J v
Figure 2-2 provides an estimate of 2.4 for the approximate local stress concentration associated with the counterbore. This estimate assumes a .015 in. radius counterbore, and as such addresses stresses in the general vicinity of the counterbore. Actual local peak stresses may be higher if the fillet radius is smaller, which is likely since no minimum radius was called out in the welding procedure. However, this value provides an approximate measure of the potential IGSCC accelerating effect of the counterbore fillet in the HAZ. 2.2.3 Stress Rule Indices in addition to piping carbon levels, Table 1 also provides a weld by weld listing of IGSCC Stress Rule Indices for Hatch Units 1 and 2 recirculation and RHR piping taken from References 1 and 2. These data are summarized for the recirculation piping in Table 6a. From this table, it is clear that there is not a significant difference in the originally calculated values between Hatch Units 1 and 2. Table 6b provides a similar Stress Rule Index summary, only with n stress concentration factor of 2.4 included for the counterbore effect in the shop welded riser welds. Based on calculations for typical welds, this effect causes approximately an 0.3 to 0.6 increase in Stress Rule Index. Table 6b shows a considerable difference in the distribution of riser weld stress rule index values between Units 1 and 2, with many more welds in the high Stress Rule Index range. The counterbore stress concentration adjustment was not applied to the 22 inch manifold and 28 inch suction / discharge welds because, even though the 8 )
FIGURE 2-2 ESTIM ATE OF STRESS CONCENTRATION EFFECT OF WELD COUNTERBORE 1 1, 4, d/2 D/2 lr jh D/2 = .7 in. d/2 = .65 in. h = .05 in. r = .015 in. i.I = .012; SC F E 2.4 d
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counterbore is unusually close to the welds, the heat affected zone is also closer to the welds in these pipe sites, such that the two are not expected to coincide in most cases. Evidence of grinding was discovered in these cases which could explain accelerated cracking. This effect is not addressed by stress rule indices, bt.1. Js discussed later in Section 2.2.5. 2.2.4 Cyclic Effects A detailed analysis of the operating histories of both Hatch Units 1 and 2 was carrired out (Reference 3). Table 7 shows a year by year listing of scram and cold shutdown cycles at both units, together with a breakdown based on how much system pressure was reduced during the cycle. Considering only cycles where system pressure was reduced below 500 psi, Hatch Unit 1 experienced 38 load cycles during its 7.0 years of operation (through January 1983). Hatch Unit 2 was load cycled 27 times durinmg its 3.5 years of operating history. The number of hours of power operation during these periods were 41,725 hours and 22,327 hours for Units 1 and 2, respectively. These data were used to establish average load cycle parameters for the IGSCC Damage Index calculations of Section 2.2.5. On the average, Hatch Unit 1 experienced 5.4 cycles per year with an average cycle duration of 1098 hours. For Hatch Unit 2 the figures are 8.2 cycles per year with an average cycle duration of 827 hours. For both plants, an average startup and shutdown ramp period of 12 hours was assumed. 10
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2.2.5 IGSCC Damage Indices The IGSCC Damage Index Model presented in References 4 and 5 offers an improved means of assessing piping susceptibility to IGSCC. This model accounts for factors such as material, material condition, environment and plant operational time and cycles, which are not addressed by ti;e stress rule index approach of Section 2.2.3. Figure 2-3 illustrates, in simplified form, application of the IGSCC Damage Model to a BWR pipe weld. Stresses at the weld location, including residual, are input to a simplified elastic-plastic analysis to determine maximum and minimum stress levels associated with the reactor operational cycles. For j purposes of this analysis, reactor operational cycles are assumed to be l representable by the simplified, trapezoidal wave form illustrated in Figure 2-3, with different average cycle parameters (rise time, hold time and cycles per year) for each unit as discussed in Section 2.2.4 above. With this simplifiction, damage accumulates as a function of time and cycles in accordance with the equation at the bottom of Figure 2-3. Differences in material, material condition and environment are accounted for in the IGSCC Damage Model via the term D*. D* represents a critical level of damage which is associated with crack initiation and for high carbon weld l l sensitized material in " normal" BWR water environments its value is on the 1 order of 3000. The IGSCC Damage Index is defined as D/D*, and crack initiation is thus predicted to occur when D/D*=1.0. 11 - j
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s FIGURE 2-3 APPLICATION OF IGSCC DAMAGE MODEL (SIMPLIFIED) STRESSES AT WELD LOCATION: STRESS - Pm Pd _i Q ,
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RESID S1 STRAIN STRESS l S2 S1 T4 ~TH ---*
. TT -
l TIME DN *
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N+C32-i,Sy, (NTH) N, CYCLES C 1 , C2 , C3 , CREEP CONSTANTS i P, EXPONENT (EMPIRICAL) Dg/D* = IGSCC DAMAGE INDEX FOR N CYCLES
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Material carbon content has a major effect on a pipe weld's susceptibility to IGSCC, and thus on its D* value. Laboratory data has been used to relate carbon content to IGSCC susceptibility, and thus to D*. In addition, carbon content has been related to degree of sensitization, which in turn can be correlated with IGSCC behavior, and Eason, et al. (Reference 6) have developed a relationship between D* and degree of sensitization. Table 8 presents the relationship between material carbon content and damage index which has been used in this analysis. Plant water chemistry also has an effect on these D* values, but as will be seen in Section 2.3 of this report, r.o water chemistry abnormality significant enough to effect piping system IGSCC was observed in Hatch Unit 2. Thus the " normal" BWR D* values of Table 8 were used. Weld by weld IGSCC damage index calculations were performed for the Hatch l Unit I and 2 recirculation systems and are documented in Appendices F and G. l The results of these analyses are summarized, and compared to the recent inservice inspection results at the two units in Table 9. This table lists, on a weld by weld basis, damage index at the time of inspection (7 years for Unit 1 and 3.5 years for Unit 2) and inspection results. For shop welded riser joints, damage index values both with and without a stress concentration factor of 2.4 for the counterbore effect are given. For the 22 inch manifold and 28 inch suction / discharge welds, no counterbore stress concentration effects were I included, but instead, selected joints were adjusted for grinding in accordance with the observed grinding on the constru'etion radiographs (see Section 2.3). The grinding adjustment consisted of adding 20 ksi to the residual stress term which is based on data in Reference 7, and of using a D* value of 3000, independent of carbon content, to account for metallurgical changes due to grinding. 13 l a _ - _ - - - - - - _ - - - - - - - - - - - - - - - _ - - - - - -
The correlation between IGSCC damage index and observed cracking experience in Unit 2 riser welds after making these adjustments is quite good. Of the 23 welds reported to have IGSCC,13 had damage indices g-eater than 1.0, 5 were in the .9 to 1.0 range, and the remainder were between 0.4 and 0.9. On the e other hand, damage indices for most of the welds found to be clean were less than 0.6, with only a few in the 0.6 and 0.9 range. The damage index result for a typical riser shop weld (12 BR-B-3) is presented graphically in Figure 2-4. Curve a) in this figure represents the results for that joint in Hatch Unit 2, and curve b) for Hatch Unit 1. The Unit 2 curve includes the effect of the counterbore stress concentration, and the differences in average cycle parameters from Unit I neted above. Note from this curve that the Unit 2 damage index is significantly greater than the Unit I curve at their respective times of inspection (3.5 years versus 7 years). Figure 2-5 presents similar data for a typical 28 inch discharge weld (28B-15). In this case, two curves (ground and unground) are presented for Unit 1. As can be seen from these etirves, the grinding influence is dominant Since Unit i radiographs were not examined for evidence of grinding, no conclusive statement can be made regarding differences between Units 1 and 2 from this figure. 1 1 1 14 o
FIGURE 2-4 IGSCO DAMAGE INDEX VERSUS TIME FOR TYPICAL 12 INCH RISER SIIOP WELD (12B R-B- 3) l 3 _
>: - (a) m Q
E w 2 O E Q O N e u Unit 2
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(w/counterbore stress I concentration) (b) Unit 1 i S 5 9 g 0 g 0 2 4 6 8 10 YEARS OF OPERATION 15 ,=
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> FIGURE 2-5 IGSCC DAMAGE INDEX VERSUS TIME FOR TYPICAL 28 INCH DISCHARGE WELD (28B-15) f 3 . U a E w 2 k E s O N
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e I Unit 1 (w or w/o grinding?) ( w/ grinding)
. , , ' s 2 4 6 8 10 YEARS OF OPERATION 16 A
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2.3 Reactor Water Chemistry A review of reactor water chemistry records was performed for both units with substantial assistance provided by Georgia Power and General Electric personnel. Appendix D presents General Electric Company data regarding reactor water conductivity, silica, reactor and feedwater copper levels for both plants from startup through mid-1982. From 1982 to the present, a more detailed summary of the conductivity, dissolved oxygen, silica, copper, chloride, and pH is provided (Appendix E). A review of a draft General Electric report prepared by G. Romeo (Reference 8) produced additional information regarding reactor water conductivity during the first three years of operation of Unit 2. In addition, a General Electric report prepared for Georgia Power Company describing the results of a chemical transient in Unit 1 (Reference 9) was reviewed. The results of these reviews are presented below. The most significant event observed as a result of the water chemistry records search is the fact that Unit 1 suffered an off chemistry introsion on April 24, 1982, which produced a chloride transient in the primary coolant. The chloride reached a level of 2.5 ppm in the reactor water and concurrently the pH dropped to 4.6. This transient resulted in failure of numerous Local Power Range l Monitors (LPRMs), thin walled austenitic stainless steel tubes used to monitor l reactor power level. With the exception of this transient, the Unit I conductivity had remained at an average of about 0.3 Jimho/cm prior to this event. There is evidence of one other conductivity increase at Unit I which produced a maximum of 7 )2mho/cm in late 1981. This event appeared to have no impact on plant operation as it is recorded only in the GE conductivity I records.
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The Unit 2 conductivity records indicate that in general the reactor water conductivity had been poorer than in Unit I through 1981. Romeo reports that for the first two years of reactor operation, the reactor water conductivity averaged 0.5 pmho/cm with a maximum of approximately 2.511mho/cm, while in 1981 the average conductivity increased to 1.0 pmho/cm with a peak of 4.6. These data appear consistent with the General Electric data (Appendix D), and suggest that Unit 2 contained a higher concentration of ionic species in the reactor water than Unit 1 on the average through 1981. Romeo did not report on a significant water chemistry transient during his three year corrosion product study (September 1978 through September 1981), suggesting by exclusion that no such transient or unusual event occurred. In 1982 and 1983, the detailed records presented in Appendix E reveal that the pH remained within the recommended limits in Unit 2 and except for one small time interval, for Unit I as well (the one deviation in pH coincided with the off chemistry intrusion of April 24,1982). The conductivity appeared to be slightly lower in Unit 2 compared to Unit 1 in 1982 and 1983 averaging 0.5 umho/cm or less for Unit 2 and nearlynho/cm for Unit 1. The chloride level remained generally within the 50 ppb specification range for Unit 2 during 1982 and 1983, whereas the April 24, 1982 incident in Unit I and subsequent operation produced several readings , greater than 100 ppb for this plant in 1982 and 1983. The recorded dissolved oxygen levels in the reactor water appear to be low in both units. It is expected that the equilibrium dissolved oxygen in a BWR lies between 100 and 300 ppb at operating temperature. In general, the recorded oxygen levels at both Hatch units are below 100 ppb. Although this level is below that expected, it provides no obvious reason for the distinction in cracking suggested by the UT results. In fact, lower dissolved oxygen in BWR water should decrease the probability for IGSCC. 18 N 1
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In summary, the review of the reactor water chemistry records provided no clue to explain the large number of reported UT indications at Unit 2 compared to Unit 1. The conductivity data suggests that overall, the plants behaved quite similarly, with Unit 1 showing lower conductivity earlier and Unit 2 producing lower conductivity later. The only unusual events which may have exascerbated cracking appear to have occurred in Unit 1. The most significant event, the off chemistry intrusion in Unit 1 on April 24, 1982, produced failures in the LPRMs. The fact that no such LPRM failures have been reported in Unit 2 suggests that no chloride or fluoride intrusion of significant short term consequence occurred in Unit 2. 2.4 Inspection Results - Comparison With Baseline Radiography An extensive review of the current UT data and baseline radiography for Unit 2 was performed with the help of a Southern Company Services RT and UT level 3 inspector. -The review consisted of identifying evidence of counterbore, grinding, or repair on the baseline radiographs and correlating those results with the current UT data. Table 10 presents the results of this investigation. As can be observed from the table, almost all the riser joints were included in this examination as were half of the end caps, several header branch connections, the RHR joints and most of the 28 inch diameter suction and discharge welds. The baseline radiographs showed that no riser welds had been post weld ground on the inside surface, about 30% of the 28 inch diameter pipe welds were ground and both of the end caps examined showed some evidence of grinding as did all of the header branch connections examined. The extent of grinding on the 28 inch diameter suction and discharge piping is illustrated in Table 11. One observes from this table that all but one of the shop welds showed evidence of post weld J 19
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grinding whereas only two field welds were post weld ground and then only on part of the root was ground in each case. l The number of indications reported by UT for the riser, end caps, RHR and discharage and suction piping are presented in Table 12 along with information related to the welding performed (shop or field welds). In addition, Table 12 correlates the UT indication location with the baseline radiography. That is, all - UT indications located within 1/16" of the weld root are associated with the root, all UT indications located within 1/8" of the counterbore are associated with the counterbore and all UT indications which lie outside the expected weld HAZ (1/2 inch from the weld root for 12 inch pipe and 1/4 inch from the weld root in 20 inch pipe or larger) is identified as such. One observes from Table 12 that among the riser welds, 78% of the indications are in shop welds. Furthermore, 90% of the shop welds show UT indications and 24% of the field ( welds have UT indications. Another significant distinction presented in the UT data is the fact that among the twenty total indications in the shop welds, seventeen (or 85%) occurred on the pipe side and three (15%) occurred on the b elbow side,. It is also noteworthy that among the five field weld indications ' correlated, two lie outside the typical weld HAZ, and two others are associated with the counterbore. No radiograph was examined for the fifth weld, a pipe to pipe weld (E-3A). -
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A review of several radiographs of Unit I riser welds (a total of eight welds) revealed little evidence of counterbore either on the pipe side or elbow side. of . l thejoint. Where a counterbore was identified, it was typically 7/8 inch to one
.j inch long, producing a stress raiser well beyond the weld HAZ. The examination '
of the RHR system UT data revealed that only 3 of eleven of the field welds produced UT indications which were relatively minor in nature. 20 e
)
e.c d The examination of the 28 inch diameter discharge and suction pipe baseline m ( radiography and UT data demonstrated further that the UT indications werc { . concentrated predominantly in shop welds. Table 12 shows tbst approximately ' 53% of the shop welds contained UT indications, whereas only 7% of the field welds contained any indiention. In fact, the location of the field weld indication (3/8" from the weld root) places it beyond the typical weld liAZ for this ,
- diameter pipe. Among the shop weld ir.dications, 88% (or 7 of the 8) are in
) welds which have been post weld ground as illustrated in Table 11. The eighth t shop weld indication (28A-10) ie located in close enough pecximity to the e counterbore to be associated with the counterbore. k 1
- la summary, the correlation betwean the baseline radiography and tiie current UT data for Unit 2 stainless steel pipe welds produced the following information
- 1) The vast majority of UT indications were reported in shop 1
, welded pipe.
