ML20086U021
| ML20086U021 | |
| Person / Time | |
|---|---|
| Site: | FitzPatrick  |
| Issue date: | 11/26/1991 |
| From: | Giannuzzi A, Licina G STRUCTURAL INTEGRITY ASSOCIATES, INC. |
| To: | |
| Shared Package | |
| ML20086U011 | List: |
| References | |
| SIR-90-063, SIR-90-063-R00, SIR-90-63, SIR-90-63-R, NUDOCS 9201070162 | |
| Download: ML20086U021 (290) | |
Text
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(]V Project No.: NYPA 260 November 1991 r I Qualification of Inconel 82 Temperbead Weld Overlay Repair With Reduced Preheat ,
. and No Post Weld Heating -;
Prepared by: , Structural Integrity Associates, Inc.
bkl A.(f Giannuzzi Reviewed by: fm Date: /l 26 / .
G. J. Licina )
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1 Table of Contents l Section bgt 1.0 P U R POS E AN D O BJ ECTI VE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Ba ckgro u n d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 j 2.0 TECHNI CAL APPROACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 New York Power Authority Temperbead Qualification Program . . . . . . 2.2 Industry Developed Temperbead Qualification Programs . . . . . . . . . . 10 3.0 TEST RES U LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.1 New York Power Authority Temperbead Qualification Program . . . . . 13 3.2 Industry Developed Temperbead Qualification Programs . . . . . . . . . . 15 ,
-4.0 DISCUSSION OF RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- 4.1 Additional Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4.2 Re sid ual S tress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 i
5.0
SUMMARY
AND CONCLUSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.0 R EFER EN CES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Appendix 1 Certified Material Test Reports Appendix 2 Weld Procedure Specification and Procedure Qualification Records - WPS: NZ Overlay and PORs: 395,745,746 , Appendit 3 Nutech Temperbead Out.lification Program for Discharge Nm21e at the Oyster Creek Nuclear Power Station (EPRI Advisory Committee for Temperbead Welding, November 2 3,1989, Charlotte, tF') - Appendix 4 CB&l Reactor Nozzle to Safe-end Temperbead Str uctura10verlayTest Program .- (EPRI Advisory Committee for Temperbead Welding, November 2-3,1989, Charlotte, NC)-
- Appendix 5 Mechanical Properties Test Reports in Support of PORs 395,745,746 ;
Appendix 6 Metallurgical Test Reports in Support of PORs 395,_745, 746
. . i SIR 90-063, Rev. O ii !
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Table of Contents (Concluded) O Setlica EBEC Appendix 7 Diffusible Hydrofp Produced as a Result of Welding on SA 508 Cl. 2 Low edloy Steel with 150*F and 300*F Preheat and No Post Heat Treatment (Presented at Second Ternperbead Advisory Committee Meeting, October 30,1990, Charlotte, NC) v h l A SIR-90 063, Rev, 0 iii %d 7N lDITEGRITY
/ ASSOCIATEINC
i List of Tables Tabk Eage 1 Base Metal and Heat Affected Zone (HAZ) Charpy impact Results for EPRI Qualification Samples [3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2 Base Metal and Heat Affected Zone (HAZ) Charpy Impact Results for NYPA Qualification '.2mples Procedure 746 (300'F Preheat 500'F P os t H e a t) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3 Base Metal and Heat Affected kne (HAZ) Charpy Impact Results for - NYPA Qualification Samples - Procedure 745 (200'F Preheat - 500*F Pos t H e a t ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4- Base Metal and Heat Affected Zone (HAZ) Charpy impact Results for
- NYPA Oualification Samples Procedure 395 (Nonle Mockup 300*F Pre heat, 5 00' F Post Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5 Comparison of Average Charpy Impact Test Results Among the EPRI and NYPA Inconel 82 Temperbead Weld Overlay Procedures . . . . . . . . . . . . . . . 23 6 EPRI Test Results Microhardness Measurements in the P-3 Heat Affected Zone of the Groove Weld (Reference 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 0,. '
7 Microhardness Traverse on SA-508 Cl. 2 Heat Affected Zones in Groove Welds from the EPRI Program (Reference 2) and the Authority Temperbead Qualification (PORs 745 & 746)........_................ 25 8 Microhardness Traverse on SA.5L8 Cl. 2 Heat Affected Zones in Groove Welds from the EPRI Program (Reference 2) and the NYPA Temperbead Qualification (PQRs 74 5 & 74 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 9 Nutech/ Oyster Creek Mockup Nonle Charpy Comparisons . . . . ........ 27 p 10- 'CB&I Mockup Nonle Charpy Comparisons (Procedure 7673 - 300'F , Pre heat, 5 00* F Post Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 11 ; CB&I Mockup Non.le Charpy Comparisons (Procedure 7718 - Wa t e r i n Nonle ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 N PR.90-063, Rev. O iv ("f u
-STRUCTURAL DiTEGRITY ASSOCIATESINC
List of Tables (Concluded) Iabh Put 12 CB&I Mockup Nozzle Charpy Comparison (Proc: dure 7717 - Nozzle D.y - No Preheat or Post Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 13 Measured Diffusible Hydrogen Content (ml/100 g) in Samples Prepared by EPRI (Appendix 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 O_ Q SIR-90-063, Rev. O v r-b N isscx u u sz c
List of Figures O Figure higt 1 Through Wall Residual Stress Before Application of the Temperbead Weld Ove rlay (Re fe re nce 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2 Through-Wall Residual Stress After Application of the Temperbead Weld Ove rlay (Re fe re nce 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Q S'" 9 - 63 "*"- O '
~ smxxuan 3 INTEGRITY
- assccuussue
l EXECUTIVE
SUMMARY
The New York Power Authority has developed an alternative Inconel 82 temperbead weld overlay welding approach which simplifies welding on reactor pressure vessel components. 1 his approach extends the temperbead welding concepts developed in a prior EPRI prograrn so that reduced preheat can be applied to the low alloy steel component being repair welded. This approach may allow for repair welding on these components without the necessity of dropping the water level in the vessel. The following items highlight the Authority's qualification program.
- No deleterious change in mechanical properties or metallurgical structure were observed when comparing the Authority's temperbead qualification program to the industry and ASME Code accepted EPRI qualification program.
- Other industry studies examining the use of no or reduced preheat or water.
O backins for the inco nei te m Perbeed w eid overiar su P r ort the A uthoriir - welding approach that reduced preheat can produce a quality, weld cverlay repair meeting the requirements of the ASME Code.
- e Potenthi adverse effects of reduced preheat welding on low alloy steel,
, notably hydrogen embrittlement, have been investigated by others and have been determined to be of nc concern.
- This subject remains a prominent research topic for EPRI and the utility
- industry as testing and evaluation continue to qualify and obtain ASME Code acceptance for a reduced preheat temperbead welding process for low alloy steel vessel and nozzle materials.
SIR-90-063, Rev. O vii ersucromu
,DITEGRITY ASSOCIAIT. SINC
l.0 PURPOSE AND OBJECT'VE O' The temperbead weld overlay repair involves welding with well controlled welding parameters to avoid high temperature (1100*F) post weld heat treatment. To perform a temperbead weld overlay repair on a reactor vessel nozzle made of low alloy material the ; recently approved ASME Section XI Code Case N432 [1] requires a 300'F preheat and 500'F post bake. Achieving these elevated temperatures requires draining the reactor vessel which may cause significant outage schedule delays and high man rem exposures. The Authority has embarked on a special weld overlay qualification program. The purpose of this pr'ogram is to expand the temperbead weld overlay qualification concept to a wider variety of repair conditions by modifying some of the welding parameters specified by the Code for performing a temperbead repair. The Authority has qualified an alternative automatie gas tungsten arc (GTAW) Inconel 82 temperbead process, employing a 200*F preheat and 500*F post heat, to the EPRI qualified Inconel 82 temperbead weld overlay process which employs a 300*F preheat and 500'F post heat for use in repair of a low alloy O stcei erguce a n atthe 3ames & Fitzre e k secieer e - er rient. This report documents the results of the Authority's modified ter,perbead program and summarizes the relevant work performed by industry leaders in qualifying reduced preheat no post weld heat treatment weld overlay repairs. The objective of this report is to provide the technical basis for requesting approval to perform a weld overlay using a water backed 200*F preheat and no post bake. The results of the NYPA temperbead weld overlay qualification program including the summary of relevant industry experience which addresscs technical issues regarding temperbead repair weloing concludes the following: SIR-90-063, Rev. 0 Q 1 , ~ moenma DfTEGRHT
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- The heat affected zone mechanical prciperties located in the low alloy base metal are not degraded by the application of a v eld overla', employing a 200*F preheat and no post weld heat treatment.
- Studies performed by other investigators that examined the use of no prehea'. or water backing for Inconel temperbead weld overlay confirm that the weld overlay has little effect on the base metal notch toughness when compared to the unaffected base metal nr the EPRI qualification process results.