- 2) Within the riser piping population, the pipe side indications i greatly outnumbered the elbow side indications.
- 3) In 'the 28 inch piping, post weld grindirg was assreinted with t '
aln.ost all of the indications. t
- 4) The location of the counterbore in the weld HAZ of the rise.r piping has clearly influenced the UT eMls. Fifty parcent of t!.e shop and field UT indications in Unit 2, are associeted with the -
1' counterbore. Only six of the twenty 7 two sized indications f J i 21 c
/ .,
k
l appear to be associated with the IIAZ, independent of the counterbore. The location of and sharpness of the ecunterbore in the radiography suggests a weld prep geometry consistant with that presented in Figure 2-1(b). i
- 5) Examination of some of the Unit 1 baseline radiography reveals no evidence of a counterbore occurring in the weld IIAZ.
Where the counterbore is located, it is barely visible on the radiograph, suggesting a weld prep geometry consistent with that presented in Figure 2-1(a).
- 6) The baseline radiography for the riser field welds in Unit 2 reveal in general a gentle tapered counterbore which at times lies in the weld IIAZ. This observation is consistent with the field weld prep information presented in Figure 2-1(d).
I j 7. The UT examination results for the recirculation and RIIR I piping systems suggest that the non-destructive examination industry has become increasingly aware of the nature of IGSCC and has increased its propensity for calling small amplitude IGSCC in austenitic stainless steel. The fact that only 7 of the 23 UT calls on the riser were sized (conservatively) at greater than 25% of pipe wall and none of the RHR and discharge and suction line indications were sized at greater than 25% of pipe wall demonstrates that fact. In addition, with 16 of the 22 sized indications identified in the riser piping associated with counterbore and weld root, the UT inspections apparently have become able to distinguish IGSCC from clearly defined root and # counterbore geometry. g
l l 3.0
SUMMARY
AND CONCLUSIONS l l The investigation of the cause of intergranular stress corrosion cracking at Hatch Unit 2 and comparison with the recent Hatch Unit I cracking experience addressed the following issues:
. Fabrication History 4
. Stresses - Operational and Fabrication
. Reactor Water Chemistry
. Inspection Results - Comparison with Baseline Radiography.
The investigation was based on the premise that the magnitude of the distinction in the reported cracking between the two units had to be based on a substantial difference in the variables which were investigated. A summary of the results of the investigation of these variables is presented below;
. Fabrication History - The review of The fabrication records included certified material test reports, weld joint design and weld procedure specifications, grinding and repair information and piping a*ield storage records. This investigation revealed that the end of the weld counterbore for the shop welds in the Unit 2 riser piping was located in the weld heat-affected zone; for the Unit I riser piping, the counterbore edge occurred beyond the weld HAZ. Other than this weld I
counterbore effect, no other differences were found in the riser piping which are believed to have had an impact on the IGSCC behavior differences of this system in the two plants. Significantly, the piping carbon levels were comparable, and the unprotected field storage of the Unit 2 piping, originally believed to be a factor was not confirmed by the records search.
?
23 g
. Stresses - Operational and Fabrication - The records search revealed that the nominal applied and residual stresses at the two units are comparable, as evidenced by a comparison of IGSCC stress rule index data. However, when these nominal stresses are adjusted upward to account for the concentrating effect of the counterbore notch, increases in stress rule index of approximately 0.3 to 0.6 are predicted, which results in a significantly higher stress rule index distribution at llatch Unit 2.
A comparison of operational histories revealed approximately the same numbers of stress cycles per year at the two units. Thus, since Unit I has been in commercial operation for seven years, the cumulative stress cycles at Unit I are greater. However, when coupled with the counterbore stress concentration factor discussed above (through the use of an IGSCC damage index evaluation, it is observed that the propensity for crack initiation at Unit 2 after 3.5 years was greater than that at Unit 1 after seven years.
. Reactor Water Chemistry - A search of the water chemistry records did not reveal a significant factor that would explain the accelerated cracking which was reported at Unit 2. The average water conductivity was lower in Unit 1 through 1981. and lower in Unit 2 in 1982 and 1983. The only chemical transient which could have impacted IGSCC was reported in Unit 1. . Inspection Results - Comparison with Baseline Radiography - The examination of the baseline X-ray radiographs from Unit I and Unit 2 recirculation piping and comparison with the current ultrasonic results can be summarized as follows:
24
/
- The vast majority of UT indications were reported in shop welded pipe.
- Within the riser piping population, the pipe side indications greatly outnum-bered the elbow side indications.
- In the 28 inch and 22 inch piping, post weld grinding was associated with almost all of the indications.
- In the 12 inch riser piping, evidence of weld counterbore was observed in the radiographs of the majority of welds with UT indications. This effect was not present in Unit I welds or Unit 2 field welds, both of which showed little or no propensity for cracking.
In conclusion, the examination of the Plant IIatch records revealed that the only substantive difference found between the two units was an unusual weld prep /counterbore configuration in the Unit 2 shop welds which resulted in a stress concentrating notch or fillet within the IGSCC susceptible weld heat affected zones. This notch also coincided with most of the observed UT indications at Ilatch Unit 2. Analyses which were performed indicated that the stress concentrating effect of this notch could accelerate the initiation of IGSCC in this counterbore region sufficiently to explain the observed cracking. Moreover, the presence of this counterbore can also have a confounding effect upon the ultrasonic inspection since it produces an ultrasonic reflector in itself which must be distinguished from IGSCC. It is thus concluded that the shop weld counterbore configuration at Hatch Unit 2 played a significant role in the unusually high number of UT indications observed in the recent inspection. J 25
)
4.0 REFERENCES
- 1. "Intergranular Stress Corrosion Cracking (IGSCC) Stress Rule Evaluation for llatch 1 Recirculation Piping," General Electric Company Plant Piping Analysis I Design Memo #170-55 (plus mechanical loads obtained from Piping, Recirculation, Piping and Equipment Loads," Hatch 1 Stress Reports, 22A7604, Rev. O and 22A7605, Rev. 0).
- 2. "Intergranular Stress Corrosion Cracking (IGSCC) Stress Rule Evaluation for Hatch 2 Recirculation /RHR/RWCU Piping," General Electric Company Plant Piping Analysis I Design Memo #170-70, Rev. 2, March 9, 1983 (plus mechanical loads obtained from IIatch 2 stress reports).
I
- 3. Informal Data Transmittal From Wanda Yee, General Electric Site Engineer at Plant Hatch, May,1983.
j 4. "IGSCC Damage Index: Application of the IGSCC Damage Model to BWR Piping and Components," EPRI NP-2807. LD, January,1983.
- 5. " Development of an Engineering Model for Predicting IGSCC Damage -
Particularly in Type 304 Stainless Steel in BWR Water Environments," EPRI NP-2808-LD, February,1983.
- 6. "A Model of Expected Time to Failure By Intergranular Stress Corrosion Cracking in 304 Stainless Steel, First Progress Report, Contract RP-2806-4, FAA-82-5-9, August,1982.
i 7. " Studies on AISI Type 304 Stainless Steel Piping Weldments for Use in BWR
; Application," EPRI NP-944, December 1978.
- 8. "BWR Corrosion Product Deposition Studies," G. Romeo, Draft Report, General Electric Company.
- 9. "Edwin I. Hatch Nuclear Plant Unit 1 Coolant Chemistry Transient Safety Analysis," General Electric Company, NEDO-22134, Class 1, May,1982.
26 # l 4
, , , , , - - . - - - - , - - - , , , .-. -- -. .--.,.n ---m ,,-,. - - - ,
TABLES 1 M
~
)
TABLE 1. SHI A CAltBON CONTENT DATA II ATCil UN.T 1 vs. IIATCil UNIT 2 SYSTEM liATCll 1 IIATCll 2 (SIZE & LOOP) WELD # WELD TYPE SRI %C SRI %C 12" Itecire, A ll-F-1 Branch Conn.-to-Pipe 1.11 .075 1.11 .065 "A" Loop -2 Pipe-to-Elbow t.421 .075 1.44 .065
-3 Elbow-to-Pipe 1.534 .075 1.53 .065
-4 Pipe-to-Safe End 1.266 M75 1.30 .065
-5 Safe End-to-Nozzle - - - -
A R-G-1 Branch Conn.-to-Pipe 1.057 .075 1.11 .075
-2 Pipe-to-Elbow 1.474 .075 1.46 .075
-3 Elbow-to-Pipe 1.557 .075 1.56 .075
-4 Pipe-to-Safe End 1.430 .075 1.33 .075
-5 Safe End-to-Nozzle - - - -
AH-II-l Cross-to-Pipe 1.118 .075 N/A N/A lieducer-to-Pipe N/A N/A 1.15 .075
-2 Pipe-to-1:lbow 1.537 .075 1.55 .075
-3 Elbow-to-Pipe 1.519 .075 1.65 .060
-4 Pipe-to-Safe End 1.382 .075 1.30 .060
-5 Safe End-to-Nozzle - - - -
A R-J-l Branch Conn.-to-Pipe 1.075 .075 1.07 .065
-2 Pipe-to-Elbow 1.476 .075 1.45 .065
-3 Elbow-to-Pipe 1.473 .075 1.56 .065
-4 Pipe-to-Sufe End 1.152 .075 1.30 .065
-5 Safe End-to-Nozzle - - - -
Alt-K-1 Branch Conn.-to-Pipe 1.101 .075 1.05 .070
-2 Pipe to Elbow 1.510 .075 1.45 .070
-3 Elbow to Pipe 1.559 .075 1.47 .070
-4 Pipe-to-Snfe End 1.262 .075 1.27 .070
-5 Safe End-to-Nozzle - - - -
12" Recire. BR-A-1 Branch Conn.to-Pipe 1.114 .075 1.04 .060 "B" Loop -2 Pipe-to-Elbow 1.409 .075 1.40 .060
-3 Elbow-to-Pipe 1.508 .075 1.44 .060
-4 Pipe-to-Safe End 1.255 .075 1.21 .060
-5 Safe End-to-Nozzle - - - -
B R-B-1 Branch Conn.-to-Pipe 1.063 .075 1.06 .070
-2 Pipe-to-Elbow 1.441 .075 1.44 .070
-3 Elbow-to-Pipe 1.447 .075 1.51 .070
-4 Pipe-to-Safe End 1.245 .075 1.26 .070
-5 Safe End-to-Nozzle - - - -
27
/
)
TABLE 1. SRI & CARBON CONTENT DATA ) HATCH UNIT 1 vs. HATC11 UNIT 2 SYSTEM HATCH 1 HATCH 2 (SIZE & LOOP) WELD # WELD TYPE SRI %C SRI %C 12" Recire. BR-C-1 Cross-to-Pipe 1.128 .075 N/A N/A "B" Loop cont'd Reducer-to-Pipe N/A N/A 1.15 .065
-2 Pipe-to-Elbow 1.527 .075 1.53 .065
-3 Elbow-to-Pipe 1.446 .075 1.60 .060
-4
-5 Pipe-to-Safe End 1.346 .075 1.38 .055 *p.
m . Safe End-to-Nozzle - - - - BR-D-1 Branch Conn.-to-Pipe 1.072 .060 1.10 .060
-2 Pipe-to-Elbow 1.510 .047 1.44 .060
-3 Elbow-to-Pipe 1.577 .047 1.53 .060
-4 Pipe-to-Safe End 1.361 .047 1.31 .060
-5 Safe End-to-Nozzle - - - -
BR-E-1 Branch Conn.to-Pipe 1.079 .060 1.11 .060
-2 Pipe to Elbow 1.451 .047 1.43 .060
-3 Elbow-to-Pipe 1.566 .047 1.49 .060
-3a Pipe-to-Pipe N/A N/A N/C .060
-4 Pipe-to-Safe End 1.279 .047 1.29 .055
-5 Safe End-to-Nozzle - - - -
22" Recire AM-1 Cap-to-Pipe 1.134 .059 1.16 .048 "A" Loop -2 Pipe-to-Cross 0.921 0.56 1.13 .056
-3 Cross-to-Pipe 1.041 .059 1.07 .056
-4 Pipe-to-Cap 1.134 .059 0.96 0.54 1BC-1 Br. Conn.-to-22" Pipe 1.072 .060 0.98 .060 IBC-2 Br. Conn.-to-22" Pipe 1.025 .060 0.98 .060 3BC-1 Br. Conn.-to-22" Pipe 1.041 .060 1.01 .060 3BC-2 Br. Conn.-to-22" Pipe 1.063 .060 1.01 .060 22" Recire. BM-1 Cap-to-Pipe 1.134 .059 .096 .048 "B" Loop -2 Pipe-to-Cross 1.037 .059 1.13 .056
-3 Cross-to-Pipe 1.043 .059 1.10 .056
-4 Pipe-to-Cap 1.134 .059 0.96 .048 IBC-1 Br. Conn.-to-22" Pipe 0.990 .060 1.07 .060 IBC- 2 Br. Conn.-to-22" Pipe 0.988 .060 1.06 .060 3BC-1 Br. Conn.-to-22" Pipe 0.982 .060 1.03 .060 3BC-2 Br. Conn.-to-22" Pipe 1.016 .060 1.02 .060 28" Recire. I Nozzle-to-Safe End - - -
"A" Loop 2 Safe End-to-Pipe 1.019 .055 1.08 .045 3 Pipe-to-Elbow 1.319 .059 1.35 .060 4 Elbow-to-Pipe 1.315 .059 1.35 .060 28 y
s p
TABLE 1. SRI & CARBON CONTENT DATA HATCH UNIT 1 vs. HATCll UNIT 2 SYSTEM HATCH 1 HATCH 2 (SIZE & LOOP) WELD # WELD TYPE SRI %C SRI %C 28" Recire. 5 Pipe-to-Pipe 0.935 .056 N/A N/A "A" Loop cont'd Pipe-to-Tee N/A N/A .96 .062 6 Pipe-to-Elbow 1.406 .059 N/A N/A Tee-to-Pipe N/A N/A 0.92 .062 7 Elbow-to-Valve 1.330 .059 N/A N/A Pipe-to-Elbow N/A N/A 1.30 .057 8 Valve-to-Pipe 1.034 .055 N/A N/A Elbow-to-Valve N/A ' N/A 1.03 .057 9 Pipe-to-Elbow 1.499 .069 N/A N/A Valve-to-Pipe N/A N/A 1.01 .045 10 Elbow-to-Pump 1.002 .069 N/A N/A Pipe-to-Elbow N/A N/A 1.46 .056 11 Pump-to-Pipe 1.144 .058 N/A N/A Elbow-to-Pump N/A N/A 1.03 .056~ 12 Pipe-to-Valve 1.056 .058 N/A N/A Pump-to-Pipe N/A N/A 1.13 .041 13 Valve-to-Elbow 1.053 .059 N/A N/A Pipe-to-Valve N/A N/A 1.03 .041 14 Elbow-to-Pipe 1.478 .059 N/A N/A Valve-to-Elbow N/A N/A 1.07 .058 15 Pipe-to-Tee 1.237 .062 N/A N/A Elbow-to-Pipe N/A N/A 1.40 .058 16 Tee-to-Cross 1.018 .062 N/A N/A Pipe-to-Tee N/A N/A 1.24 .062 17 Tee-to-Cross N/A N/A 1.09 .062 18 Cross-to-Reducer N/A N/A 1.04 .063 28" Recire 1 Nozzle-to-Safe End - - - -
"B" Loop 2 Safe End-to-Pipe 1.087 .055 1.01 .045 3 Pipe-to-Elbow 1.484 .059 1.28 .060 4 Elbow-to-Pipe 1.411 .059 1.21 .060 5 Pipe-to-Tee 0.956 .055 N/A N/A Pipe-to-Pipe N/A N/A 0.91 .045 6 Tee-to-Pipe 0.939 .056 N/A N/A Pipe-to-Pipe N/A N/A 0.84 .045 7 Pipe-to-Elbow 1.415 0.59 1.29 .057 8 Elbow-to-Valve 1.020 .059 1.37 .057 9 Valve-to-Pipe 1.041 .055 1.01 .045 10 Pipe-to-Elbow 1.524 .069 1.41 .056 11 Elbow-to-Pump 1.004 .069 1.02 .056 12 Pump-to-Pipe 1.142 .058 1.13 .041 1
29 s 1
)
TABLE 1. SRI & CARBON CONTENT DATA HATCH UNIT 13. HATCH UNIT 2 SYSTEM HATCH 1 HATCH 2 (SIZE & LOOP) WELD # WELD TYPE SRI %C SRI %C 28" Recire. 13 Pipe-to-Valve 1.056 .058 1.03 .041 "E" Loop cont'd 14 Valve-to-Elbow 1.056 .059 1.05 .056 15 Elbow-to-Pipe 1.496 .059 1.32 .056 16 Pipe-to-Tee 1.237 .062 1.24 .062 17 Tee-to-Cross 1.035 .062 1.08 .062 18 Cross-to-Reducer N/A N/A 1.03 .063 20" RHR 1 Tec-to-Pipe 0.920 , .055 1.33 .062 1BC Pipe-to-Br. Conn. 0.897 .070 1.00 .056 2 Pipe-to-Elbow 1.289 .055 1.61 .056 3 Elbow-to-Pipe 1.313 .056 1.56 .056 4 Pipe-to-Pipe 0.826 .056 N/A N/A Pipe-to-Valve N/A N/A *
- 5 Pipe-to-Valve - - *
- 24" RHR 10 Pipe-to-Elbow *
- 2.57 .060 "A" Loop 11 Elbow-to-Valve *
- N/A N/A Elbow-to-Pipe N/A N/A 1.69 .062 12 Valve-to-Pipe 0.773 .070 N/A N/A Pipe-to-Elbow N/A N/A 1.70 .062 13 Pipe-to-Pipe 1.144 .070 N/A N/A Elbow-to-Tee N/A N/A 1.74 .060 14 Pipe-to-Tee 1.121 .048 N/A N/A 24" RHR 10 Valve-to-Elbow *
- N/A N/A "B" Loop __ Pipe-to-Elbow N/A N/A 2.58 .060 11 Elbow-to-Valve *
- N/A N/A Elbow-to-Pipe N/A N/A 1.68 .062 12 Valve-to-Pipe 0.745 .070 N/A N/A Pipe-to-Elbow N/A N/A 1.70 .062 13 Pipe-to-Pipe 1.102 .070 N/A N/A Elbow-to-Tee N/A N/A 1.74 .060 14 Pipe-to-Tee 1.098 .048 N/A N/A 1
- Carbon Steel 30 y
TABLE 2.
SUMMARY
OF RECIRCULATION SYSTEM PIPING CARBON CONTENT DATA FROM TABLE 1. WELDS IN CATEGORY HATCH UNIT 1 HATCH UNIT 2 i RISER MANIF. SUC/ DIS RISER MANIF. SUC/ DIS
<.035 .035 - 0.499 3 10 .05 - 0.599 6 8 23 2 5 12 .06 - 0.699 2 8 8 25 8 12 .07 .08 32 14 40 16 31 41 16 34 9
31 [ y-
TABLE 3 Stainless Steel Pipe Fabrication Information FABRI- WELD WELD CATION WELD PROCEDURE FILM LINE - SIZE TYPE SilEET NUMBER SPEC. LOCATION B31-1RC-12BR-A-1 FW - B-10 15GE 44194-0060 B31-1 RC-12 BR-A-2 SW RD-2-B4 B 102 44303-0029 B31-I RC-12BR-A-3 SW R D-2-B4 C 102 44303-0029 B31-1RC-12BR-A-4 FW - B-15 16GE 44194-0065 B31-1RC-12BR-A-5 SW - - - - B31-1 RC-12BR-B-1 FW - B-11 15GE 44194-0061 B31-1 R C-12BR-B-2 SW RD-2-B5 B 102 44303-0030 B31-1 RC-12BR-B-3 SW RD-2-B5 C 102 44303-0030 B31-1 RC-12 BR-B-4 FW - B-16 16GE 44194-0066 B31-1 RC-12BR-B-5 SW - - - - B31-1 RC-12BR-C-1 FW - B-12 15GE 44194-0062 B31-1 RC-12BR-C-2 SW RD-2-B8 B 102 44303-0033 B31-I RC-12 BR-C-3 SW RD-2-B8 C 102 44303-0030 B31-1RC-12BR-C-4 FW - B-17 16GE 44194-0067&68 B31-1RC-12BR-C-5 SW - - - - B31-1 RC-12 BR-D-1 FW - B-13 ISGE 44194-0063 B31-1 RC-12BR-D-2 SW R D-2-B6 B 102 44303-0031 B31-1 RC-12BR-D-3 SW RD-2-B6 C 102 44303-0031 B31-1RC-12BR-D-4 FW - B-18 16GE 44194-0069 B31-1 RC-12 BR-D-5 SW - - - - B31-1 RC-12BR-E-1 FW - B-14 15GE 44194-0064 B31-1RC-12BR-E-2 SW RD-2-B7 B 102 44303-0032 B31-1 RC-12BR-E-3 SW R D-2-B7 C 102 44303-0032 B31-1 RC-12 BR-E-4 FW - B-19 16GE 44194-0070 B31-1 RC-12 BR-E-5 SW - - - - B31-1 RC-12 A R-F-1 FW - A-10 15GE 44194-0020 B31-1 RC-12 A R-F-2 SW RD-2-A4 B 102 44303-0023 B31-1 RC-12 A R-F-3 SW RD-2-A4 C 102 44303-0023 B31-1 RC-12 A R-F-4 FW - A-15 16GE 44194-0029 B31-I RC-12 AR-F-5 SW - - - - B31-1 RC-12 A R-G-1 FW - A-11 15GE 44194-0022 ! B31-1 RC-12 AR-G-2 SW RD-2-A5 B 102 44303-0021 ) B31-1 RC-12 AR-G-3 SW R D-2-A5 C 102 44303-0021 B31-1 RC-12 A R-G-4 FW - A-16 16GE ~44194-0030 1 4- B31-1 RC-12 A R-G-5 SW - - - - l J^ 32
.i
TABLE 3 Stainless Steel Pipe Fabrication Information FABRI- WELD WELD CATION WELD PROCEDURE FILM LINE - SIZE TYPE SHEET NUMBER SPEC. LOCATION B31-I RC-12 A R-H-1 FW - A-12 15GE 44194-0023 B31-1 RC-12 A R-H-2 SW RD-2-A 8
- B 102 44303-0019 B31-1RC-12 A R-H-3 SW RD-2-A8* C 102 44303-0019 B31-1RC-12 A R-H-4 FW -
A-17 16GE 44194-0031 B31-1RC-12AR-H-5 SW - - - - B31-1RC-12 A R-J-1 FW - A-13 15GE 44194-0026 B31-1 RC-12 AR-J-2 SW RD-2-A6 B 102 44303-0017 B31-I RC-12 AR-J-3 SW RD-2-A6 C 102 44303-0017 B31-1RC-12 AR-J-4 FW - A-18 16GE 44194-0034 B31-1 RC-12 A R-J-5 SW - - - - B31-1RC-12A R-K-1 FW - A-14 15GE 44194-0027 B31-1 RC-12A R-K-2 SW RD-2-A7 B 102 44303-0018 B31-1 RC-12 A R-K-3 SW RD-2-A7 C 102 44194-0018 B31-1 RC-12 A R-K-4 FW - A-19 16GE 44194-0029 B31-1 RC-12 A R-K-5 SW - A-19 - 44194-0035
*Used carbon steel weld rod - removed by grinding, rewelded using 15 & 16 (GE) 7 33 L_ _ _
TABLE 3 Stainless Steel Pipe Fabrication Information FA BRI- WELD WELD CATION WELD PROCEDURE FILM LINE - SIZE TYPE SliEET NUMBER SPEC. LOCATION 2 B31-1 RC-28 A-1 SW 2 B31-1 RC-28 A-2 FW Al 16GE 44184-0001&2 2 B31-I RC-28 A-3 SW RS-2-Al A 102 44303-0037 2 B31-1 RC-28 A-4 SW RS-2-Al B 102 44303-0037 2 B31-1 RC-28 A-5 FW A2 15GE 44194-0003 44194-0004 44194-0005 44194-0009 2 B31-1 RC-28 A-6 SW RS-2-A2 E 102 44303-0041 2 B31-1 RC-28 A-7 SW RS-2-A2 B 102 44303-0041 2 B31-1 RC-28 A-8 FW A3 16GE 44194-0006 2 B31-1 R C-28 A-9 FW A4 16GE 44194-0007&* 2B31-1 RC-28 A-10 SW RS-2-A 3 D 102 44303-0039 2B31-5RC-28 A-11 FW A5 15GE 44194-0010&11 2B31-5RC-28 A-12 FW A6 16GE 44194-0012&l3 2 B31-SRC-28 A-13 FW A7 16GE 44194-0014&l5 2B31-5RC-28 A-14 FW A8 16GE 44194-0016&l7 2 B31-5RC-28 A-15 SW RD-2-A2 A 102 44303-0014 2B31-5RC-28 A-16 SW RD-2-A 2 C 102 44303-0014 2B31-4 RC-28 A SW(FW?) A9 15GE 44194-0018&l9 2B31-4 RC-28 A-18 SW RD-2-A3-2 E 102 44303-0022 2B31-1 RC-28B-1 SW 2B31-1RC-288-2 FW B1 16GE 44194-0040&41 2B31-1 RC-28 B-3 SW RS-2-B1 A 102 44303-0040 2 B31-1 RC-28 B-4 SW RS-2-B1 B 102 44303-0040 2B31-1 RC-28 B-5 FW B2 15GE 44194-0042&43 2B31-1RC-288-6 (Delete) RS-2-82 G 102 44303-0038 2 B31-1 RC-2S B-7 SW RS-2-B2 E 102 44303-0038 2B31-I RC-28B-8 FW B3 16GE 44303-0038 2 B31-1 RC-28 B-9 FW B4 16GE 44194-0046&47 2B31-I RC-288-10 SW RS-2-B3 D 102 44303-0042 2B31-2RC-28B-11 FW B5 16GE 44194-0048&49 2 B31-2 RC-28B-12 FW B6 16GE 44194-0050-52 2 B31-2RC-28 B-13 FW B7 16GE 44194-0053&54 2B31-2RC-28B-14 FW B8 16GE 44194-0055&56 2831-2RC-28B-15 SW RD-2-B2 A 102 44303-0025 2B31-2RC-28B-16 SW RD-2-B2 .E 102 44303-0025 2831-1RC-28B-17 SW(FW?) B9 15GE 44194-0058&59 2B31-1RC-28B-18 SW RD-2-B3-2 E 102 ? 34 i s 1
TABLE 3 Stainless Steel Pipe Fabrication Information FABRI- WELD WELD CATION WELD PROCEDURE FILM LINE - SIZE TYPE SHEET NUMBER SPEC. LOCATION B31-1 RC-22 BM-1 SW RD-2-B3-2 A 104 44303-0028 B31-1RC-22 BM-1 BC-1 SW R D-2-B3-2 B 106 44303-0028 B31-1RC-22BM-1BC-2 SW R D-2-B3-2 C 106 44303-0028 B31-1 RC-22BM-2 SW RD-2-B3-2 D 104 44303-0028 B31-1RC-22BM-3 SW(?) RD-2-B3-2(?) F(?) 104(?) 44303-0028 B31-1RC-22BM-3BC-1 SW RD-2-B3-1 G 106 44303-0027 B31-1 RC-22 BM-3 BC-2 SW RD-2-B3-1 H 106 44303-0027 B31-1 RC-22BM-4 SW RD-2-B3-1 J 104 44303-0027 B31-1RC-22 A M-1 SW R D-2-A3-2 A 104 44303-0022 B31-1RC-22AM-1BC-1 SW RD-2-A3-2 B 106 44303-0022 B31-1 RC-22 A M-1 BC-2 SW RD-2-A3-2 C 106 44303-0022 B31-1 RC-22 A M-2 SW RD-2-A3-2 D 104 44303-0022 B31-1 RC-22 A M-3 SW(?) R D-2-A 3-2 F(?) 104(?) B31-1R C-22 A M-3BC-1 SW R D-2-A 3-1 G 106 44303-0012 B31-1R C-22 A M-3 BC-2 SW R D-2-A3-1 H 106 44303-0012 B31-1RC-22 AM-4 SW R D-2-A 3-1 J 104 44303-0012 35 J
TABLE 4. Nominal Stress Values in Hatch Units 1 & 2 Stainless Steel Pipe Joints (Typical) l STRESS COMPONENT AXIAL STRESS IlOOP STRESS Internal Pressure 6 KSI 12 KSI Dead Weight 0-2 KSI - Thermal Expansion 0~2 KSI - Welding Residual 27-40 KSI 27-40 KSI TABLE 5 ASME Section Ill NB-3600 Design Stress Indices (Typical) INDICES COMPONENT B C K Straight Pipe Weld ..5/1.0
- 1.1/1.0 1.2/1.8 Elbow 1.0/3.3 1.2/4.4 1.2/1.8 Tee 1.0/2.4 1.5/3.2 1.2/1.8 4
Pm+Pb 7 ~ 14 KSI Q 5 ~ 20 KSI F 2 ~ 10 KSI
*X/Y: X = Multiplier on Hoop Pressure Stress Y = Multiplier on Dead Weight and Thermal Expansion Stresse j 36 -
y
TABLE 6
SUMMARY
OF IGSCC STRESS RULE INDICES FOR RECIRCULATION SYSTEM PIPING a) Origin 81 Data HATCH UNIT 1 l HATCII UNIT 2 SRI RISER MANIF. SUC/ DIS RISER MANIF. SUC/ DIS
< 1.0 4 3 5 4 1.0 - 1.2 11 12 15 10 11 17 1.2 - 1.5 18 12 21 13 1.5 - 1.8 11 1 9
> 1.8 4
40 16 31 40* 16 34 b) Adjusted for Counterbore Stress Concentratien HATCH U VIT 1 1 1ATCH UNIT 2 SRI RISER MANIF. SUC/ DIS. RISER MANIF. SUC/ DIS l
< 1.0 4 3 5 4 1.0 - 1.2 11 12 15 10 11 17 1.2 - 1.5 18 12 10 13 1.5 - 1.8 11 1
>1.8 20 40 16 31 40* 16 34 CTotal excludes pipe-to-pipe weld recently found on riser BR-E. SRI not calculated in Ref. 2 37
)
TABLE 7
SUMMARY
OF PLANT OPERATIONAL CYCLES SINCE COMMERCIAL OPERATION HATCII UNIT 1 NUMBER OF SCRAMS TO MINIMUM PRESSURE INDICATED (IN PSI) YEAR 1000-750 749-500 499-250 4249+ Cold Shutdowns 1983 3 - - 1 1982 6 1 - 3 1981 6 2 1 6 1980 13 3 4 5 1979 4 - - 6 1978 10 1 - 4 1977 11 3 1 7 1976 28 4 - 1 HATCH UNIT 2 NUMBER OF SCRAMS TO MINIMUM PRESSURE INDICATED (IN PSI) YEAR 1000-750 749-500 499-250 <249+ Cold Shutdowns 1983 - - - 1 1982 5 3 1 6 1981 6 4 3 5 1980 5 3 1 8 1979 5 3 - 3 l 38 #- 1
! TABLE 8 ASSUMED RELATIONSIIIP BETWEEN CARBON CONTENT AND DAMAGE MODEL CONSTANT D* , C% D f
<.03 60,000
.03.04 24,000
.04 .05 10,000
.05.06 5,000
.06.07 3,600
>.07 3,000 4
4 39 / M?