- The ytential effect of hydrogen embrittlement resulting from the reduced preheat arid no post heat has no harmful effect on the GTAW process.
- The temperbead welding process produces residual tensile stresses on the surface which is welded and compressive residual stresses on the opposite surface. This result leads to a more favorable through wall axial stress distribution which tends to stop cracking.
A V ~ Following a brief background and history of the evolution of temperbead weld overlay repairs, this report describes the activities performed by the Authority to qualify a modified Inconel 82 temperbead weld overlay repair which allows welding the overlay with reduced preheat, thereby permitting water-backed welding. The appendices contain, for easy reference, temperbead qualification work performed by EPRI, CB&I, and Nutech, as well as material performed by Structural Integrity on pipe residual stress after applying a weld overlay, and EPRI's evaluation of hydrogen embrittlement during GTAW welding. O SIR-90-063, Rev. 0 2 U
& .STRtJCTIJRAL ,
INTEGRITY
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1.1 Background
r ( De use of the weld overlay for austenitic stainless steel piping as an intergranular stress corrosion cracking (IGSCC) repair is widespread in the BWR industry. Originally the weld overlay was designed as an interim measure, but extensive laboratory testing, analysis, and field performance have demonstrated its suitability as a long term repair for stainless steel piping. As a result of the extensive activity qualifying the overlay as a long term repair, the Nuclear Regulatory Commission approved its use in NUREG 0313, Revision 2, [2]. In addition, a Code Case has been introduced to Section X1 of the ASME Pressure Vessel Code which would allow the overlay to be applied to stainless steel components without the need for tase by case NRC review and approval as is presently required. This Code Case has received a favorable endorsement by the utility industry and the jurisdictional and regulatory personnel involved and is expected to be cdopted in the near future. During the past several years, IGSCL has also been observed in Inconel 182 weld metal associated with nonle cladding and noale butter, recirculation inlet and outlet nonles and (l incore spray safe-end to nonle welds. IGSCCin inconel 182 weld metal has been reported v in domestic and foreign BWRs. The IGSCC associated with Inconel 182 in the nonle butter at some plants also involved reported stress corrosion cracking which may have progressed into the low alloy steel nonle material. Recognizing the Incor,el 182 butter susceptibility to IGSCC in BWRs, an effort was undertaken in 1985 to develop and qualify an inconel 82 weld overlay repair which could be used to mitigate the consequences ofIGSCC in components containing Inconel 182 butter or cladding. The project team for that program included the Georgia Power Company (GPCo), the Electric Power Research Institute (EPRI), General Electric Company (GE) and 1 1 Structural Integrity Associates (SI). The team performed the analysis, welding, metallurgical examinations, fracture mechanics, mockup evaluations, Code and licensing activities 1 ' SIR-90-063, Rev. 0 3 v INTEGRITY
/ /LssoctATESINC
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- tuali econel we.ld overlay repair to the low alloy steel to safe-end pressure
, y
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;ar, iomt ic. L jicalBWR[3).
y ) i m recirculatio' inlet nozzle (N-2) joint for that -tudy because it ai- which has t.ff .. , the largest incidence of IGSCC .i Inconel 182 in
"/ . . #R N-2 c ou to safe-end was modeled as the joint to be qualified 9 tb weling and post weld heat treatment parameters selected were based
. op a ' -nce provided by Section 111 and Section XI of the ASME Code and upor. the a
pri eurk y t'ormed by the Babcod & Wilcox Company (B&W) under contract to EPRI [1]. The B&W cffort invt.- -d development of a temperbvad welding procedure for welding on low alloy steel nonle materials using automatic GTAW technology. In that study, various wtMing ap zoaches were evaluated ir an at - 1pt to develop an alte'. native welding techniquc m3 che Code appror.-4 half-bead" shielded metal arc welding (SMAW) technique which was the only ASME Cede approved repair technique at ine time for low alloy steel h components which did not require a full post weld heat treatment. The successful completion of the B&W program and the RI sponsored Inconel 82 weld overlay program led directly to the incorporation of Code Case N-132 into the ASME Code
'[1]. Code Case N-432 allows one to perform a gas tungste> . gerbead repair to a carbon or low alloy steel component (P-1 or P-3 material) wanout a full post weld heat treatment provided the requirements in the Code Case are met. This Code Case has (
provided the basis for all temperbead Inconel 82 repairs which have been performed in operating BWRs and has also been u;ed for Inconel 82 temperbead weld build-ups in P%Rs. g SIR-90-063, ~Rev. 0 4 o(mucrunn INTEGRITY
/ ASSCCIATESINC
One of the shortcomings of the EPRI temperbead study is that the required 300*F preheat g and 500*F post bake result in the need to perform the repair with water removed from the sicinity of the joint. This need can create scheduling and refueling problems. EPRI recognized this short-coming and assembled a Temperbead Advisory Committee to determine the technical feasibility of reducing the preheat and post bake to temperatures which would allow the temperbead weld overlay to be applied with water in the pipe. The Authority and Structural Integrity Associates, as well as the NRC are represented on this EPRI Temperbead Advisory Committee. In addition to the EPRI sponsored activities, other experimental studies have been performed examining the effect of a reduced preheat or no preheat temperbead repair to low alloy steel nozzle materials. The results of two of these studies are presented in this report. As presented in Section LO of this repcrt, the objective of the current New York Power Authority study is to expand the temperbead weld overlay concept to a widet variety of h repair conditions by modifying some of the welding parameters which were qualified in the original temperbead weld overlay qualification program [3]. The parameters which were ndjusted in this study are the preheat and the post weld heat treatment. As noted in the preceding paragraphs, the original temperbead weld overlay qualiScation required a 300*F preheat and a 500 F post bake. In this study, an Inconel 82 temperbead weld overlay was qualific witt,1200*F preheat and no post weld bake. The incorporation of the 200'F preheat w' ..o post heat treatment will allow the utilities a peiform the temperbead weld overlay repair without draining any of the piping systems of water, thereby providing a potentially significant reduction in outage schedule. Additionally, the presence of water in the pipe can reduce the man-rem exposure associated with the repair and may provide additional benefits to the repair, such as improving the inside surface residual stress distribution when comp; red to a full post weld eat tretted safe-end to nozzle joint. Issues g SIR-90-063, Rev. 0 5 m srauerunn. h9 INTEGRITY
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such as unfavorable residual stress distributions, incomplete tempering of the low alloy steel weld heat affected zone and hydrogen embrittlement effects were evaluated. The following sections of this report describe the welding activities performed by the New York Power Authority in qualifying a modified Inconel 82 temperbead weld overlay repair which allows welding the overlay with reduced preheat, thereby permitting water backed welding. O SIR-90-063, Rev. 0 6 mucmu.