TABLE 9 1 IGSCC DAMAGE INDEX VERSUS i INSPECTION RESULT CORRELATION HATCH 1 , HATCH 2 WELD DAM AG E* INSP. DAMAGE
- INSP.
LINE - SIZE TYPE INDEX R_ESULT INDEX RESULT 12BR-A-1 FW .67 Not examined .32 Clean 12BR-A-2 Sil .76 Clean .41 .8 *
- Clean 12BR-A-3 5V .87 Clean .47.9 3600 Int. 25%
12 BR-A-4 FW .36 Clean .46 Clean 12BR-A-5 SW N/C Not examined N/C Clean 12BR-B-1 FW .61 Clean .46 Clean 12BR-B-2 SW .8 Clean .62-1.19 3600 Int. 26% 12BR-B-3 SW .8 Clean .7-1.36 3600 Int. 22% 12 BR-B-4 FW .87 Not examined .67 3600 Int. 23% 12BR-B-5 SW N/C Not examined N/C Clean 12 BR-C-1 FW .68 Not examined .45 Clean 12 BR-C-2 SW .97 Clean .58-1.13 3600 Int. 28% 12BR-C-3 SW .81 Not examined .58-1.13 3600 Int. 30% 12BR-C-4 FW 1.02 Clean .49 3600 Int. 32% 12BR-C-5 SW N/C Not examined N/C Clean 12BR-D-1 FW .45 Not examined .36 Clean 12BR-D-L SW .32 Not examined .45 .88 3600 Int.14% 12BR-D-3 SW 32 Clean .53-1.03 3600 Int.17% 12BR-D-4 FW .33 Clean .54 Clean 12BR-D-5 SW N/C Clean N/C Clean 12BR-E-1 FW .46 Not examined .37 Clean 12 BR-E-2 SW .3 Not examined .43 .83 Clean 12 BR-E-3 SW .33 Clean .5 .98 3600 Int. 22% 12BR-E-3a FW N/A N/A N/C 3600 Int. 21% 12BR-E-4 FW .31 Not examined .44 3600 Int.18% 12 BR-E-5 SW N/C Not examined N/C Clean 12 A R-F-1 FW .67 Not examined .42 Clean 12 A R-F-2 SW .77 Not examined .49 .95 -3600 Int. 25% 12 AR-F-3 SW .91 Clean .6-1.16 3600 Int.10% 12 AR-F-4 FW .89 Not examined .6 Clean 12 AR-F-5 SW N/C Not examined N/C Not examined 12 A R-G-1 FW .6 Not examined .52 Clean 12 AR-G-2 SW .84 Clean .65-1.26' 3600 Int.14% 12 AR-G-3 SW .9 Clean .77-1.51 3600 Int.15% 12 AR-G-4 FW 1.07 Clean .78 Clean 12 A R-G-5 SW N/C Clean N/C Not examined.
- Damage index at time of inspection (Unit 1 = 7 years; Unit 2 = 3.5 years)
- A-B: A = Damage it.dex based on original GE stress data B = Damage Index adjusted to account for counterbore SCF or #
grinding, as appropriate. 40
TABLE 9 IGSCC DAMAGE INDEX VERSUS INSPECTION RESULT CORRELATION HATCH 1 HATCH 2 WELD DAMAGE
- INSP. DAMAGE
- INSP.
LINE - SIZE TYPE INDEX RESULT INDEX RESULT 12 A R-H-1 FW .67 Not examined .57 Clean 12 AR-H-2 SW .97 Clean .74-1.45** 3600 Int.10% 12AR-H-3 SW .89 Clean .62-1.23 3600 Int. 30% 12 A R-H-4 FW 1.02 Clean .65 Clean 12AR-H-5 SW N/C Not examined N/C Not examined 12 AR-J-1 FW .63 Not examined .38 Clean 12 A R-J-2 SW .89 Clean .51 .99 3600 Int. 23% 12 A R-J-3 SW .89 Clean .6-1.17 3600 Int. 20% 12AR-J-4 FW .76 Not examined .57 3600 Int. 28% 12 A R-J-5 SW N/C Not examined N/C Not examined 12AR-K-1 FW .66 Clean .45 Clean 12AR-K-2 SW .95 Not examined .6-1.16 3600 Int.19% 12 AR-K-3 SW 1.01 Not examined .67-1.3 3600 Int. 6% 12 AR-K-4 FW .9 Not examined .69 Clean l 12 AR-K-5 SW N/C Not examined N/C Not examined 22BM-1 SW .25 .73 Axial, 64% .10 .76 Cire. 40% 22BM-1BC-1 SW .36 Clean .34 Outside HAZ 22BM-1BC-2 SW .36 Clean .33 Clean 22BM-2 , SW .38-1.01 Clean .3.87 Geometry 22BM-3 SW .36.99 Clean .29-85 Geometry 22BM-3BC-1 SW .35 Clean .31 Outside HAZ 22BM-3BC-2 SW. .37 Clean .29 Outside HAZ 22BM-4 SW .25.73 Axial, 67% .15.76 3600 Int. 37% 22AM-1 SW .25.73 Axial, 63% .15.76 Cire., 42% 22AM-1BC-1 SW .44 Axial,12% .26 Outside HAZ 22AM-1BC-2 SW .4 Clean .27 Outside HAZ 22AM-2 SW .24 .77 Clean .29 .86' Geometry 22AM-3 SW .38-1.02 Clean .28 .83 Geomtery. 22AM-3BC-1 SW .42 Clean .29 Outside HAZ 22 A M-3BC-2 SW .43 Clean .29 Outside HAZ 22AM-4 SW .25.73 Axial, 72% .23.76 Cire.19%
- Damage Index at time of inspection (Unit' 1 = 7 years; Unit '2 = 3.5 years)
*
- A-B: A = Damage index based on original GE stress data B = Damage index adjusted to account for counterbore SCF or grinding, as appropriate 41 s t
..m- _._______m__ __m_. .__
TABLE 9 IGSCC DAMAGE INDEX VERSUS INSPECTION RESULT CORRELATION HATCH 1 HATCH 2 l WELD DAMAGE
- INSP. DAMAGE
- INSP.
LINE - SIZE TYPE INDEX RESULT INDEX RESULT 28A-1 SW N/C Clean N/C Clean 28A-2 FW .32 Clean .13 Clean 28A-3 SW .3 9-1.03 *
- Not examined .4-1.0** Cire.12%
i 28A-4 SW .39-1.03 Not examined .35.89 3600 Int.17% , 28A-5 FW .27 Not examined .26 Clean 28A-6 SW .45-1.11 Not examined .24 .63 Geometry 28A-7 SW .45-1.11 Not examined .27 .78 3600 Int. 8% 28A-8 FW .33 Not examined .27 Clean 28A-9 FW .75 Not examined .12 Clean 28 A-10 SW .49 Not examined' .36 Cire.10% 28 A-11 FW .44 Not examined .26 Clean 20 A-12 FW .38 Not examined .09 Clean 28A-13 FW N/C Not examined .08.77 Clean 28A-14 FW .39 Clean .29 Clean 28 A-15 SW .46-1.13 Clean .32 .86 Geometry 28 A-16 SW .38 .95 Not examined .34 .84 Geometry 28A-17 SW(FW?) N/A Not examined .27 Clean 28 A-18 SW N/A Not examined .32 Clean 28B-1 SW N/C Not examined N/C Not examined 28B-2 FW .24 Not examined .11 Clean
.28.75 28B-3 SW .51-1.3 Clean 3600 Int.15%
28B-4 SW .47-1.23 Not examined .25.68 Geometry 28B-5 FW .27 Not examined .09 Clean 28B FW .27 Not examine,d N/A N/A 28B-7 SW .46-1.19 Clean .28.8 3600 Int.18% 28B-8 FW .38 Not examined .31 3600 Int. 7% 28B-9 FW .34 Not examined .12 Clean 28B-10 SW .78-1.44 Clean .35 .98: 3600 Int. 20% 28B-11 FW .49 Not examined .25 Clean 28B-12 FW .43-1.17 Not examined .1 .87 Clean 28B-13 FW .38 Not examined .08 Geometry 28B-14 FW .4 Not examined .26 Clean 28B-15 SW .44-1.26 Clean .26 .79 3600 Int. 23% 28B-16 SW .46-1.13 Not examined .35 .85 Geometry 288-17 SW(FW?) .39 Not examined .26 Clean 28B-18 .SW N/A Not examined .32 Clean
- Damage Index at time of inspection (Unit 1 = 7 years; Unit 2 = 3.5 years)
" A-B: A = Damage index based on original GE stress data B =~ Damage index adjusted to account for counterbore SCF or -
grinding, as appropriate ' d
'42 s e
l TABLE 10. Comparison of Baseline Radiography to Current Ultrasonic l Ibsults for Unit 2 l INDICATION LINE - SIZE MAXIMUM SIZE REMARKS 12 BR A-1 Nothing. Counterbore is 1/4" from root on pipe side. Branch connection has counterbore , f 1" away. No grinding. I 12 BR A-2 Nothing. No grinding. Counterbore 1/4" from root edge of weld. , 12 BR A-3 25% just adjacent to Counterbcre 7/16" from root root. Not in counter- of weld. No grinding. Smooth bore. Low DAC ~40% transition on elbow side. (pipe side), indication intermittent 3600 around weld. 12 BR A-4 Counterbore geometry Minor counterbore 3/8" from (1/2" from weld root). root on pipe side. Smooth on safe end side. 12 BR D-1 Root geometry only. Minor counterbore 3/8" from root on pipe side. Minor counterbore on branch 9/16" from root. 12 BR B-2 26% on pipe side ~ 1/8" Counterbore 3/8" on elbow, from root, essentially 1/4" - 5/1G" on pipe (no grinding). 3600 arcund weld. Gradual counterbore, not sharp
, transition.
12 BR B-3 22% in pipe side and 21% Counterbore sometimes tapered on elbow side. 1/16" sometimes sharp 7/16" to 1/4" from weld edge on elbow. from weld on pipe side. Gentle 1/2" from weld on pipe taper on elbow side. No grinding. side, essentially 3600 i around weld. 12 BR B-4 23% on pipe side. 3/4" Hand prepped. Possible evidence from root of weld. of repair. No real counterbore. DAC N85-40%, inter- No grinding after welding. Trans-mittently 3600 around ition is in the 3/4" to 1" distance wcid. from weld root. 12 BR C-1 Root geometry only Minor counterbore 3/8" from root on pipe side. No counterbore on L branch. i l 12 BR C-2 28% on pipe side or -1/4" Counterbore 3/8" - 1/2" on pipe from root of weld, essen- side; 9/16" on elbow side. .More
- l. tially 3600 around weld.
gentle on ' elbow side. Elbow side may have been hand ground. post weld grinding. - w. 43 2
TABLE 10. Comparison of Baseline Radiography to Current Ultrasonic (cont'd) Results for Unit 2 INDICATION LINE - SIZE }1AXIMUM SIZE REN ARKS 12 BR C-3 30% of wall on pipe side Counterbore 5/16" - 3/8" from 5/16" from root, inter- root on pipe side, 5/8" - 7/16" mittently 3600 around on elbow side. No post weld weld. grinding. Counterbore sharp on both sides of welds, sharper on pipe side. . 12 BR C-4 32% pipe side,1/4" Minor counterbore 3/8" from root from root, inter- on pipe side. No counterbore on mittently 3600 around safe end side. weld. 12 BR D-1 Nothing Counterbore is 3/8" pipe side; 1/2" branch side. No grinding. 12 BR D-2 14% on pipe side Counterbore 1/4" on pipe side 3/16" from edge of weld, 7/16" on elbow. Sharp on pipe intermittently 3600 side, gradual on elbow side. No around weld. post weld grinding. 12 BR D-3 17% on pipe side, 3/16" Counterbore 3/8" on pipe side, from root of weld, 7/16" - 1/2" on elbow. Sharp on essentially 3600 around pipe side, gradual on elbow side. weld. No post weld grinding. 12 BR D-4 No indications. Minor to none counterbore on pipe side, 3/8" from root. No counter-bore on safe end. 12 BR E-1 Root geometry. Minor counterbore 3/8" from weld pipe side. Nothing on branch side. 12 BR E-2 Nothing. Counterbore on both sides gradually tapered. No real counterbore. No post weld grinding. 12 BR E-3 18% on pipe side,1/8" Counterbore on pipe side is gradual from weld edge. Right 5/16". No counterbore, gentle at the toe of the root taper on elbow. No post weld on the elbow side (22% grinding. through wall), essentially 3600 around weld on both ' sides. 12 BR E-3A 21% on pipe side, inter- Pipe to pipe field weld. mittently 3600 around weld. 12 BR E-4 18% on pipe side,1/2" Counterbore minor pipe side 3/8". from root, intermittently No counterbore safe end side s-3600 around weld. 44 } L
TABl.E 10. Comparison of Bmehe Radiography to Current Ultrasonie (cont'd) Results for Unit S INDICATION LINE - SIZE MAXIMUM SI7E REMARKS 12 AR F-1 No apparent defects. Minor counterbore 7/16" from weld on pipe side. Nothing on branch side. 12 AR F-2 25% on pipe side, Counterbore is 1/4" from root on 3/16" - 1/4" from root, pipe side, S/8" on elbow. Sharp intermittently 3600 on pipe side, not so sharp on elbow. around weld. No post weld grinding. 12 AR F-3 10% on pipe side,1/8" Counterbore is 1/8" - 3/16" from
- 3/16" from root root on pipe side,1/2" on elbow (rechecked to confirm side. Sharp on pipe side, more it not counterbore), in- gradual on elbow side. No post termittently 3600 weld grinding.