. INTEGRITY ASSOCIATESIIC
2.0 TECHNICAL APPROACH O' 2.1 New York Power Authority Temperbead Qualification Program As described in Section 1 of this report, the objective of the Authority's program was to qualify an alternative automatic gas tungsten arc (GTAW) Inconel 82 temperbead process, employing a 200'F preheat and no post heat by comparing the results to the EPRI qualified Inconel 82 temperbead weld overlay process, which employs a 300'F preheat and a 500'F post heat, for use in repair of a low alloy steel nozzle application at the James A. FitzPatrick Nuclear Power Plant. The approach used in this program was to procure two SA 508 Cl. 2 ring forg*ngs from the same heat of material in a size consistent with the recirculation inlet nozzle (N 2 nozzle) at the FitzPatrich plant, perform the required post weld heat treatments to simulate the heat treatment condition of the existing nozzles at the plant, and perform the Inconel 82 temperbead overlay welding procedure on the ring forgings and machine qualification test samples. The' certified material test reports for the ring forgings used in this test program are presented in Appendix 1 of this report. TN kj' Three procedure qualification tests (PORs) were performed in accordance with Authority weld proced. ire specification (WPS) NZ-Overlay. Two of the qualification tests were performed to compare tiie lower preheat, no post bake temperbead approach to the EPRI approach. -The third procedure qualification was of an actua' weld overlay using the EPRI preheat and post bake parameters. WPS NZ-Overlay and the supporting PQRs (POR 395, 745 and 746) used to perform these qualifications are appended to this report as Appendix
- 2. One of the PORs, POR.746, was ud to deposit an Inconel 82 temperbead groove weld in the ring forging (see figure in POR 746, Appendix 2). This temperbead groove weld, deposited using a 300'F preheat and 500*F post bake in accordance with the EPRI temperbead Inconel 82 qualification program [3], used welding parameters which approximated those used in the Reference 3 project. The principal difference between the welding parameters in the EPRI welding procedures and in the Authority WPS NZ-Overlay SIR-90-063, Rev. 0 7
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involved the arc voltage which was reduced by approximately 10% for the temperbead weld overlay qualified in the program. This reduced are voltage, applied consistently as in the Authority program, has no effect on the temperbead results. The second POR, POR 745, was used to deposit an Inconel 82 temperbead groove weld in the ring forging (see figure in POR 745, Appendix 2) with a 200*F preheat and no post bake using the same welding parameters as in POR 746 (WPS NZ-Overlay). This temperbead weld represents the Authority alternative to the EPRI temperbead Inconel 82 weld overlay process. The final weld, the demonstration Inconel 82 weld overlay weld, involving fabrication of a simulated nozzle to safe-end mockup by welding a section of a ring forging to a Type 304 stainless steel simulated safe-end in accordance with Authority welding procedures employing both automatic and manual welding techniques (GTAW and SMAW). A GTAW temperbead Inconel 82 weld overlay was then applied to the simulated nozzle to safe-end joint. The nozzle to safe-end mockup temperbead Inconel 82 weld overlay was welded in 'I . accordance with WPS NZ-Overlay employing a 300*F preheat and 500*F post heat in accordance with the EPRI' qualification program [3]. Following welding, the weld was sectioned and destructively examined as illustrated in the Physical Test Report for mockup 395 (Appendix 2), and the metallurgical and mechanical properties of the low alloy steel weld ' heat affected zone were compared to the base metal properties for this nozzle to safe-end joint. The purpose of these tests on welded components is to determine whether the component properties were degraded by welding. Section XI requires that repairs to components be performed which result in the base metal being left in a state equal to or better than the original as installed condition. Proper selection of weld metal can generally ensure that the weld metal properties will meet or exceed those of the base metal which it is replacing. However, tne weld fusion zone and the base metal heat affected zone can be adversely SIR-90-063, Rev. 0 8 STRUCTURAL INTEGRITY ASSOCIATESINC
i affected unless careful selection is made of welding materials and welding parameters and ) high quality welding is performed. The ASME Boiler and Pressure Code requires that, for heat treatable steels, of which low alloy vessel and nozzle steels are examples, appropriate post weld heat treatment must be performed to ensure that mechanical properties of the component are not degraded by the welding process. The GTAW temperbead process simulates the post weld heat treatment metallurgical
]
condition in the weld heat affected zone of a carbon or low alloy steel component by judicious selection of welding heat input for each of the layers of the temperbead weld. The EPRI/B&W program illustrates that using controlled welding parameters can produce a suitably tempered low alloy steel metallurgical structure without post weld heat treatment (4]. The EPRI Inconel temperbead study demonstrates that this automatic GTAW process could be extended to an Inconel 82 weld overlay on a low alloy steel nozzle using an automatic orbital welding technique [3]. WPS NZ-Overlay (Appendix 2) illustrates how the temperbead welding paremeters have Q V been selected to provide the metallurgical tempering and grain refinement normally obtained by a post weld heat treatment at typical temperatures of 1100 to 1300*F. One observes from WPS NZ-Overlay that the welding heat input is quite low for the initial weld layer, increasing in the secord layer and again in the third layer to allow the second and third layers to temper and grain refine the low alloy steel heat affected zone beneath the first weld overlay layer. The demonstration of this tempering effect on the low alloy steel heat affected zone is obtained by ASME Code mandated mechanical property testing. The Code l tests required for these heat treatable steels are tensile tests, bend tests, and Charpy V-notch L impact tests. The tensile and bend tests evaluate the soundness of the weld metal and the welding process. The impact tests examine the weld metal and the weld heat affected zone comparing the results to the unaffected base metal. In subsequent test programs, EPRI has demonstrated that increasing heat input with each temperbead layer not required. Rather, ! well controlled heat input will produce the required tempering effect. SIR-90-063, Ilev. 0 9 mocronar. DiTEGR17Y ASSOCIATESINC
2.2 Ir.dustry Developed Temperbead Qualification Prograrns In addition to the EPRI qualification program (3) which the Authority used to develop parameters for its temperbead qualification program, other temperbead qualifications have been performed by engineering organizations supporting the nuclear power industry. Among the performed programs, two are particularly notable since preheat and post heat var 6d. from the EPRI qualification program,in a manner similar to that performed in the Authority program. These qualification programs were performed by Nutech, Inc. and by _CB&I ) Services,Inc., and were reported at the EPRI Advisory Committee Meeting for Temperbead l Welding held in Charlotte, NC, on November 2 and 3,1989. : Sections 2.2.1 and 2.2.2 summarize the qualifications performed by these two organizations. Detailed descriptions of these activities are presented in Appendices 3 and 4 of this report. 2.2.1 Nutech Temperbead Qualification Program for Discharge Nozzle at the Oyster Creek Nuclear Power St '
-O Genera! Public Utilities contracted Nutech, Inc. to develop a contingency plan for providing an Inconel 82 temperbead weld overlay repair to a 26 inch diameter recirculation system discharge nozzle at the Oyster Creek Nuclear Power Station. The temperbead repair was identified as trie preferred approach compared to a full post weld heat treatment, since the geometry of the nozzle end the physical space .:onstraint resulted in difficulty in accommodating preheat and post weld heat treatment equipment. Consequently, Nutech developed procedures and performed qualification welds for both the temperbead weld overlay approach developed in the EPRI program [3] and a modified temperbead approach in which no preheat or post heat were applied to the joint.
A SIR-90-063, Rev. 0 10 mmemm b N issoC-sana -
.. . . - -- - ._ = . - _ - - . . _ . - . .- - ~ _ _ - . - . --
A 14-inch diameter nozzle was heat treated to simulate the post weld heat treatment condition of the discharge nozzle, buttered with inconel 182, and stress relieved at 1100-1150*F for one heur. Following the stress relief heat treatment, a Type 304 stainless steel safe-end was welded to the buttered nozzle using Inconel 182 manual welding techniques. Following the welding of the safe-end to the nozzle, two additional grooves were machined into the nozzle for temperbead welding in order to provide procedure qualification test samples. The configuration of the nozzle to safe-end including the grooves for the procedure qualification samples is presented in Figure 3 in Appendix 3. The procedure qualification temperbead welding 6 performed by welding other temperbead welds including a weld overlay using the EPRI 300'F preheat,500'F post heat technique (5 layers), then removing the preheat and performing the water backed other one-half of the temperbead welds (5 layers) without any preheat or post heat. The average temperature for the water backed welds was 70-75'F. Following the welding of the three temperbead welds as illustrated in Figure 3, Appendix 3, the Code required mechanical tests and supplemental metallurgical tests were O performed. Results of these tests are presented in Appendix 3 of this report and are Q. discussed in Section 3.2.1 of this report. 2.2.2 CB&I Reactor Nozzle to Safe-end Temperbead Structural Overlay Test Program The test program developed by CB&I Services, Inc., presents an ahernative to the EPRI temperbead qualification [3] and affords utilities increased flexibility in performing a temperbead repair to a low alloy steel nozzle to safe-end joint buttered with Inconel 182 weld metal. This test program, presented in Appendix 4, investigated the use of a non-water backed, non-preheated, non-post heated condition and a water backed non post heated condition as alternatives to the EPRI temperbead qualification [3]. l O SIR-90-063, Rev. 0 11 Q: STRUCTURAL INTEGRITY ASSOCIATESINC.
The CB&I program used an SA 508 Cl. 2 low alloy steel nozzle forging to perfonn the - appropriate post weld heat treatment to simalate the vessel heat treatment, and to weld a Type 304 stainless steel safe-end to the nozzle. Subsequent to the welding of the safe-end to nozzle, a one inch deep groove was machined in the nozzle remote from the rozzle to safe-end weld as illustrated in Appendix 4 and a six layer Inconel 82 temperbead weld was deposited to fill the groove using a 300*F preheat and 500'F post heat to simulate the EPRI temperbead process [3]. In addition to the temperbead groove weld, an Inconel 82 temperbead weld overlay was applied to the nozzle to safe-end weld as a wet / dry overlay, using a partial thermal sleeve (see Appendix 4 for details). With this configuration, one half of the nozzle at the safe-end would be filled with water while the other half remained dry. This configuration allowed the welding to be affected by a severe quench and a moderate quench. Neither preheat nor post heat was applied to this joint. Following welding, Code required mechanical tests and supplemental metallurgical tests were performed on the temperbead groove weld and the-modified temperbead weld overlay. The results of these tests are presented in the Appendix 0 4 renort =#a re disc #ssee ia secti " 3.2.2 of this report. t i i l i-q u SIR 90-06.5, Rev 0 12 ! TEGRITY bK-W'SOCIATESINC t
3.0 TEST RESULTS 3.1 New York Power Authority Temperbead Qualification Program This section of the report presents the mechanical and metallurgical tests performed to qualify the 200*F preheat, no post heat Authority Inconel 82 temperbead weld overlay for low alloy steel nozzle to austenitic stainless steel safe-end welds (POR 745). The results of i these tests are compared to the Inconel 82 te.mperbead weld overlay test results from the EPRI por.sored program [3] and the results from the Authority simulation of the EPRI qualification (POR 746) Finally, a simulued nozzle to safe-end Inconel 82 weld overlay mockup was fabricated using the same welding parameters as POR 746, and the test results for this mnckup are presented (POR 395) and compared to the EPRI qualification results. 3.1.1 Mechanical Property Tests Professional Service Industries,Inc. performed all of the tensile and bend qualification tests and for the metallurgical tests. The Charpy V-notch impact tests were performed by Lucius Pitkin, Inc. All physical property tests were performed in accordance with the ASME Code requirements of Sections IX and XI and Code Case N-432. The physical test reports for PORs 395,745, and 746 are included as Appendix 5 of this report, and the metallurgical reports for the temperbead samples removed for the qualification welds are provided in
. Appendix 6. Tensile and bend test presented in Appendix 5 illustrate that acceptable results were achieved for all samples tested. No defects were observed in any of the bend tests, and the tensile specimens all failed in the weld at a stress level near the certified material test report base metal tensile strength. .Charpy V-notch impact tw were performed on weld metal, heat affected one and base metal samples for each of the test conditions and were compared to the EPRI test results.
1 he heat affected zone Charpy samples for PORs 745 and 746 were oriented normal to the SIR-90-063, Rev. 0 13 INTEGRITY ASSOCIATESINC
_ ._. . ._ ~ _ _ . . _ _ . . _ _ _ .. _. . __ . weid so that the entire sample failure was in the heat affected zone. The base metal sample was oriented the same way so as to make a direct comparison between HAZ and base metal L/ . for these two PORs. Figure 1 in the Lucius Pitkin report for these two PQRs in Appendix 5 presents the orientation for these samples. Tables 1 through 4 present the results of the Charpy V-notch impact tests for the three procedures qualified in the Authority's program, comparing the results to the EPRI test results for the HAZ and base metals at 40*F, the test temperature for the EPRI tests [3]. Table 5 is a summary of the average Charpy impact results for the three Authority temperbead weld procedures and the EPRI procedure. All of the samples meet the 50 ft lbs absorbed energy and the 35 mils lateral expansion required by ASME Section XI and Code Case N-432. In all cases, the energy absorbed in the weld heat affected zones is greater than the base metal absorbed energy. This result meets the mechanical property requirements of the Code and of Code Case N-432 for the process to be qualified. No degradation of physical property resulted from the 200'F preheat, no post heat treatment used in the POR 745 qualifiuition. 3.1.2 Metallurgical Tests Metallurgical tests were performed to provide a direct comparison between the results of these tests and the prior EPRI study [3]. The metallurgical tests involved microhardness te.sts and metallographic examination of the weld heat affected zones for each of the procedures qualified in this prsgram. L The metallurgical tests were performed by Professional Service Industries, Inc. and are g D appended to this report as Appendix 6. Examination of the metallography for the 1 Authority's PQRs 395,745 and 746 revealed that the anticipated grain refinement occurred l in the low alloy- steel weld heat affected zones for each of the procedures. The microstructural results are quite similar to those presented in Figures 3-8 and 3-9 of the SIR-90-063, Rev. L 14 sTaocrunn. DITEGRITY ASSOCIAIESINC
~ Reference 2 report. The base metal structure for these specimens appears to be a tempe ud bainite or tempered martensite structure, the anticipated structure in this steel following quenching and tempering.
In order to confirm the tempering effect of the temperbead welding in the low alloy steel heat affected zove, microhardness measurements were performed on the groove weld samples in the Authority's qualification program (POR 745 and 746), and compared to the EPRI groove weld qualification results using a 500 yam Knoop indentor traversing the weld heat affected zone as was done in the EPRI study. The results of the traverses for the EPRI groove weld sample [3] are presented in Table 6 and are compared to the Authority's POR 746 groove weld sample and the POR 745 groove weld sample in Tabler 7 and 8. Table 7 presents the actual Knoop data for the three traverses and Table 8 presents these data converted to the Rockwell hardness scale. Examination of the Table 8 results reveals that the hardnesses for the three procedures are quite comparable, within anticipated data scatter, to a distance of approximately 1000 micr<ms (0.04 inches) from the weld fusion line.- Beyond that point, the hardness in the EPRI sampb is significantly lower than for the two
]
Authority samples, reflecting the fact that the base metel hardness of the EPRI nozzle was markedly lower than for the Authority ring forging. However, it is within the initial 1000 microns in the low alloy heat affected zone where high hardness due to improper tempering may create a low toughness or embrittled joint. No such concern is observed from these microhardness results. 3.2 Industry Developed Temperbead Qualification Programs This section of the report summarizes the significant mechanical and metallurgical tests performed in the Nutech and CB&l programs to qualify alternatives to the EPRI qualified temperbead welding program (3]. These two alternative p:ograms qualified a water backed temperbead procedure without preheat or post heat and a dry temperbead procedure again without preheat or post heat treatment. In each case the results are compared to the EPRI o l' lp SIR-90-063, Rev. 0 15 srmxmmm. INTEGRITY ASSOCIATESINC r --- e
- qualification program results [3]. Detailed descriptions of the Nutech and CD&I programs l are enclosed as Appendices 3 and 4 to this report.
3.2.1 Nutech Temperbead Qualification Program for Discharge Nozzle at the Oyster Creek Nuclear Power Station As described in Section 2 of this report, the Nutech qualification program compared an Inconel temperbead weld overlay using the EPRI qualification program parameters [3] to a temperbead weld overlay using water-bacxing and employing no preheat nor post heat treatment. In addition to fabricating a weld overlay on a nozzle to safe-end mockup, two groove welds were also fabricated to provide procedure qualificat.icn test samples comparing the EPRI temperbead parameters to the water backed temperbead parameters. One of the groove samples was welded in a part of the nozzle containing a 1/2 inch remaining wall thickness beneath the groove (the 1/2 inch groove), and the other procedure qualification test specimen was welded in a part of the nozzle with a 1-1/4 incil remaining thickness beneath the groove. The two different thicknesses were examined to evaluate the effects of location. Details of these tests are presented in Appendix 3 to this report and are
~
summarized below. Results of the tensile and bend tes.s for the procedure qualification welds illustrate no unusual failures for any of the samples tested. No defects were observed in any of the bend tests, and the tensile specimens all failed in the base metal remote from the weld heat affected zone indicating that the temperbead welding had no deleterious effect on the tensile results and bend test results. Charpy V notch impact tests -were performed on the two procedure qualification weld samples for the base metal and heat affected zones. Table 9 presents the results for both the water backed (wet) and the " dry" 300*F preheat,500*F post heat temperbead groove weld at the 1/2 inch and the 1-1/4 inch nozzle locations. Also included in Table 9 are the g SIR-90-063, Rev. 0 16 O sTaucreanL INTEGRITY r ASSOCIATESINC
Charpy V-notch results for the base metal on the ". vet" and " dry" halves of the nozzle. q These test results show that the absorbed energy and lateral expansion mee: the Code b requirements of 50 ft-lb energy absorbed and 0.035 inches lateral expansion in all cases. The impact energy absorbed and lateral expansion for the " wet" temperbead process are generalli lawer than that for the " dry" process. However, in the case of the heat affected side samples, the " wet" properties are somewhat better than the " dry" results. One other noteworthy result is that there is significant variability in properties in a nozzle forging. The differences between the " wet" and the " dry" results at a specific location in the nozzle are generally less than the differ nces in properties when comparing thinner and thicker locations in the same no72.ie. Table 9 also presents Charpy V-notch impact results for the weld overlay, using the EPRI parameters (dry) for one half of the overlay and the water backed " wet" temperbead parameters for the other half of the overlay. The weld overlay toe Charpy results in Table 9 illustrate that these results approximate the best base metal results in absorbed energy and lateral expansion. Further, these results are essentially the same whether the welding was OG performed " wet," without preheat and post heat or " dry," with a 300* F preheat and a 500* F post heat treatment. The variability :n properties within the forging Lppears to dominate the result obtained with the material notch toughness properties being far superior at the outside surfax than within the forging. The implication of these results will be explored further in Section 4 of this report. 3.2.2 CB&I Reactor Nozzle to Safe-end Tempe: bead Structural Overlay Test Program The CB&l test program for the nozzle to safe-end is similar to the Nutech program. A water backed " wet" overlay was qualified and compared to an overlay using the EPRI qualification parameters [3]. However, the CB&l program contains an additional qualification in which a " dry" temperhead weld overlay is applied to 1/2 of the nozzle to SIR-90-063, Rev. 0 17 q
%J INTEGRITY k ASSOCIATESINC l
safe-end joint without preheat or post heat. The results of this overlay qualification program are presented below. Results of the tensile and bend tests for the procedure qualification welds show no unusual failures for any of the samples tested. No defects were observed in any of the bend tests, and the tensile specimens removed frorn the groove weld failed in the base metal remote from the weld heat affected zone. Only all weld metal tensile specimens were evaluated for the weld overlay specimens. The *. ensile and bend test results indicate that the temperbead
-welding has no deleterious effect on the mechanical properties for these temperbead qualifiention welds, as illustrated in Appendix 4 The Charpy V-notch impact results for the temperbe.ad groove weld welded using the EPRI
. qualification pararneters [3] are presented in Tab:e 10. These results illustrate that the heat affected zone absorbed energy and lateral expansion are superior to the base metal results.