around weld. 12 AR F-4 Counterbore 3/4" from Very minor to no counterbore root on pipe side. 3/8" on pipe side. Nothing o.n safe end. 12 AR G-1 Nothing. Radiograph not examined. 12 AR G-2 14% on pipe side, Counterbore is 5/16" - 3/8" from 3/32" from root, essen- root on pipe side; 7/16" elbow. tially 3600 around weld. Sharp on both sides. No post weld grinding. 12 AR G-3 15% on pipe side,1/4" Counterbore is 1/4" on pipe side, from root on pipe side, 3/8" on elbow. Sharp on pipe essentially 3600 around side, less sharp on elbow. No post weld. weld grinding. 12 AR H-1 Nothing. Counterbore is 3/16" from root on both sides. No post weld grinding. 12 AR H-2 10% on pipe side, 3/16" Counterbore is 3/16" on pipe side, from root, intermittently 1/2" on elbow. Sharp on pipe side, 3600 around weld. less sharp on elbow. No post weld i grinding. 12 AR H-3 30% on pipe side. Counterbore is 5/16" from root on 3/16" from edge of weld, pipe side, feathered ~in on elbow side. essentially 3600 around No post weld grinding. weld. 45
TABLE 10. Comparison of Baseline Radiography to Current Ultrasonic (cont'd) Results for Unit 2 INDICATION LINE - SIZE MAXIMUM SIZE REMARKS 12 AR J-1 O.D. geometry. Counterbore (minor to none) on pipe side, 3/8" from weld. Nothing on branch side. 12 AR J-2 23% on pipe side. Counterbore is 3/8" from root on 3/8" from we!d root, ipe side, 3/8" on elbow. Sharp intermittently 3600 on pipe side, gradual on elbow around weld. side. No post weld grinding. 12 AR J-3 20% on pipe side, Counterbore is 3/8" from root on 3/16" from weld root, pipe side, S/8" on elbow side, intermittently 3600 Sharp on pipe, gradual on elbow. around weld. No post weld grinding. 12 AR J-4 28% indication 5/16" Counterbore pipe side 3/8" minor from root, intermittently to none. Nothing on safe end 3600 around weld. side. 12 AR K-1 12 AR K-2 19% on pipe side, Counterbore is 5/16" from root on 1/8" from weld root, in- pipe side, 3/8" on elbow side. termittently 3600 Sharp on both sides. No post weld around weld. grinding. 12 AR K-3 6% on elbow side right Counterbore is 5/16" from root on at the root (may be pipe side, no noticeable counterbore nothing), intermittently on elbow side. No post weld 3600 around weld. grinding. Counterbore on pipe side so gradual as to be difficult to find. J 46
.p.
Table 10. Comparison of Baseline Radiography to Current Ultrasonic , (cont'd) Results for Unit 2 INDICATION LINE - SIZE MAXIMUM SIZE REMARKS 1RC-22 AM-1 Pipe side indications 25-1/2" Radiograph not examined. and 9" long, cap side indi-cations. 53" and 7-1/2" long, maximum size varies from
~
14% to 42% IRC-22 AM-2 ID geometry. Relook Counterbore pipe 1/2". Counterbore next outage. cross 3/4". Ground flush 40E 1RC-22 AM-3 ID root geometry. Relook Counterbore pipe & cross 3/4". next outage. Ground flush. IRC-22 AM-4 19% pipe side approxi- Radiograph not examined. mately 60" long. 22 BM-1 BC-1 No indications . No counterbore. Ground 3600 (All branches ground.)
~
1RC-22 BM-1 40% in. end cap, 25-1/2" Counterbore 3/8" from root on and 5-1/2" long,16% on end cap side. Intermittent post pipe side, approximately weld grinding. 27 inches long. IRC-22 BM-2 ID geometry 0.3" from Ground flush in repair areas. weld on manifold side. 40% of circumference. Minor Relook next outage. counterbore, pipe cross 3/4" from root. IRC-22 BM-3 ID geometry at root. Ground flush. Counterbore Relook next outage. heavy, pipe & cross 1/16" from root. s, IRC-22 BM-4 3600 intermittent, Counterbore S/16" from root on - 37% in pipe side,1/16" cap. Counterbore on pipe side from edge of weld; is 1" from root. 30% on cap side, / 3/16" from edge of weld. ( i
.t f h .'
u 47 ,- y , T
7
- TABLE 10. Comparison of Baseline Radiography to Current Ultiosonic (cont'd) . Results for Ubat 2 INDICATION LINE. - SIZE MAXIMUM SIZE -
REMARKS-24 A-1 Combustion Eng. Radiograph Radiograph not examined.
. 28 A-2 Nothing Minor counterbore 3/8" open from weld. Root blended in places.
28 A-3 12% indication. elbow Ground flush. Counterbore 3/8" pipe side,1/4" from weld side, no counterbore elbow side. root, approximately 5-1/2" in length.
. 28 A-4 17% elbow side, 3/16" Ground flush. Counterbore 3/8" pipe side, no counterbere elbow from weld root, inter-mittently 3600 around side.
weld. 28 A,5 Nothing Counterbore 7/16" on pipe side. No counterbore elbow side. No
. grinding.
/ 28 A-6 Nothing. Counterbore to counterbore is 1".
, Root is. ground d600 28 A-7 8% pipe side,1/4" froni ~ Counterbore 3/8" pipe side, no root,13% right at root counterbore elbow side. Ground elbow side, approximately flush.'
3600 around weld on both sides.
~ 28 A-8 OK Counterbore 1/2" valve side. No counterbore elbow side. No grinding. .
. 28 A-9 OK- No counterbore on either side.
, No grinding.
28 A-10 10% pipe side,1/4" Heavy:'counterbore 3/8" ~on _ elbow side.
^' from weld root,1-1/4" Minor counterbore pipe side 3/8".
in length. ' No grinding. 28 A-11 iOK , Very, minor counterbore 1/2" on pump side. Nothing on elbow. No grinding. 28 A-12 No film , Radiograph not examined. 28 A-13 OK Some grinding 40% of. circum-ference. Minor counterbore 3/8" on pipe side.
^ '
7 28 A-14 OK ; No counterbore either side. No grinding. H im JY . . 48
'~
t
TABLE 10. Comparison of Baseline Radiography to Current Ultrasonic (cont'd) Results for Unit 2 INDICATION LINE - SIZE MAXIMUM SIZE REMARKS 28 A-15 OK, relook next outage. No counterbore, ground flush 3600 around pipe. 28 A-16 OK, relook next outage. Counterbore tee side 5/8", ground flush 3600 28 A-17 OK Counterbore tee side 5/8", no counterbore cross side. No grinding. 28 A-18 No Film Radiograph not examined. 28 B-1 No Exam 28 B-2 Nothing Counterbore, very minor pipe size 3/8". No grinding. No counterbore elbow side. 28 B-3 15% pipe side, essen- Ground flush,1/2" counterbore, tially .1600 around weld. pipe side. 28 B-4 Reloiak Ground flish. 7/16" counterbore pipe side. 28 B-5 Nothing No counterbore either side. No grinding. 28 B-6 No Weld 28 B-7 18% pipe side, 3/16" Ground flush. 7/16" counterbore from root, essentially elbow side. 3600 around weld. 28 B-8 t 7% elbow side, 3/8" No counterbore. No grinding. from root, intermittently 3600 around weld. 28 B-9 Nothing No counterbore. No grinding. 28 B-10 19% pipe side,1/4" No counterbore. Ground flush. from root. 20% elbow side, 3/16" from root, essentially 3600 around weld on- both sides. 28 B-11 Nothing No counterbore. No grinding. 28 B-12 Nothing Ground flush in one area. No-counterbore.- 49 ;
}
TABLE 10. Comparison of Baseline Radiography to Current Ultrasonie . (cont'd) Results for Unit 2 INDICATION LINE - SIZE MAXIMUM SIZE REMARKS 28 B-13 OK, relook next outage. No counterbore. No grinding. 28 B-14 OK, ID root geometry No counterbore. No grinding. 28 B-15 23%. elbow side,1/8 Ground flush, No counterbore, from root, essentially 3600 around weld. 28 B-16 OK, relook next outage. Ground flush. No counterbore. 28 B-17 Nothing Very minor counterbore,1/2" on tee side. No grinding. 28 B-18 ID root geometry. Radiograph not examined. . 50 7 b
TABLE 10. Comparison of Baseline Radiography to Current Ultrasonic (cont'd) Results for Unit 2 l l INDICATION LINE - SIZE MAXIMUM SIZE REMARKS l RHR 20-RS-1 Nothing No radiograph examined. RHR 20-RS-2 13% of pipe wall at Counterbore is 3/8" from weld on l root ( 0.1" into HAZ), pipe side. No grinding. intermittently 360o around weld. RHR 20-RS-3 14% on pipe side, 360% grinding. Can't find weld intermittently 3600 root. around weld. RHR 24-AR-10 Nothing 1/2" from weld. No grinding. RH R-24-A R-11 Nothing Counterbore elbow side 1/2". None pipe side. No grinding. RHR-24-AR-12 Nothing No counterbore. No grinding. R H R-24-A R-13 Nothing Heavy counterbore elbow & tee 5/8" from weld. No grinding. RHR-24-BR-10 Nothing Counterbore pipe & elbow 5/8". Ground 3600 RHR-24-BR-11 Two indications elbow Counterbore pipe and elbow side; first is 5/8" long, 11/16" from root. No grinding. 11% wall, second is 10-9/16" long,12% wall. One indi-cation pipe side, 5/8" long, 18% of wall. RHR-24-BR-12 OK, relook next outage. Heavy counterbore 3/4" pipe side. Minor counterbore elbow approxi-mately 3/4". No grinding. RHR-24-BR-13 OK Counterbore in elbow 5/8" from root. In tee 3/4". No grinding. 51 ;;
,7
TABLE 11. Grinding of Recirculation System Suction & Discharge Piping 4 i WELD TYPE TOTAL WELDS # CRACKED /# GROUND # CRACKED /#UNGROUND Shop Weld 15* 7/12 1/1 Field Weld 16* 0/2t 1/14 TPart of circumference ground.
- Incomplete information on several welds.
52 ,
- j. _
t !
, .i
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i TABLE 12. Ultrasonic Indications For Each of the Stainless Steel Pipe Systems
-[,
Number of Indications No. of Welds Location of Indication
- Shop Field Weld System Welds Welds Root Counterbore HAZ Othert Riser 18/20 4 10 6 5/21** 2 2 End Cap ** 4/4 1 1 20"RHR 2/3 1 24" RHR 1/8 2 28" Reciret I 8/15 1 2 6 1/1 1 i
l t Outside exoected HAZ . l Number of indications may exceed total of welds because of cracking in i both HAZ's. l
** Incomplete data, l
it Uncertain whether 28A-17 and 28B-17 are shop or field welds. L [
/
53 g
i i
]
APPENDIX A WELD PROCEDURE SPECIFICATIONS FOR UNIT 2 i SIR-83-001
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Rev. 0
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....W ... evuuas K E L incoarea LOGG AnoC O M P A N Y Sheet 1 of 5 -
PlPING FA8RICATeoN - - i l ' 'tILLIAMSPORT. PA. 1770s spec No- r8-xt-rs-s"^w-tt-2c Referei12. 0,n-y Date: 3/29/68 Rev. Date: 2/19/70
. . Rev'. Date: 6/11/71
- . , 11-12-71*
- Added 3 A of 5 -
TITLE: SPECIFICATION FOR WELDING OF Austenitic S.S. Pipe SCOPE: This specification covers preparatien, welding, weld finish, inspection' . and heat treatnient of: Austenitic S.S. Pipe . . BASE METAL: ASTM-A312-TP304 - FILLER METAL: ASTM-A371-ER 308 and AS m-A298-E 308 , , ,
~
SLIB AuC FLt!X: None . INSERT METAL: ASTM-A371-ER308
- a F, . . TUNGSTEN ELECTRODE: 27. Thoriated-AWS EWTH-2
~
TORCH INERT GAS- Shall be ARGON 20 CFH, HELIUH --- CFH, Purity 99.9957. minimum. BACKING: Prior to welding, the I.D. of the root' of the weld shall be purged with
' Argon Gas. Purge time shall not be less than that shown on Chart K-lGBP for each.
pips size to assure that the oxygen content is below 0.57.. . POSITION: Welding shall be donc in the Fixgd Vertical Pipe Position (2G), no down-wIrd welding shall be permitted. PROCESS: The welding she'i be don'c by th'e GTAW (Root), SMAW' (Build-Up). - - CURR ENT: The current used shall be shown on Sheet #3' . PREHEATING AND INTERPASS TEMP. : None, Interpass Temp. 350' F. Max. POST HEAT-TREATMENT: None . '. . e . f , ,. ,
.i .. : :- : * / .
no . A-1 - 4 . . . . . , , . . . . .
Coav l{ l Ygg u.W.KELLOCG CouPANY
..........,euttuas i>.ccaroaatco Ecet 2 M h PlPlNG r Afi A lt Af l oN 9 witLIAusroRT. PA. 1770s _,
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[ Date: 3/28/68 Rev. Date: --2/19/70 - - - - - - Rev. Date:-- 6/11/71
~
~
l
- 11-12 - --
Base Metal Preoaration: The edges or surfaces of the parts to.he joined by.. welding 1 i shall be prepared by ikgoroanctnn plasma arc, grinding, machinin'g or any combin. i l a tion of methods to form the geometry of the weld shown-on Sheet #3.-- Surfaces for . welding shall be clean and free from paint, scale, rust or other foreign materials
- that are detrimental to quality welding. -
I Cleaning: All slag or flux remaining'on any nead of weld metal or on adjacent base f ' metal shall be removed before depositing the. next successive head. Stainless Steel wire brushes shall be used which have not bee . previously used on any metal but S.S. ~ Weldine Technique: Welding technique shall ubstantially be performed as shown on , Sheet #3. - I Underside Groove Jrecaration: None 1 Defects: All defects in welds requiring.repates shall be removed by grinding, arc, chipping, gouging, Xbol:ut or machining. Re sair welds shall be accomplished to a
' qualified procedure and the method of examir.ation shall be the same as_ for the ori-
/ ~g inal weld. - --
\ - . . ..
-Equioment:-- The-machine source of curren shall have a good regulation over the entire range of current required. For GTAW a-remote foot control shall be used to initiate high frequency, are starting, current decay, to climinate crater indications.