The Charpy V-notch impact results for the water backed temperbead weld overlay and the dry temperbead weld overlay employing i o preheat or post heat treatment are presented I h~ in Tables 11 and 12. Also included in these tables are the corresponding base metal impact test results repeated from Table 10. One observes from Tables 11 and 12 that the heat affected zone notch toughness for both ginalification tests are superior to the base metal properties in absorbed energy as well as in lateral expansion. No impact tests were performed at the weld averlay toe regions for the water backed or dry qualification tests. However, hardness te vs illustrate.J that full structural temperbead weld overlays covering the nozzle to safe-end weld can be temperbead welded at the toe tie in points without the use of filler- to obtain similar hardness and impact strength levels to that of the EPRI
- qualification (3).
SIR-90-063, Rev. 0 18 n.y STRUC N b assoc 1' smURA e--v
i l Table 1 (~} _V l i Base Metal and Heat Affected Zone (HAZ) Charpy i Impact Results for EPRI Qualification Samples [3] Tested at 40'F Energy Lateral Fracture Absorbed Expansior. Appearance Location (ft-lbs) (inchesi (% Sheari HAZ 67 0.056 60 88 0.066 70 69 0.051 50 Average 75 0.058 60 y Base Metal 65 0.053 50 v' 83 0.056 70 76 0.053 50 Average 75 0.054 57 SIR-90-063, Rev. 0 19 IO v DITEGRfTY ASSOCIATESINC
Table 2 Base Metal and Heat Affected Zone (HAZ) Charpy Impact Results for NYPA Qualification Samples - Procedure 746 (300'F Preheat - 500*F Post Heat) Tested c 40*F Energy Lateral Fracture Absorbed Expansion Appearance Location (ft-lbs1 (inches) (% Sheari HAZ 103 0.059 100 153 0.084 100 94 0.077 100 89 0.057 100 89 0.057 100 Average 95N 0.064N 100" Base Metal 97 0.066 70 68 0.050 40 78 0.054 50 118 0.076 100 87 0.066 60 Average 87N 0.062N 60N - Note: (a) Base Metal _- Average of three readings excluding highest and lowest values HAZ - Average of three readings excluding highest and lowest values SIR-90-063, Rev, 0 20 lINTEGRITY
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Table 3 Base Metal and Heat Affected Zone (HAZ) Charpy
/] Impact Results for NYPA Oualification Samples - Procedure 745 (200*F Pr: heat - No Post Bake)
Tested at 40*F Energy Lateral Fracture Absorbert Expansion Appearance Location (ft-lbs) finches) (f% Shearl HAZ 80 0.058 100 180 0.080 70 89 0.060 100 94 0.064 100 98 0.067 100 Average 94N 0.064N 100N Base Metal 108 0. ' . 70 O- 74 0.058 50 73 0.055 50 111 0.072 80 80 0.057 50 Average 87N 0.062W 56.7N - Note: (a) Base Metal- Average of three readings excluding highest and lowest values a HAZ - Average of three readings excluding highest and lowest values SIR-90-063, Rev. 0 21 DITEGRITY ASSOCIATESINC
Table 4 l Base Metal and Heat Affected Zone (HAZ) Charpy Impact Results for NYPA Qualification Samples - Procedure 395 (Nozzle Mockup 300*F Preheat,500*F Post Heat) Tested at 40*F Energy Lateral Fracture Absorbed Expansion Appearance I;> cation (f1:]h) (inches) (% Shearl HAZ 64 0.049 40 68 0.052 40 94 0.063 60 127 0.087 100 62 0.049 40 Average 75M 0.055m 46.7M (G _/ Base Metal 66 0.051 40-67 0.052 40 64 0.050 40 67 0.052 50 82 0.065 40 Average 67N 0.052m 40M Note: (a) Base Metal- Average of three res: lings excluding highest and lowest values HAZ - Average of three readings excluding highest and lowest values
-. SIR-90-063, Rev. 0 22 O v l 7STRUC'I'URKL
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Table 5 eg Comparison of Average Charpy impact Test C/ Results Among the EPRI and NYPA loconel 82 Temperbead Weld Overlay Procedures Tests at 40*F EPRI-Procedure Procedure Procedure Procedure (Reference.2) 746 745 395 Base Metal (BM) 75 87 87 67 Absorbed Energy (ft - Ibs) Base Metal Lateral 0.054 0.062 0.062 0.051 Expansion (iaches) Heat Affected Zone 75 95 94 75 (HAZ) (ft - lbs) HAZ Lateral Expansion 0.058 0.064 0.064 0.055 (inches) Ratio e' MAZ to 1.0 1.09 1.08 1.12
. BM - : bed Energy Ratio of HAZ to 1.07 1.03 1.03 1.08 BM Lateral Expansion SIR-90-063, Rev. 0 23
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Table 6
'- EPRI Test Results Microhardness Measurements in the P-3 Heat Affected Zone of the Groove Weld (Reference 3)
Distance From Knoop Haroness Converted Fusion Line Values Rockwell (Microns) (500 cram loadi Hardness Values (Peak) (Valley) (Peak) (Valley) 50 380 323 38C 31.5C 100 387 337 38.5C 33.5C 300 421 295 41.5C 28C 500 408 363 40.5C 36.5C 700 340 397 33.5C 39.5C 900 348 342 34.5C 34C 110C 343 294 34C 27.5C 1300 300 278 28.5C 25C 1500 277 269 25C 23.5C -Q v 1700 1900 268 252 241 220 23.5C 20C 98B 94B 2300 207 217 91B 93B 2700 201 217 90B 93B Base Metal 204 203 90.5B 90.5B SIR-90-063, 'Rev. 0 24 STRUCTURAL DITEGRITY ASSOCIATESINC
l Table 7 O Microhardness Traverse on SA-508 Cl. 2 Heat Affected Zones in Groove Welds from the EPRI Program (Reference 3) and the Authority Temperbead Qualification (PORs 745 & 746) l l Knoop Hardness Values (500 gm load) Distance From Fusion Line EPRI POR POR (microns) Sample 746 745 50' 323 322 300 100 337 347 350 300 295 380 375 500 363 370 420 700 177 317 328 900 342 392 355
.. 1100 294 2% 365 -O' <'
1300 2.78 269 323 290 315 288 1500 1700 241 275 321 1900 220 277 296 2100 - 242 242
~2300 217 250 246 2700 217- 238 268 Base Metal- 203 - -
h, SIR-90-063, Itev. 0 25 l M INTEGE#if ASSOCIATESINC
Table 8 Microhardness Traverse on SA 508 C1. 2 Heat Affected Zones in Groove Welds from the EPRI Program (Reference 3) and the NYPA Temperbead Qualification (PORs 745 & 746) Table 6 Results Converted to Rockwell Scale l Distance from Fusion Line EPRI POR POR (microns)_ Sample 746 745 50 31.5C 31.5C 28.5C 100 33.5C 35C 35C 300 28C 38C 37.5C 500 36.5C 37C 41.5C 730 39.5C 31C 32C 900 34C 39C 35C 1100 27.5C 28C 36.5C 1300 25C 32C 31C O~ 1500 23.5C 27C 26C 1700 98B 24.5C 31C 1900 94B 25.C 28C 2100 - 98B 98B 2300 91B 20C 99B 2700 908 97B 23C base Metal 90.5B - - SIR-90-063, Rev. 0 26
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Table 10 CB&I Mocxup Nozzle Charpy Comparisons (Procedure 7673 - 300*F Preheat,500'F Post Heat) Tested at 20*F Fracture Lateral Absorbed Energy Appearance Expansion Location (ft-lbs) (% Shear) (inches) iia 2 70 45 0.037 (uaom of Groove) 62 40 0.044
. 84 50 0.063 98 70 0.059 91 65 0.055 93 70 0.056 Average 83 56.7 0.052 Base Metal 43 40 0.036 (1/4T from OD Surface) 48 50 0.045 60 50 0.040 lA V 43 51 40 35 0.033 0.042 L 45 35 0.037 Average 48.3 41.7 0.039 F
SIR-90-063, Rev. 0 28 x 0 - INTEGRITY - ASSOCIATESINC
A sv a v$>s 9 4> o (0 i. IMAGE EVALUATION / #b, \/ T[^59 k,*If fd (g j '( $ TEST TARGET (MT-3) 4 /Q 'g3 f~4ge V'459 N%v 4sr<<(e i.o y m e a l p= =n 3g 1.1 te m # "22
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C3&l Mockup Nozzle Charpy Compuisons (Procedure 7718. Water In Nozzle)
-. Tested at 20'F Fracture Lateral-Absorbed Energy Appearance Expansion Location (ft-lbs) (% Shear) (inches)
HAZ 111 50 0.075 - (Beneath Overlay) 89 40 0.063 99- 70 0.072 Average 99.7 53.3 0.070
-Base Metal 43 40 0.033 (1/4 from OD Surface - 51 35 0.042 Repeated from Table 10) 45 35 0.037
. Average 46.3 36.7 0.037 L
11 i W - SIR-90 063, Rev. 0 29 klc ., sTauctuum INTEGRITT ASSOCIATESINC
Table 12 CB&I Mockup Nor21e .Charpy Comparison (Procedure 7717 - Nor21e Dry No Pt '. eat or Fost Heat) Tested at 20*F Fracture Lateral
, Absorbed Energy Appearance Expansion Locatiqa (ft-lbs) (% Shear) (inches)
. HAZ 95 50 0.060 (Beneath Overlay) 76 40 0.057 95 55 0.065 Average 88.7 48.3 0.061 Base Metal 43 40 0.036 (1/4 from OD Surface - 48 50 0.045 Repeated from Table 10) 60 50 0.010 Average 50.3 46.7 0.010 I.