Records: Records shall be kept of welders', operators qualifications dates, proce. dure qualifications dates, symbols and all *prtinent information as to process and-radiographic inspection. . s Appearance of W. Idi'ne Beads: Each weltline bead shall show complete fusion to-adjacent weld ueposit and to base metal. 'The finished surface of the weld shall merge ' smoothly into the component surface. . inspection: Inspectior shall conform to applicab'le job code. , Electrode Condition: All low hydrogen electrodes and flux shall be kept in a dry rod oven at temperatu res recommended by electrode manufacturers to minimize moisture
~ -
absorption. . . Wel There shall be a minimurr. amount of interruptions du' ring weld-h i ng.. dine Sequence: Pipe in a fixed vertical position (2G), the maximum width o be three (3) times the core diameter of the c'ectrode being used. .- Pipe in a ' fixed horizontal position (SG), the maximum width of a weld bead shall be 1- 1/4 ". The maximum thickness of any layer, except. che first layer shall be 5/32.
~
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( . ' *. .-- -_- _ _ _ . . .
- 11. w . ILE l l o s t C O B P n M T Sheet 3 uf' 5 ,
T,H t. ... . ... .. rm i u s ini.oaeoa al s o - - - picino rannic.ation . ci tt.: Ausreint , cA. :)708 3,,, c , g,,, g,g y3 3g;n.9c 114Le- . . , 3/28/68.. __
. . _ ~.,, . ; -
Itev. 11a t e , ,2/J9/'/0, . . . Rev. Date: 6/11/71 -
- 11. 12-71 .,
~
. GROOV E I)l; Tall.S ' W E;1, DIN (i T ECllNIQU ES. j,! _ .
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i , Pass No;. Fille r Fille r Torch Tungsten
. Am p's Volts Polarity 8 Gas ,
Size and ,-
.and Metal Metal Proc e s s Type Size Max. Flo Rate Polarity 1 Insert , Argon 3/32 Dia.
1 1/8 x5/32, 85-95 13 Straight 20 CFl! Straight CTAW ER 308 2-3 3/32 45-80 24 ., SMAW E 308 1/8 70-110 25
- Reverse ---- ---- _
70-110 25 L 4 1/8 , SMAW E 308 5/32 90-140 26 Reverse ---- ---- ,. 11-15 5/32 90-140 26 , ! SMAW E 308 3/16 130-180 27 Reverse ---- ---- r 1 C 9_ Bare wire may be used for '.ntermitter.t ' CNOTE: voids or mismatch 'in root set-up.. Fy: M ' _/W-TitlI: ,. ~ Vf 6 1rli n i K ir;t n c e r A .
-- . . . . . . . '. .- . . - . .... - . _~ .. .. . .. _.. . , , _ , , _ , , _ _
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i Spec. > No. .E.8 -EL-E4. .SM AW . I 1 2G [ 11 12 71
~
II,it e: lle". Date: ' q 1 n r - l . . t GROOV E DETAILS - VIRI. DING TECHNIQU ES (
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Title:
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Tilt E.W. KELL 0tG COHPANY'
......... ..evu mas incoereouse
.' PIPIRS FAnkiCATI0a RECOMMENDED FO!!M Q-1 MANIIFACTilitEll's REcont) 0F KEl. DING PROCEDURE .
C, , QtlAl.lFICAT.ON TESTS 5pecification N., _P9-KI-FS-SMAW-11-2G n.., 3/28/68 Rev. Date 2/19/70 weldias Process d'PW & SI'W Manual or Machine _ M. - - -- 8 , io P.No. 8 Maeerial specification - A312 to A312_ o, p.No. _ .. Dickness (if pipe. diameter and =all ihicknens! . 6-3/8",_QA_x_,,718" Thk. j Dicknese Range this tea r qualifica _)/.J6."_tD 1.4" Filler Metal Group No. F. 5___and_ F-7 Ft.UX OR ATMOSPHERE Weld Metal Analysis No. A- 7 Flus Trade Name or ( omeusision
' Describe Filler ucial if not included in Table Q-il.2 imte Gas (.omposition __ . Argon ,
Flow Rae, 20 CFH et QN II.2 _ Trade Name la atacking strip used' None
'[
For osyncerylene =cidins-State if Filler Metalis sit. ' icos ce aluminum killed. Echen: Temperature Range See Sheet 1
. WEl. DING PRO ("EDURE larerpass Temperseure Range E r' e Sheet 1 ,
Siaste ce Wisiple Pese ML11tiDie W sehen: Treatmesis See Sheet 1 ,,' single or Mulsiple Are Sinele , Position of Groove Ferirontal (2C) (c.ce Pars. & Fias. Q 2 at Q 4 oc QN 2 4 QN.3) s
. (Fses. siw6seenes. veeences se evenness. il verus es. .seee =neener isi. ee va ee-a. ee s , 3 l.
~'
FOR INFORMAT10N ONI.Y i Filler Wire-Diam,,,, 3/32, 1/8, 5/32 wEl.nisc rErnNIQutS ',! _ . Trade'Nana, Chromend - Chromenar Jo.no nimensions Accord wish Sketch Type of liseking Arron Gas , 45-140,oi,,13-26 ,ncbe per ein.
-i- .
ruerene DC p ga,;i, Strainht (GTAW) , Fevehead or Itachhand
- RFDilCED SECTION TENSil.L TSST (Figs. Q4 and QN fil Reverse (SMAW)
! 'l III'E'aste l'ai Charersee of Failure
- Specimen No. Area 't and 1.oension
* "# Eidah 1heckness I ud. lb. N "' Pss 9.2/1 .759 .458 .348 30,600 . 86,200 Basc Metal 9.2/2 .754 ' .469 .354 31,200 88,000 Base Matal
" CUIDED llEND TES1?i(Fige. Q 7.1. Q 7.2 QN 7.I. QN 7.2 QN 7.))
. Type end g,, ,g ,~ -~ . Type and gg ,
Esgure No. Segure No. Q-7.1 Bent 180 * - OK 9'7*I Bent 180' - OK SB-1 SB-3 1 Bent 180' - OK Bent 180* - OK , !- -Results of I'illenwelJ Test s. Fig. Q 'xe I -
~
l welder's Name H. Knarr ria k Nii. 82 3 , no. BT - Mo by virsue of these seses meets =tider perfoemaner requirements. Test Conduesed by Frank Richards I.sho,sio,y_r,s, No. 71-35-9 . per Te ecreify shot the assiements in this secord see coreces anJ' ther she sese welda were prepared. welded anJ. ' tested in accordante wish she realwiremente of Section IX of she ASME Code. l *
- signed The M. W. Kellogg cou:nany
<msen.d eou wee n D
page 3/28/68 - py w _ (peneil of record of eeses are illustrative only and may be modified so confor[o che type sad number of sesas , reepsired by the rode. Recogunended Furm Q l is available for purchase se ASMI*.lleeJguassee..) NOTE: Any essensial varialJen in aJJieion so shoac above shall be recoeded. ,
' ~
Prinsed in II.S.A. (11/g) This l'orm is obseineble froen she ASME.141 E. -87 h Se., New Ye CN.y 100l? A-b -- --__.___. .. _.. ___-- --
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. int W. K!LLOCG COMPANY *
.... .W. .. .. co.i u u. in....u .. m o i
P I r t h. 6AHAILAlld4 _. httLIAuSPORT. PA. 17708
- No. .K.IcnP
^ --
Date: $/6/iO
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._1 , . -w * .Rev. - Date: -_7/20/72
~ . _. .
- ~ - -_ . . .
i . . TIT 1.F.: Argon cas Backup Purging che.rt for pipe of various inside{ diameters.
~
F- - _ _ __ . r_ l SCOl'M: The following purge times for Argon' das Backup Purging were derived at. by actual testing. Various I.D. pipe 12" long scaled off at both ends to represent dams were used. Argon Gas was purged into one end of the pipe"a'nd ~out'- the opposite l end into a neckman Oxygen Analyzer. .
~ . .
3'- -
~~ Argon Cas
'~
Bleed Hole- Purge Time- Oxygen Analyzm (Sizei (Min.) Reading 8- Size Schedule (CF11) , i .. .
' 2.5" S/40' E 25 -
~ ' ~
1/8 '1-1/2 - Below 0.5%
" 25 S./40 - ' ..-. T./8 " . '-., ., __1_.172. . . . g... '. .. Below 0. 57.
". ( ~3. . . .
. n - ;.. . - . .. ... .- _ . , . _ _ -
3.5" S/.40 25 1/8" 2 -
, Belew 0.57.
,2 - ,4 . " 'S/40 25 : 1/8" .
-2 <
, Below 0.57.
'- ' Below 0.57.
- 5. " 'S/40 -
25 . .* ?1/8"
. 3' -
. n'h .
'E Below 0.57.
" 4' -
- 6. " S/la 0__ 25 1/8" - -
S/40 1/8" 6 Below 0.5%
- 8. " , . :_. . . . 25 . .\.5."...
. ~
10." S/40 '25.. - ~ _. 1/8" - 10 , Below 0.5% l . . . . 12." s/40 . 25 .1/8" 12 Below 0.57.
. ?. . ..~. ' .
14." - S/40 25' 1/8" 14 . Be' low 0.57. l 16"
.s/40 - . . ._ -25 '.-- -1/8" --
; -Belov 0.5%
18" S/LO ~ 25
- 1/8"' .. -25 -
Below 0.5% 20" s/h0 .- 25 - - - - -
---1/8" 30 -- Below 0.5%
2h" S/ho. 25 - 1/8" 45 ' Belov 0.5% 30" s/30 --
- 25 ' .- - ----1/8"'
70 - ..- , Below 0.5%
- When Argon Flow Rate (CFH) is increased or decreased, Purge Time (min.) shall be adjusted proportionately.
Whese distance between dams exceeds 12", purge
- t ir.ie shall be increased proportionat pi'tri -s *A!: EArK11t> l'WS!sta:>r: Al'ter purging i.. com;ilet e. when ecquired to contre t und side veld bead contour.. the backup purge ra t. - (25 s.Fil's can he lowered er raised to matniain a pressure at 0.] to 0.2 of war.et on nn 1.u 11ned water manometer.
A-6 I. ' #C'# ii 1. : Weld b:y, F::, in/e r .
s
- l(p CouPANY' Sheet 1 of 5 T.H
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. . .M.
. . .W. Pu:. iuKaEN i,.compon L L O GArco G t PIPING &ADRICA13ON .
WILLIAblSPoRT, PA. 37701 Reierent(Only spec No. P8-u-rsJ -n-sG Date: 3/28/68 Rev. - Date: 2/1o/70 Rev. Date: 6/11/71 11-12-71*
- A dd. d Pa ne 3 A of 5 TITLE: SPECIFICATION FOR WELDING OF Austenitic S.S. Pipe '
SCOPE: This specification covers preparation, welding, weld finish.. inspection - " and heat treatment of: Austenitic S.S. Pipe
.. .. ..,.., . .; . , ~."..
uS s METAL: ASE-A312-TP304 S.S. . F!LLMR METAL: AS E-A371-ER308 and AS E-A298-E308 . -
. . - -~.1 St!h h C F1,UX: None
.k e. :
INSEF[T METAL: AS m-A371-ER308 _ u.-. . . . (
) --
TUNGSTEN ELECTRODE: 27..Thoriated-AWS EWUI-2 .
~
~
TORCll INERT GAS Shal1 be ARGON 20 CFH HELIUM --- CFH, Purity 99.995% minimum. BACKING: Prior to welding- the I.D. of 'the root of the ' weld shall be purgid with Argon Gas. Purge time shall not be less than that shown on chart K-1GBP for..,each pipe si=e to assure that the oxygen content is below 0.57.. . POSITION: Welding shall be donc in the Fixcd Horizontal Pipe Position SG, no down-ward welding shall be permitted. ~~ PROC ESS: The wc! ding shall be donc by the GTAW (Boot),. SHAW -(Bui14aDP), i , CURRENT: The current used shall be shown.on Sheet #3. - PREHEATING AND INTERPASS TEM P. :. Ni.na,. In.terpass Temp. 350' F. Max. POST IlEAT-T REATMENT: None ,
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..... RELLO C G COMPANT inconronAtto Sh'e'et 2 of 5 . .
p rariuc rAnnicArios q g w a s.L i AusroRT . eA. 77kt , , , , , , Spec. No. P8-KI-FS- SMAW-11 -SC [ d.: c , .... a L. t. j Date: 3/28/68 , Rev. Dat.c:. 2/19/70
'~ Rev. Date: 6/11/71 L1-12-71 -
l Base Metal Prepar*ation: The edges or surfaces of the parts to be joined by welding i shall be prepared by <*=- =*=PF. plasma arcigrindingumachining_or any combin. I ation of methods to form the geometry. of the weld shown on Sheet #3. Surfaces for ; ~ r welding shall be clean and free from paint, s cale, rust or other foreign m.aterials ! "that are detrirHiritil~to quality weliling. . ,, l ,
.: t__ _..: -
.' -2 .- -. ,
j Cleaning: All slag or flux remaining on any bead of weld metal or on adjacent base ' i metal shall be removed before depositing the next successive bead. Stainless Steel wire brushes shall be used which have not been used previously on any metal but S.S.
. Welding Technique: Welding . technique shall substantially be ~ performed as shown on ;
Sheet #3 ... . .
. ' . . ._ . c Underside Groove Preparation: None -
- ..' ' Defe cts: All defects in welds requiring repairs .shall be removed by grinding, arc.
chipping, gouging, C2;tma or machining. Repair welds shall be accomplished to a l g - qualified procedure and the method of examination shall be the same as .for the ort-
. ginal weld. -
.f.y ... 1 =:'- *
-Equipment: The machine source of current shall have a good regulation over the entire range of current required. For GTAW a remote foot controf shall be used to j
l'nitiate high frequency, are starting, current decay, to. eliminate crater indications. Records: Records shall be kept of welders, operators quailifications dates, proce.
. dure qualifications dates, symbols and alf pertinent information as to process and -
radiographic inspection. .. - s .. .,. . .
~
Appearance of Welding Beads: . Each welding bend'shall'show complete fusion to adjacent wcld deposit and to base metal. The finished surface of the weld shall; - merge smoothly into the component surface. - - - Inspection: Inspection shall conform to appli,:able job code. . Electrode Condition: All low hydrogen electrodes and flux shall be kept in a dry rod oven at temperaturee recommended by electrode manufacturers to minimize moisture , absorption. , j Welding Secuence: There shall be a minimum amount of interruptions during weld-ing. Pipe in a fixed vertical position (2G), :he maximum width of a weld bead shall i be three (3) times the core diameter of the e.ectrode being used. .
-)
Pipe in a fixed horizontal position (SC), the maximum width of a weld bead shall be 1-1/4". '1he maximum ' thickness of A-8 any layer of weld, except the first layer, shall
~
be 5/32". . ,
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ci.. i. eannication a s i,i,i aw s r o n t . ra. 17701' S;s.. c . Nei. P8-KI-FS-SMAW-11-5G ' f]' '
^
. 11.as i.
I(cy. Ila t '- 3/,28/68 21.19/70 ... r'- t l
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Rev.'Date: 6/11/71
. 11-12-71 . ;
s, . Wiri. DING TEcitN1Gi!ES 0;ROOV E I)MTAll.S
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S - 32 h. i-I . . .. . 7 Torch T ung sten . Pass No. Fille r Filte r & Gas Sir.e and - Metal Metal Amp's Volts Pola rity j' - and Flo Rate Polarity Type Size Max.
;. Proc es s .,
3/32" Dia.
.
- e Argon 1 Insert Straight 20 CFH Straight -
1/8 x 5/32 80-95 13 GTAW . ER 308 ' 3/32 45-80 24 2 Reverse ---- .------ 1/8 70-110 25 I CHAW E 308 I - . 1/8 70-110 25 3-6 ------ 5/32 90-140 26 Reverse ---- SMAW E 308 ,i . I-j . i u . l f -
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By:. ,.- # b M' M. Isling Engineer A-9 Titi.9
W Code 16 - a Iyt u.W.1[LLOGG C o ll P A li f
..........emswN u.c oman n s u . .
Sticci 3A of 6 rePiNG F AR Al8 All ON t yfLLIAMSPORT* *A. liint
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W*so-cs . _ . . _ Te 8,si...s u...v.rsuma KnA 0. 6~ @ no 0D W . s iceiros PlPluG FABRICATION RECOMMENDED F0llH Q-1 MANt' FACTI!REli'8 RECORD OF REl. DING PR QtlALIFICATION TE8TS g P8-XI-F5-SMAW-11-5G na,, 3/28/68 Rev. Date 2/19/70 & 6/11/71 specification No. _ ~ MA. M.inval or Machin, Welding Process GTrW & SIMW eo P.No. 8 of P.No. 8 .
** Material specification A312 io _A312 _
Thickness (if pipe. diameser and =rall ihickness) 6-5/8" O.D. x .718" @k. Thickness Range chia'iest qualifica 3/16" to 1.4" Thk. FLUX OR ATMOSPHERE
- Filler Metal Group No. F. J and F-7 -----
Fli.e Trade .%ame or Composition Weld Metal Analynia No. A '7 ! lacre Gas Composition Jrton Describe Filler Metal if not included in Table Q-II.2 ---- _ Flow Rate _ 20 CFE ;
------ Trade Nasee
, , or QNall.2 la nacking Scrip used? None For oayacetylene welding-Since if Filler Metal in sil- See Sheet 1 Pechen Temperature Range icon er aluminuta killed. In<cepens Temperature Range See Sheet 1 WELDING PROCEDt1RE see Rheet 1 Multiple P ,sehen: Tre ssmene Single or Multiple Pass . Single , , Single or Multiple Arc Position of Groo,e Vertical (SG) ......- Is,e pa,. o ,is.. A .Fie.s.
. .- .. Q 2 4 Q 8. or QN.2 & QN 3)
(rsei,a.,u..iai...,i .i.m .... .( a...i FOR INI'ORMATION ONI.Y
- Filler Wire-Diameset 3/32" & I/8" . WEl. DING TIT 11NIQU1:5 Sketch Chromenar & Chromend poi,,, Di.nen..ons Acco,d =iih '
Trade Name ---- 1 ang.,45-110, oles 24-25 inches p , min. Type of Itacking Armen cas P,,larit y Straight (GTAW)
----- ( i.eiene DC Forchand or liackhand _ Reverse (SHAW)
REILM El SECTION ll.Nsil.1: TI.ST ltiss. Q+ and QN.(,1
"' . t!!iinsee Unit <
('hsent act of Failure Area al N'*** P ** d ' I** * * ' I'" Speciesen No. width '1hiihnese I m l.l.b_. .
.464 .349 30,800 88,300 Base Metal ,
9.5/1 .753 ,
.465 .351 31,100 88,600 B(.se Metal 9.5/2 .754 .
GUIDED llENI) TESDi(Fig.. Q-7.1. Q 7.2, QN-7.1. QN.7.2. QN.7.)) . Type anal . g,, ,g , Type and g, , ,g , I egure No. Fsgure No. ... . 1 Bent 180' - OK D[j g3 l Bent 180* - OK
~
I h[j l Bent 180' - OK (( Bent 180* - OK
- Results of I ille =eIJ Tesis. I is. Q-WeI 82 3 amp No. BT H. Knstr __, , e lo..k No.
- WelJee's Name The by viriuc cf these tesis meets = cider reef. rmanic seguirements. 71-35-9 Frank Richarda 1.nhorntory.-Teen Nir. '
Test Conducted by per d lJed and } .We erstify then the seatemenin in this record are correce and that she sees welds tr'ere peepare , we seseed in accorJance with the segwuements of Seesion IX of the ASME Code.
. stja,a %e M. W. KelloRR Company l ina.. ei ., e 7
p.,, 3/28/68 ny A- N I dd F, (Dessil of resoid of icesa are illustrasive only and may be modif ed so confor[so the syre an seguised by she rode. Retommended l'oem Q.1 is available for purchase as ASMElleadquarseve.) NOTI:s Any essensial variables in aJJition to ihose above shall be seco#ded.
' This l'oem is beainable from the ASME.14% E.17 h St., New Yeek. N.Y. 80017
- I Peinsed in li.S.A. (11/6(,) A-11 . ,
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e No. X-IGBP Date: 5/6/70
'"/ .
- Rev. Da t e:- 7/20/72
- .' -.-+.
i TIT).E: Argon Gas Backup Purging Chart for pipe of various inside diameters. H
" .T.Ol'M The following purge times for Argon' Gas Backup Purging were derived at. by actual testing. Various I.D. pipe 12" long scaled off at both encs to represent riams were used. Argon Gas was purged into one end of the pipe anc out the opposite l . cad into a lleckman Oxygen Analyzer. . ,-
' Argon Gas -'
Bleed Hole Purge Time Oxygen Analyzer (Min. ) Reading (Sizei 8- Size Schedule (CFil) i .- . Below 0.5%
' 2.5" S/40 25 - 1/8" 1-1/2 ,
3 . __". s_ S/40 - _ _ _ _ _ : 25_. . r-;. 1/8" . . , . . . 1-1/2 . .. s....- s
.Below 0.5% -
. . .t ... . :
1/8" 2 1elow 0.5%
> 3.5". ___ S/.4 0_
. s
._ _. . _2 5-g 4 , , : - . .: s/4 0- ~' - -'. "- " 25 - 1 1/8" .
2' .
,Below 0.5%
{ , j- - . 3' Below 0.5%
- 5. " S/40 ,
2,5
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- 8. " ~~ , s/,40 T 75- ,.
+
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- Below 0.5%
-~
2h" S/h0 25 - 1/8". . la5 30" S/30 25 . . . 1/8" - TO . Below 0 5%
- When rgon Flow Rate (CFH) is increased or decreased, Purge Time (min.) shall be adjusted proportionately. '
t l Whes e distance between dams exceeds 12", purge t ir.ie shall be increased proportionar l - . l'!!;tn -RAS ltArKttl* l'tWSSI'"F : Af ter purging is cor:ple t e, when required to control und l ' side weld Scad contour. the backup purgo rni.- (25 i.1il's can he lowered or raised to maint ain a pressure at 0.1 to 0.2 of water on ein 1.u lined water manometer. A-12 ..,, M d gg.,g iI I;i . : ~ Welding c:ngin/e r
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WILLIAMSPORT, PA. 17 7 0 t' , .. .' 4 . . . . . eP'.W. '.'" 4 .
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. . Spec No. P8-K-1.T-F5-SMAV-11-5G -*-
, r. s. . ., . . ,
( . . - .jy r q.. sj.y- ::. Date:
. i .
3/11/67 -"- g
-l. _ ' :'..: M.. ..hi 4 ,'[# k .y Re& Date: _2/19/70 .- 1j I
Rev. Dato: -6/11/11
'.'R..i .. , , , .
1< TITLE: SPECIFICATION FOR WELDING OF Austenitic S/S Pipe SCOPE: This specification covers preparation, welding, weld finish,' inspection . .E.
. and heat treatment of: Austenitic Stainless Steel' Pipe.. .( . ., :.. . I,,: : ..
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. . .. . .c . . n.-.. . . ... .' , , <... . s...
.1 BASE METAL: ASME Seetion.1X P8 Base Metal - Type 304
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FILI.ER METAL: AWS A5.9-ER-308' AWS AS.4-E308, . Ferrite ' Con' trol per customer ' . , -
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i specifica tion. ".. . '.- . < . . . .".....
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SUB AaC FLUX: None ' . 7 p '
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, INSERT METAL: None "
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- TUNGSTEN ELECTRODE: AWS EWTH-2' '2% Thoriated ' . . :- 5 1- '.: ' ;:.7
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i TORClf INERT GAS Shall' be ARGON 20 CFH, HELIUM -- .CFH, Purity 99.995% minimum.. . .I
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. BACKING: Argon Gas Purge per Chart K-1GBP to have oxygen content below 0.5% prior to. ,.1.
weIding. .
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POSITION: Welding shall be donc in the Fixed Horizontal pipe position -(50).- Noi 7.{.. j. downward welding is permitted. .' '
'<.5
~
(,'.- PROCESS: The welding shall be done by the . GTAW (root) .&,,(final), _ SMAW (build-up)..: '.; .
.. . . . . . . ,. . :. a. . .
. ... .. v. ..: .%:r CURR ENT: The current used shall be 'shown on Sheet #3. '." ;, " ..s. J.W. M. ... .H.M. .. 'Y .
, . . . ~.,.e.. c.r
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7 Min. Interpass: Temp! 300
- FEMazN PREHEATING AND INTERPASS TEM P. : 60 *'.F ,. [
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POST HEAT-TREATMENT: ... Non e . , a. .
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Sheet 2 of 8 ', T.H.E.. .M. Winconronmo . K E L ' O G 'Q CouPANT-
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- PlPING FAORICATION
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". Spec. No. P8-K- LT-F5- SNAW 20 *
. .).E Gj . , N ,; " .? Date: 3/11/67 '
b Rev. Date: 2/19/70
.P.':'
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.i' Rev. Date: 6/11/71 .
., 6.,
~
Base Metal Preparation _: The edges.or surfaces of the parts to be joined by welding shall be prepared by Zhm.nt1.mtx plasma arc, grinding, machining or any combin-I ation of methods to form the geometry of the weldrust shown or cther on Sheet foreign #3. ' SurfacesJ materials welding shall be clean.and free from paint,. scale, > . that arc detrimental to quality welding. , . '- .
, ., . 3 ,
Cleaning: All slag or flux remaining on any bead of weld metal or on adjacent bassy wire brushes shall be used which have not been previous
". Welding Technique:. Welding technique'sha11 substantia 11y be performed as show l-
- :. .. i ; . .* ry o.. ......L.y.,, u .; ~y
.. .4 Sheet H3. ~_
. . \-
i J,
- h".' '
U, ' Underside Groove Preparation: ' None E* ' ~
" Defects: All defects in welds requiring' repairs shall be removed by grinding, arci -
Repair welds shall be s,ccomplished to a .
' chipping, gouging, XDueut or machining.
i qualified procedure and the method of examination shall be the same as for the - -
;.?
.2: Ub ginal weld.
,. , [ .. - ,
A a; ,r - Equipment: The machine source ;of current shall have a good regulation over the j t entire range of current required. , For GTAW a remote foot control shall be used to
- ::i..
- initiate high frequency, arc starting, current decay, to eliminate crater indications. -
-g.
,i Records shall be kept of welders, operato'ra qualifications dates, proce-
* 'I . Records:
, q. ~ dure qualifications dates, symbols and all pertinent information as - <
to process and "
. radiographic inspection.
,i- .. . ,
y, Each welding bead shall show complete fusion to
** Appearance of Welding Beads:
adjacent weld deposit and to base metal. The finished surface of the weld shall
.,.. a,1 9
merge smoothly into the component surface. . .
' Inspection: Inspection shall conform to applicable job code.
All low hydrogen electrodes and flux shall be kept in a dry rod l:- Electrode Condition: ii isture
' . oven at temperatures recommended by electrode manufacturers to min m ze mo * -
h, '. absorption. . Welding Sequence: There shall be's minimum amount of interruptions during weld. .
'lhe maximum width of a weld bead !
'lhe . maximum
-ing.
.shall Pipe in s Fixed Horizontal position (5G).(3) times the core diamete be three thickness of any layer of weld,; excepe the first layer, shall be 1/8". .;,.r .
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W . R E L L O G G C o u r A N f, , i' T*/.*,'. . ., . . . - . J ' . Sheet 3 of 8 - K.:..'" l
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*:cinu ranner.ation .u. .
..; i J' - .OlLLIAW8Pont* PA. 17701 ..- '.2 ,. p p,,. , ..
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. . ') .. Spec. No.3/11/6.7. - ~
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';[.(( Rey. 'pate: 6/11/71
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PIPING'FAtRICAfl0B w. MECHANICAL TE3iiX3 LAB 0 RAT 0RT;e. .c.. ,.'. il?ai <,n;;.
. .' ' 'W . J .*/;.k-
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l PROCEDURE. DOCUMENTATION REPORT..' - , - :C'.Uc<.~. .-' . '.
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specific.iidNo. _P8-K-LT-F5-SMAW-11-5G - - ou,'3/11/67 Rev. Date 2/19/70' And-s - Yelding Process GTAW & SMAW u nual or u. chine _ MA 6/11/71
. Naserial Specification A _t 76 to A376 of P.No. 8 to P.No. _8 - '*' . -' *. -
- Thickness (if pipe, dissierer sad well ihicknese) 6-5/8 " 0. D. x . 718 " . ';- .;.'D
~-
Thicknese Range this test qualifies 3/16" thru l-7/16" Filler Metal Group No. F. 7 and F-5 .
.- .r w
, * ((
veld Metal Analreis No. A. 7 * *
* . , . ~ ~ . . --~'
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; REDUCED SECTION TENSILE TEST (FIGS.Q.S AND QN=6) j . . ' ..".!
As wtLDED OlMENSIONS SEC. YIELD PCINT TENSILE 5TNENGTH , ELONG . MARK AREA ihas.pta Jt E M A R K S.
* - I'CMES S 0. I N . actuahS Leap t I g o . s 'e . u tearL et a.w e s a . l t t l Les.
S o . f eta as . L I N CTle it , TTS-1 .749 x .667 499_ 31,000 62,100 42,400' 84,900 50 hroke in Base Metal ..
.TTS-2 .753 x .6261 .471 30. BOO l63,600 40.100- 84.900 50 .hroke in Base Metal l , . . ,
STRESS RELIEVED .*. ~
~
, SEC. YlELD POINT ' TENslLE STRENGTH T. ELONG . .