L + L ()%
. SIR-90-063, Rev. 0 30
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4.0 DISCUSSION OF RESULTS O The results of the mechanical and metallurgical tests described in the prior section i of this report illustrate that much research has been performed in developing and qualifying alternative procedures to the EPRI qualified 300*F preheat,500*F post
- heat temperbead procedure for producing a weld overlay repair to a low alloy steel nozzle to austenitic safe-end joint [3]. The Authority's process examined the effect of a reduced preheat (200'F) and no post heat inconel 82 temperbead weld overlay .
repair process on mechanical and metallurgical properties of a low alloy steel nozzle material. The two groove weld procedure qualification tests performed in the Authority's program, comparing the reduced preheat process (POR 745) to the EPRI process (POR 746), demonstrated that little or no difference in mechanical or metallurgical properties is to be expected when the preheat is reduced and no post heat is performed. The slight differences in absorbed energy and lateral expansion between the two processes fall well within the expected within lmat data scatter for impact tests in this class of material. This observation is confirmed by the Nutech and CB&l results in which a water , backed temperbead weld overlay is compared to the EPRI qualification results [3]. In the CB&I case, Charpy V-notch absorbed energy and lateral expansion results for the no preheat, no post heat procedure are superior to 'he unaffected base metal results indicating that no deleterious effect would result from such a temperbead overlay repair whether water backed or dry. The Nutech test results indicate that both the wet and the dry temperbead groove welds produce heat affected zone absorbed energy and lateral expansion which are reduced from the base metal results. However, the actual temperbead weld overlay fabricated over the nozzle to safe-end-weld produces absorbed energy which approximates that for the unaffected base SIR-90-063, Rev. 0 31 m u c m m I. TINTEGRITY 6 asoc mEstwa
metal and the lateral expansion exceeds that for the base metal for both the . vet and .O; the drx weid everier with ee nrcheet er nest heet treatment. When comparing the water backed temperbead welding process to the dry temperbcad welding process on the same heat of material using the same welding parameters, the dry temperbead profess produce: somewhat improved toughness results. However, this effect is less sig.tificant than the within heat variability in notch toughness which appears in each of :Se tests described in this program. Th,e toughness of the as-fabricated and heat treated forging 's quite variable due ta the metallurgy associated with this heat treatable material. Although this alloy is designed for improved through-thickness hardenability, there remains a significant variability in properties from the surface to the interior. The Nutech and CB&l base metalimpact values illustra.e the through thickness variability in the notch toughness of this class of steel. The outside suiface of the nozzle (or ring forging) always has the best properties, since it is most rapidly quenched during component fabrication.
- The fully quenched ma-tenait structure will always be tougher than a bainitic structure when properly tempered following the quenching. Therefore, this surface
-and the near surface region should have the highest notch toughness within the component. Consequently, a temperbead weld overlay repair over this surface can readily produce a significantly tougher structure than that of the base metalinterior.
This feature of a quenched and tempered low alloy steel provides added assurance that the overall nozzle properties will not be degraded by a well controlled temperbead weld repair. Of greatest importance, however, is that the base metal
- properties always met or exceeded the Code required 50 ft-lbs and 35 mils lateral expansion at temperatures of 40*F or greater in the tcst programs described in this report.
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The previous discussions have illustrated that the use of reduced or no preheat, with or without water-backing, can indeed produce an inconel 82 temperbead weld overlay repair on an SA 508 Cl. 2 low alloy steel forging which meets the Code requirements for not'h toughness provided the welding is well controlled. 4,1 Additional Issues l Additional issues were addressed providing further confidence that such a repair will have no deleterious effect on the low alloy steel torging material. The issues are hydrogen produced during welding, and the high residual stress due to the welding of>eration. Both the hydrogen effect and the residual stress effect result from the lack cf a post weld heat treatment. 4.1.1 Hydrogen EPRI recently initiated a program to address the issue of hydrogen in SA 508 Cl. 2 ( low alloy steel. The prograni involved preheating two sections of this material to 150*F and 300*F. Once the preheat was established, welding was initiated under conditions of 95% humidity and a 120* F laboratory working temperature. Following welding, the samples were prepared in accordance with the AWS Standard A4.3-86,
" Standard Methods for Determination of the Diffusable Hydrogen Content of a Martensitic, Bainitic, and Ferritic Weld Metal Produced by Arc Welding." The results of these tests are presented in Table 13.
The amount of diffusable hydrogen in t're sample preheated to 150*F was somewhat lower than that produced during the 300* F preheat. Both diffusable hydrogen results are at least one order of magnitude lower than the maximum allowed by the Interr.ationalInstitute of Welding for acceptance as a hydrogen controlled weld when welding mild and low alloy steels [5]. The results of this test program were presented SIR-90-063, Rev. 0 33 c mmcroma F INTEGRITY ASSOCIKIESINC
V at the_ Temperbead Advisory Committee Meeting on October 30, 1990 and are
. included as Appendix 7 to this report. These results demonstrate that neither the 150'F nor the_300'F preheat GTAW temperbead welding process will produce
-diffusable hydrogen in quantities which would produce a hydrogen embrittlement conceru in this alloy.
-This result is expected, since the bare wire GTAW process contains no obvious i
source of hydrogen. There is no flux or coating which can be a source or hideout location for hydrogen as could be the case for the shielded electrode welding processes. I - l 4.2 Residual Stress-l The issue of high tensile residual stress resulting from the welding operation is important to low alloy steel components. The ASME Code contains specific post weld heat treatment requirements to address the residual stress issue and provides
- e.:emptions depending on material hardenability and the restraint imposed by material thickness. The use of a well controlled welding process may reduce the size of a heat affected zone thereby-limiting the extent of the residual stress field.