NARK DlMENSIONS AREA RCMARKS _Incuts actuat a 3fsa,. e, ,t a W tu Las.*ta
. so.in. (n.ote. , toL i o (a ,r 3, t ,a,,,, stuotw- en
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~
l GUIDED BEND TESTS ( FIG 5. Q.7.1. 0 7.2. QN.7.l.. Oft.7.2.' ONe7.3) . [. SB-5 180' Passed ' j SB-6 180' Passed } l - SB-7 180 ' Pa s sed I I SB-8 180* Passed I l CHARPY IMPACT BARS BROKEN AT - i - TYPE AND RESULT
= TYPE AND FIGURE NO. FIGURE NO. 'IM i
I l
' weldee's Na., H. Knner cl e3 go. 82 siemp No.. W e who by eirtue of these seses meene welder pesfoemance requiremente.
Teen conducied by Frcnk J. Richards Laboenioet-Tess No. 71-35-7904 pee 9- ~ Ve certify then she sensevnenes in this record are coerece and thee the see welde were prepared, welded sad h<. easied in accordance wisti the require.nents of Secilon IX of the ASME Code. I - Signed- MN ' .h 8
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- PlPIES FAIRlCAfl0E ,
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RECOMMEND 5D FORH Q 1 MANilFACTilRER'S RECORD 0ROC URE .
~
QUAI.lFICATION TESTS f.
> .i' ,
.. specificcion No. _F8-X-1,T-F5-SMAW-11-5G _
pai, 3/_11/67 Rev. Date_2/19/JO'4 6/11 Welding P wees GTAW & SMAW mnval et mchine* Manual ,.,:~
,J.',* , , ,
'- mental specificuien - A376 co A376 of P No. 8 to P No. 8
- **A .
" . :.4~
Thiennene (il P re diameter and well inicknesen 6-5/8" 0.D. x .718" i Thicknese Ranse shie seet qualifies J/16" thru l-7/16" ,'. . , l ' ' ?,' '
..h'9 *c ).'p.
Fillee Metal Group No. F. 7 and F-5 Fl.TJX OR ATMOSPnERE . Weld Metal Analyale No. A. 7 Fles Trade Name or Composition --"- ].". , L/ Describe Fillet Metal if not included in Teple Qll.2 Iner: Gas Composition Argon .. , .'; f,
' . ***-- ' Trede N$me Flow Rete 20 CFH 7'..
4 , w QNell.2 Is llachas strip need? No .? 3,'y' *l
*..$-[ . c.*E..' *
.. Fee especetylene =elding-state if Fillet Metal ie eil.
.' ..N..; ' - Prehest Tempere: vee ns.,e 60* F. Min, i;:. :..
~ * -..',581 h Icon er sluminem killed. ', " "'*
' /f 7/ .
- WELDING PRtx'.F.nllRE
~'
E ', N Interpees Tempereiwee Rense 300
- F. Max.
dl[,." *;' ( .' Siegle se Winirle Pese )8ultiple -' J Peethese Treement ------- ,;. O ,*;[_,7 [.,** ' '** .' ' Single er Multiple Are___ 'SinR1e , , ,* . , * . }3. . g;. "
;...;U,' 'i . ; r Cro (See Pees. & Fise. Q 2 4 Ql. er QN 2 & QN.1)1 . . f '.h ; (:
., , c , :,. ,. Peeliice tries, serie of ases.ese Hori zontal eertie s a. er ...ene.e. .i ..ri so n s, 5G eies. -neow e ie-.ed se d e-n- .dl . , , '; F ..g ,
bf. * ' FDR INFORMATION ONI.Y '
. [th )
- FiWe Wire-Dience, 1/16". 3/32".1/8". 5/32" WEl.nlNo TECHNIQUES #; !! A. I
% d ' ,* -
Trede Name Chround & Chromenar ' Joine nimensions Accord olih_eketch
-k
_. j.2 -
' Type of meki'is Araon cas -
empe 45-140,a e12-26 inches p., min. --- f'.. . ..
------ ( .,,, n, DC pole,isy- Straight (GTAW)1'.'l. ,.
' 'd. ,/' ' Ferehend er neckhead
, REnllCED SECTION TENSil.E Tl;5T (Fine. Q6 and QN 4) , Reverse (SMAW)l. ,. 1
,,/
. ,y ,
2
"'"" " "" III'I"*" U".it Chere ee of Failure
?,- Specimen No. Width nichneea
' Ares el g ...ed . I h. N' b P' ' ""d I ** *8 E** I-[1 *.,. /N[
~
u:.,. . . , .: .
..i- .
j (SEE SHEET 6 OF 8) .. ..r. -3.
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2 ;n. < . - ,.;.g a .
..* A. .~
. r~,;<c GuinEn nENn.TC5TSIFla.. Q 7.1. Q7.2. QN.7.1.' QN.7.2. QNg,.)) . .g
,l f,& *. , , *.f
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.- .s . - .
Type smi n, e ,g , Type sad , g,,g,
'. a u g.c Figwee No. Fepte Nis. .f. j. i.O
' r:.'!;.
.s '
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(SEE SHEET - 5 0F 8) -
...W',
. , Reselse of Filles =eIJ Tene. Fig. @He t , ; . ,' 'd* l Weldev'e No., H. Knarr riech No. 02 Stomp No. BT .
. .?
Who by sisive of these temes meets.= elder reslawmance neguireseenes.
.t
. Tees Ciendweied by M.W. Kellogg Lab, l.shorescey-Test N s. 71-35-7904 '
1.* .%
~3
. p,, Frank .I. Richards .
. ) . '; ., ,{
. We cevaily sket the seesemente in this neceed see eseeees and shee the sees welds were prepered, welJeal and ,.';. .
.,, J,,,'
,teseed in ecceedence with she requisemente of Section IX of the ASME Code. . ,
{ Sipa' A?.fh4.CL PL1 ':
,,, 3 -.n . c q innen of ,u.,d . .eese e.e iii.e ,esiec .ni, and me, he modified .. . nfo,mg she ,,pe and n.she, e, ,es... . a ...c
,, ff Nff -
,e,.t a h, ,me cae. nn-wa reem Q.i is e eisewe f ,=,ehese e. ASME nedqueteeve.) ..'.. j? ' . . .'k.
NOTE,. An, essen.iei ...iewee in adicion .<.h se she e eben he . e 4a. o , "' " " :7*
- A-23 fe== she ASME. MS E.17 h St.. New York. N.Y. 300l7 .-
A 4-Peine d in ll.S.A. (11/66) This Form i *
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"*'-~ '~*- - - - . , , _ _ , __
P e TN! U. O . Kill 0GG COMPANY *
, . . . . . . . . . . . r o i e a e. i s.. ...o si a t t o .
*l P l P t N.. D A lt bl 8 L A 1 I i.)ts ,
) natt:Ausront. PA. 1710:
2 No. K.lonP g'
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e a - 5/6l'io
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gl, X.
Datc: - 1
. .I *
.
- Rev. Da t e:. 7/20/72 e .
TIT I .F.: Argon Cas Backup Purging Cha.rt for pipe of various inside diameters.
'l SCOl'l*h The following purge times for Argon Cas Backup Purging were derived at. by Various I.D. pipe 12." long scaled off at both ends to represent t
actual testing. dams were used. Argon cas was purged into one end of the pipe and out the opposite I cad into a Heckman Oxygen Analyzer. . Purge Time- Oxygen Analyze Argon cas " 111eed Hole Readinr; I- Size Schedule (GF10 (Sizei (Min. ) . I .- .
' 25 e 1/8" 1-1/2 Below 0.5%
2.5" S/40'
~ ~#~
3, u _ 3/4o _ _. 25 $... U.i/8" _. 71 -1/2 .
. *.,....Below 0.5% . -
- g 3.5" S/.40 25 1/8" 2 -
, ,'Below 0.57.
- 4. " S/40 .L-- 25 -- --.i :.'::.1/8" 2 . , . Below 0.57.
. .-.-u..' . . ..........-
3.- Below 0.57.
- 5. " S/40 . 25 -
.C' '1/8 .
~
', 1/8" '4 'Below 0.57.
6 . 5/40 . , 25 -
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,'25' 1/8" 6 Below 0.57.
- 8. " S/40 ,
' Below 0.5%
-'-- -- 10 g o ,,n . .. S/40 '25 - N - 1/8" ---
1 .. . . . 12 Below 0.57. 12." S/40 - - ~; - OS -
. , . ...T1/H" l
25 1/8" 14 l Below 0.57. 14 . "
- S/40 16" _ S/LO , __ , "_25. -
'1/8" -
20 ' Below 0.5% 18" S/ho. 25 '
"1/8" - -- - 25 -
Below 0.5% 20" S/ho 25 1/8" 30
- Belov 0.5%
2k" S/h0- 25 - 1/8" h5
- Below 0.5%
30" S/30 25 . 1/8" - 70 . Below 0.5%
- When Argon Flow Rate (CFH) is increased or decreased, Purge T 'ime (min.) shall be ,
adjusted proportiona tely. Wher e distance hetu : dams .sxceeds 12", purge
- t irie shall be increased proportionat l'!!'.tr:-8 A!: tW Rtil' l'tWSSI'"I': After purging is cor:plet e, when tequired to control und side weld bead contour the backup purge rat.- (25 s.I'll's can he lowered er raised to matnt ain a pressure at 0.1 to 0.2 of wat.cr o. nii 1.ic11ned water manometer.
. A-24
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Sheet 1 of 8 ' %. . A
.. .5. f . KPuttuaN E ll 0laccaroaatto G G COMPANT T.II.E =
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. pg . OR - F5. guAV- 2 4- 5 C
. . . Date:
~- .. .
.- 8-14-69 ':
g(y, Y h; .( .,.i; bnI'd,,i 'l .c..
. ? Rev. . Date: 18 70 1
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. Rev . Da t o : 11-5-70
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r.. .c Rev. Date: 6/11/71 _ L. l TITLE: SPECIFICATION FOR WELDING OF AtJSTENITIC S.S. PIPE, N0ZZ1.ES & FII.LETS. . > SCOPE: This specification covers preparation, ' welding, weld finish, inspection .[: .. and heat treatment oh ( Austenitic Stainless Stgit Pipe, Hozzles & Fillets..p.'
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,9; '.Q,<., , ... ,.. .. .F:.j?/Q BASE METAL: " ASME Section IX Y P8 Base Metal Type 304 . f.7;'. , ,
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AWS AS.4-E308'.I '.AWS A5.9-ER308'.3 Ferrite .
. FILI.ER M ET A L,:
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SU n A.,C FLUX! None' ' , . - m,s.%,. -
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INSERT METAL: None .- , (.. ,.. . ,
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~ TUNCSTEN ELFC'i RODE: AWS DrI!G2, ;. *@._.
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' CFH, Purity 99.995L q f, . ...
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g.. TORdil'IN,b, lT C AS* Shall be ARCON . 20,'; ,, CFH,... HEL111M
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POS TION: Weleling shall be.ri~ o ne. in the, Fixed Horizontal' Pipe PositionJ50)'.. .'t p."; '. " .
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The welding shall bc 'done by the SMAW (Root & Bui1 dup)'GIAW (Wash Pass) , . , , d"
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,.- CUR R ENT: The cu rrent usect sha'll be .shownon' Sheet.# 3. ,:..s m., L . L.'. ., *
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- PitEl{ EATING AND INT ERPASS TEM P. E'. 60CF'. Hin.. Interpass Temp. 300,, .Max,.l,. -
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POST HEAT. TREATMENT: None .,:%: e v&.: . .~...::>.?:i. . r . e!d:;
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COMPANY .' .'.Sheet 2 of 8 s' T.il. E...M. ......VPuttuan
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S:. " .. . , . PIPING FAORICAfl0'4 .li . . *
. i.}3 WILLIAMSPORT, PA. 17701 ... . 0.1 .
'. . Spe c. No. P8-OB-FS-EMAW-24-5C U '.
O- .
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M 1,, ' .W
,J 8-14-69 .';c
~
.25'I.f .. .- Rev. ' Datei Date: 6-18-70 v*- .N. .
.@i .T V.U .s.. . . a n.
' .p.
Rev. Date: 6-11-71
. . t.
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Base Metal Preparation: The edges or surfaces of the parts to be joined by welding . shall be prepared by nXfeQuestDqt, plasma arc, grinding, machining or any combin >
- otton of methods to form the, geometry of the weld shown on Sheet #3. Surfaces for "..
l
. welding shall be clean and free from paint, scale; crust or other foreign materials. ;
that are detrimental to quality welding, ., l l s.' , ,,
.. i.;.g, I ' Cleaning: All slag or finx remaining on any' bead of weld metal or on adjacent base','6 metal shall be removed before depositing the next successive head, Stainless 8 teel .; .
wire brushes shall be used which have not besn previously used on any metal but 8,8. .
...j' Welding Technique: ', Welding technique shall substantially be performed '
as shown on" . .
'i . , . ' ;.d.N % iV .'.i 4 *1 s' ' . . i'. . 1 " Tc'.i ' - . ' . "
l : ^ ' Shee t # 3.
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, Underside Groove Preparation: (; rind, back gouge or drill the root pass to solid Q.
l - . .v l . sieta l. t ,. ... . Defects: All defects in welds requiring repairs shall be removed by grinding, ar c, ;,.V l C I.' ~ chipping, gouging, DecotKor machining. Repair welds shall be accomplished to a .f.i l I
- h. ;ginal qualified weld. procedure
.'. .cand 5... o ..':the .
b.., smethod u.... .nf; '.. .; >of
. examination.
. shall
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b - " Equipment: The . machine source .of c'urrent shall' have a good , regulation over the
./ ' entire range of current required. For.GTAW a remote foot cont: ol shall be used to -
i '. : initiate high frequency, arc ' starting, current decay, to climinate crater indications....
..... .~ . a.. y . e. .,
, . ; .. .y
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Records: Records shall be kept of welders, operators' qualifications. dates, proce. .^
~
- dure qualifications dates; symbols and' all' pertinent information as.to process and O '
radiographi'c inspection. ;q. .f s, p.. , , , . , , l't . . , ' 3 1,, , , ' ' ,, ; . - :.> 2,,i 4
- t. . . v. ..e-V
Appearance of Welding Deads: ' Each ~ welding bead shall show complete thsion to 1
l1 - adjacent wuld deposit and to base metal. The flnished surface of the weld shal1 ;. N l merge smoothly into the compone'nt surface. yr- . .. .'. g.,.;',,4 : . ' ' . .
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- s. .
~
Inspection: lnspection shall confobm N. applicable job code. i
'[.
Electrode Condition: All low hydrogen electrodes and' flux shall be kept in a dry rod. ' 1 ' oven at temperatures recommended by electrode manufacturers to minimize moisture ' absorption. d . , , ;[ ;. ~. . . . . ,'. ,"," ., b; l Welding Sequence: There shall be a minimum amount of interruptions during weld. ::s ing. Materials to be welded shall.be in a fixed horizontal position (5G), the sisximima - e,h f width of a weld layer ~ ahall be lj '.:1/4",.j The maximum thickness of any one layer shall
-(/ be 5/32". .. :,: , ;. , . g .p*p. jp ,g. Aj, ,,q.. j ., g. . . -. g . e.. g
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