However, it is difficult to reduce or eliminate the peak residual stress caused by melting of the base metal and resulting solidification shrinkage. In the case of a weld overlay, however,it is possible to use the residual stress effect l to an advantage. Since the weld overlay is applied to the outside surface of the l l component, opposite the surfa:.e which sees the aggressive coolant, one can use the added heat sink effect associated with low or no preheat for residual stress redistribution. In the EPRI Inconel 82 temperbead weld overlay qualification 5 program, residual stress analyses were performed using finite element modeling to l evaluate the effect of a temperbead weld overlay o- e state of ID stress in tne ISIR-90-063, Rev. O ; 34 L - ocru m
,(INTEGRITY V ASSOCUMMC
nozzle and safe end in the vicinity of the butt weld [3]. In that study, a temperature _h model was used to develop the transient temperature history due to welding. A stress model using the temperature history as input, provided the residual stresses and strains due to the temperbead welding, comparing the residual stresses of the butt weld with those 4 the temperbead weld overlay. The residual stress distribution due to the butt weld before the application of the overlay is illustrated in Figure 1, taken from Reference 3. This figure shows that, as a result of the relaively thick pipe wall modeled in this study, the inner surface of the pipe and nozzle are under compressive axial and hoop stresses and the outer surface of the pipe and nozzle are under tensile stress in the butt weld region. Residual stress distributions after the application of the overlay are 3e 4mted in Figure 2 [3] for the axial and hoop stresses. The weld overlay extends the compressive region for axial residual stresses to almost the entire thickn-ss of the original pipe wall under the overlay. The stresses at the ID surface are slightly less compressive following the overlay compared to the residual stresses prior to the overlay application. However, the temperbead weld overlay significan:ly improves the through thickness residual stress state compared to the butt weld residual stress distribution. A lower preheat would have little effect on the weld overlay distributions presented in Figures 1 and 2, because any reduction in preheat would be expected to produce an even more favorable ID and through the pipe wall residual stiess distribution. Any increase in the through wall temperature gradient would produce a more favorable ID residual stress state, much as is observed-with heat sink welding and with the induction heating stress improvement process. The favorable residual stress improvement due to a weld overlay application stands in marked contrast to a temperbead repair which is performed on the same surface as is exposed to the aggressive coolant. In that case, the temperbead repair produces l l ten;ile residual stresses in a location susceptible to stress corrosion cracking. In the L Q SIR-90-063, Rev. 0 35 l N L . INTEGRITY L
/ ASSOCIATESINC
1 temperbead weld overlay application, the tensile residual stresses occur in the surface opposite to that exposed 'to the aggressive coolant, thereby having no deleterious effect on the exposed surface, i 1 e l l SIR-90-063, Rev. 0 36 srmx n mar. INTEGRITY
/ ASSOCIATESINC
Table 13 Measured Diffusible Hydrogen Content (ml/100 g) in Samples Prepared by EPRI (Appendix.7) HY-150m HY-300m 0.846 0.973
. 0.343 1.108 0.361 1.244 1.092 1.077 i
Average 0,6605 1.1005 O Notes: (1) preheated to 150' (2) preheated to 300*
/
s SIR-90-063, Rev. 0 37 l mocrann. , i
/> ASSOCIATESINC DrFEGRHY j
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\ ! \
Figure 2. Through-Wall Residual Stress After Application of the Temperbead Weld Overlay (Reference 3) ; j SIR-90-063, Rev. 0 39 b
,e a - - _ _ _ - _ - - - - - - - - - - - . _ _ _ _ - _ _ - - _ _ _ _ _ _ . _ - _ - . . - _ - . . _ _ _ . _ _ _ - _ - . - _ _ _
5.0
SUMMARY
AND CONCLUSIONS Q The New York Power Authority has developed u. alternative Inconel 82 temperbead weld overlay repair method for low alloy steel components at the James A. FitzPatrick Nuclear Power Plant. This temperbead welding approach provides an alternative to the EPRI and the Code Case N 432 temperbead qualification i approach. In the Authority's qualification, a 200'F preheat, no post heat treatment j
~
temperbead welding approach is compared to the EPRI and Code Case N-432 l temperbead approach in which a 300'F preheat,500*F post heat treat weld was ! qualified. The results of the Authority qualification are summarized below, e The Authority's Inunel 82 temperbead wela overlay qualification program demonstrated that the tensile, bend, and Charpy V-notch impact properties of the SA 508 Cl. 2 low alloy steel heat affected zone - are not degraded by the application of the temperbead weld overlay employing a 200'F preheat with no post heat treatment. No O. metallographic changes were noted in the Authority samp'n welded with the lower preheat as compared to the Authority sample welded in accordance with the EPRI temperbead parameters.
- Studies performed by other investigators examining the use of no preheat or water-backing for the inconel temperbead weld overlay support the Authority's observation that the lower preheat has little effect on the notch toughness of these materials when compared to the unaffected base metal or the EPRI qualification process results. In some cases, the "no preheat" case produces superior notch toughness as compared to the EPRI and Code Case N-432 parameters. In other cases, the "no preheat" case produces somewhat lower notch toughness.
Although the notch toughness may be reduced slightly when using sir-90-063, Rev. 0 40 sTaucrunst INTEGRrrY h ASSOCIATESINC
(. water backing or no preheat during the temperbead welding, the within heat variability in notch toughness properties in this class cf materials is ' more significant than the lack of preheat during welding in determining the Charpy V notch impact properties of these weldments fabricated from SA 508 Cl. 2 low alloy steel. e Reduction of the preheat from 300'F to 200'F and climination of 500*F post weld bake permit repairs to be made without dewatering the pipe.. Significant reductions in outage schedule and decreased
, radiation exposure to craft are potential advantages of the revised procedure.
e The potential effect of hydrogen embrittlement resulting from the reduced preheat and no post heat has been investigated. For the GTAW process, no deleterious effects of the reduced preheat are noted. The amount of diffusable hydrogen within the low alloy ste:1 following low temperature GTAW welding on SA 508 Cl. 2 is at least one- order of magnitude less than that required for a hydragen embrittlement concern.
- The temperbead welding process on a low alloy steel component produces tensile residual stresses on the surface which is welded and compressive residual stresses on the opposite surface. This result leads to a more favorable through-wall axial residual stress distribution for the temperbead weld overlay in which the cracking is initiated on the surface opposite to that surface which is weld repaired. For weld repairs to surfaces exposed to the aggressive environment, the tensile residual stresses resulting from the temperbead repair must be accounted for in the repair program.
. SIR-90-063, Rev. 0 - 41
~. m
. INTEGRITY
/ ASSOCIATESINC
1 In summary, the Authority, Nutech and CB&l qualification programs demonstrate
=
that an inconel 82 temperbead weld overlay repair can be applied to a low alloy steel nozzle with no or reduced preheat and no post heat treatment, without deterioration of notch toughness of the SA 508 Cl. 2 steel properties. Any changes observed in notch toughness are smaller than the within heat variability which exists in a typical nozzle. Since the overlay is applied to the outside surface of the nozzle, opposite the surface exposed to the aggressive coolant, no residual stress concerns or hydrogen embrittlement concerns have been observed or are anticipated. 0 x SIR-90-063, Rev. 0 42 g e _TEGUTY M N- ASSOCIATESINC
} _ _ _ _ - - - - - - - - - - - _ -
6.0 REFERENCES
- 1. " Repair Welding Using Automatic or Machine Gas Tungsten Arc Welding
'(GTAW) Temperbead Technique, Section XI, Division 1," Code Case N-432, ASME Boiler and Pressure Vessel Code, February 20,1986.
- 2. ' Technical Report on Material Selection and Processing Guidelines for BWR Coolant Pressure Boundary Piping," NUREG-0313, Revision 2, U.S. Nuclear Regulatory Commission, January,1988.
- 3. P. Norris, et al., " Development of Incone; Weld Overlay Repair for Low Alloy Steel Nozzle to Safe-end Joint," EPRI Research Project RPT3031, Structural
, Integrity Associates Report SIR-86-015, June,1988.
- 4. " Repair Welding of Heavy Section Steel Components in LWRs," EPRI NP-3614, Volumes 1 & 2, July,1984.
- 5. " Weld Metal Hydrogen Levels and the Definition of Hydrogen Controlled Electrodes," International Institute of Welding, Document IIS/IIW-452-74, Provided by D. Gandy, EPRI NDE Center,1990.
10
)
SIR-90-063, Rev. 0 43 m sinuorumI. INTEGRITY ASSONINC
Report No.: SIR.90-063 Resision: 0 Project No.: NTTA 260 November 1991 O l 1 l VOLUME 2 - APPENDICES l l Qualification of inconel 82 Temperbead Weld Overlay Repair With Reduced Preheat ! and No Post Weld Heatmg l i l l Prepared by: l StructuralIntegrity Associates, Inc. ; San Jose, CA O Prepared for: New York Power Authority White Plains, NY
- i W[ 5 arrowTY
- .O . / ASSOCATESK l'
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\.4,s' NUCLEAR fMODUCTSi INC.
NEW YORK POWER AUTHOR!TY JAMES A. FITZPATRICK NUCLEAR
-POWER PLANT
' LAKE ROAD F.AST .
Town OF SCRIBA OSWEGO,' NEW YORX 13126 ' 4 REF: WF1 WN4228 HEAT TREATMENT ATTACHMENT 7%TERIAL SA508 CLASS 2 1 HEAT CODE 6BBBN1 PAGE 2 MATERIAL AND TEST PIECE % 1, 2, s 3 1 NORPALIZE AT 1675' F + 250 AIR COOL; AUSTENITIZE AT 1600' F i 250F, 2 HOURS HEAT VP TIME, 2 1/4 H AT TEMPERATURE AND WATER QUENCH; F, 2 HOURS HEAT UP TIPE, 2 1/4 HOUR 5 TEMPER AT 1250' F 2 1/4 HOURS AT TEMPERATURE AND AIR COOLED. f. 25 0 F, 2 HOURS HEAT UP Tile, t N 45T PIECE # 2 , POST WELO HEAT TREAT AT 1150' F + 250 TEST PIECE d 1. TO 150' F. HEAT UP AND C00E DowNF.RATE ABOVE 600F iI,FOR CONTROLLED TO 1000 F TEST PIECE # 3 POSTFOR TREAT WELD TESTHEAT PIECE 9TREAT 1, AT 11500 F g 250 F FOR 40 HOURS IN ADDITION I TO H TC 100'#F TO 150' F. HEAT UP AND COOL DOWN RATE ABOVE 500* F CONT '
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O Appendix 2 i Weld Procedure Specification and l Procedure Qualification Records I WPS: NZ Overlay and PQRt 395, 745, 746 i O , SIR-9043, Rev. O O i
I (F '.82 SLUISn:D FDMT FOR 'aHIDG PFLGLTI SPECITICAn0[(MS) E (Sce (P-201.1, Section IX, ASG lbiler and Pressure Ve"el Ccaje) 4-cgpany Neu N.Y.P.A. By: Neal On;run Procedure Specificatien No. NZ-Oterlav Date
!b. Ibte Support PQR fb.(s) _ -A9 ' 7 *y 4 7 ac.
Prtcess(es) G"u; Types ._ Autcratic Nchine (Autcratic, Mrml, natine, or Sani-Auto) __
' JOINIS (ty-402)
Joint Design Wid Build-lb CVerlav Detaile
-Eacking (Yes) L.imal .
'A p-c, N , .
(!b) ~ ,U ~
= Backing Material (Ty;e) _ Dcisting Material c g r , {~e '3, r { g 1
- Sketches, Production Draring;s, Wld Sy6cis, or /
. Written Description shculd show the general arrangement of tre parts to be wided. 'nhere _
5, ~ [G gg applicable, the toot sW and the detai1= of F_, weld grocwe cay be specified.
' , .. ,. ' j I s
(At th2 option of the Mfgr., sketches eny be A ' i-ettached to illustrate joint design, wid layers and bead seqJence, e.g., for rotch tough-ness procedures, for tultiple process procedures, 6tc.
**FASE MEIAIS @ -.03)
P b. 3 Croup No. 3 to P4b. 8 Croup !b. I on Sp~ iffr ae4m type and grade N/A ication type and grade N/A Om. Analysis armi Nch. P: p. N/A-to Qa_ Analysis and Mech. Ewy, N/A
'Ihickness Range:
Base Metal: Awe Overlav on P3=5/8" to 2-1/2" F-We Depcsited Wld Metal:-Ome Overlay - 1" unxi,r, Overlav on P8 = 3/16" to 2-1/4" Pipe Dia. Range: Fillet Ncue - Lt Overlav = All Other on + ,.... u '.w - - m,', Fillet _ tbne
. . . . . <; W2 P P - Nt Gree ve u t_
- m s .= N ~ . , ~ . * * -
'EnIR MEIALS ((p-404)
F b. , _ 43
' A46. None Other N/A l Spec, tb. (SFA) 5.14 Other N/A !
AWS 15. (Cla ") EWiCr-3 Si:e of filler tern 1s .035" 1 l (Flw-trode, Cold Wire, )bt Wire, etc.) i Electrode-Flux (Class) N/A Flux Trade Name N/A Constcable Insert N/A -
- h haca untal-fille metal c:rbinatico shau.ld be recorded individually.
ID V
i Q4 482 (Back) I kTS No, M R-a vrlav,Fa . O i "1 (F-405) POS1VE1D HEAT IREAIMLNr (Q4-407) sitax.s(s) of Crrove O.vtlav M Tcqerature Range 500'F 2 50'F 1 ding Pr g m ion: Up 'bne rwn: Vertical Ti::e P,rge 2 hars sition(s) of Tillet Nme T.AT (CF-'.06) GNS (Q4-408) eheat Te:p Min. 300*F Shieldire Cas(es) Arcan iterpass Ta p. Max. 450*F Percent Ca::positico (mixtures) 99.9% Pure theat M11ntenance Contiruns
- kmtinu:us or special heatire dere applicable F1w Bate 104 chi
- h:uld be recorded.) Gas Backirg N/A r.*m thru to FMtr Trailing Shielding Gas Ccc: position N/A
'.'ICICAL GARACIERISTICS (QA409)
Irrent AC or DC DC Polarity DCEN
- ps (Range)
- Volts (Pangt)
- kps and volts range sh.uld be recorded for each ,
slectrode size, position, and thickness, etc Ihis infomation cay be listed in a tabular for:n si-ilar to that 'rNn belw.) : i Electrode Size and Type 1/8 E'DI-2
,(Pure Tungsten, 2% 1horiated, etc.)
- de of Metal Transfer for Q W N/A (Spray arc, short circuiting are, etc.) ;
lectrede Wire Feed Speed Range See attached para:eters sheet
. HNIQUE (Q4-410) tring or Weave Based Strirgers only rifice or Cas Cup Size 10 thru 12 nitial ard Interpass Cleaning (Brushing Orindi.q, etc.) Grittiing Sa:ning, Wire brushirg, F111rg, a:xi acoreved solvent wish tched of Back Gouging Gri:xiing w 411mH nn Ncre ' ttact Tube to 'vbrk Distance a N/A bitiplo or Single Pass (per side) Itltiple bitiple or Single Electrodes Sirs,le tavel Speed (Range) See attached paraceters sheet i 'ecrur:g Not Allowed !
ther
E' Page 3 NZ-Overlay, Rev. O NEW YORK POWER AUTHORITY VELDING PROCEDURE SPECIFICATION Mschine Settine Laver No. IPrepurge Time ' 1 Laver No. 2 b Sec. b Sec. ICurrent Start Mode Touch i Touch l Current Start Level i 50 Amps j 50 Amps current Upslope Time _ 5 Sec. I . Primary Current i 5 Sec. 210 A=ps 230 A=ps i Background Current 120 Amps 140 Amps I , Primary Voltage Background Voltage Current Sync i i 9.8 Volts 9.8 Velt_s (F6TsjV Remo t e 9.8 Volts
.9 1 Volts l
I Q'ulf3/ Remote I Primary Pulso
' Background Pulse
'Out Dwell 4 Sec.
.2 Sec.
Sec.
.4 Sec.
.2 Sec.
Sec. Excursion Sec. Sec. In Dwell Sec. Sec. Oscillator Amplitt de Inch Inch AVC Un-lock Delay 4 Sec. 4 Sec. I AVC Response AVC Mode 1 Sample 1 Sample iStub Out Mode Auto Auto Iiravel Start Delay I(g N ITravel at Tungsten Travel Sync. m
- t. .
4 5.5 Sec. 8.5 Inch / Minute 5.0 Sec. 7 Inch / Minute Continuous Centinuous Wire Start Delav 5.2 Sec. 4 Sec. IPrimary Wire Speed 43 Inch / Minute (Background Wire Speed 63 Inch / Minute 30 Inch / Minute Wire Sync. Current 51 Inch /Minuti Current I : Current Downslope Tice Wire Stop Delay 10 Sec. 1 Sec. 7 Sec. 1 Sec. l Wire Retract Time .125 Sec. .!.15 Sec. AVC Lock Delay 2 Sec. I Travel Stop Delay 10 Sec. 1 Sec. 7 Sec. iPostpurge - 10 Sec. l Heat Input Max. 10 Sec. 12.451 Joules / Inch 16,800 Joules / Inch l l I I G
Page 4 NZ-Overlay, Rev. O NEW YORK POWER AUTHORITY [~'} VElDING PROCEDURE SPECIFICATION
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Layer No. 4, Machine Settine Layer No. 3 and Ewa=xte. Prepurge Time 6 Sec. 6 Sec. 1 Current Start Mode i Touch Touch l ICurrent Start Level I 50 Amps 50 Amps ICurrent Upslope Time 5 Sec. 5 Sec. iPri=ary Current 240 Amps 230 Amps jBackground Current i 140 Amps 140 Ampr Primary Voltage i 9.8 Volts 9.8 Volts Background Voltage i 9_._d i'ol t s 9.8 Volts q. Current S ync I fuls e.J Remo t e Pulse / Remote 't Primary Pulse .4 Sec. 4 Sec. Background Pulse .2 Sec. .2 Sec. Out Dwell Sec. Sec. Excursion Sec. Sec. In Dwell Sec. Sec. Oscillator Amplitude Inch inch AVC Un-lock Delay I 4 Sec. 4 Sec. AVC Response i 1 1 AVC Mode Sample Sample Stub Out Mode Auto Auto Travel Start Delay 5 Sec. 5 Sec. l l Travel at Tungsten 6 Inch / Minute 7 Inch / Minute l , ITravel Sync. Continuous Continuous Wire Start Delay l 4 Sec. 4 Sec. Primary Wire Speed i 69 inch / Minute 63 Inch / Minute Background Wire Speed i 56 Inch / Minute 51 Inch / Minute Wire Syne. Current Current Current Downslope Time 10 Sec. 7 Sec. Wire Stop Delay 1 Sec. 1 Sec. Wire Retract Time .125 Sec. .125 Sec. l AVC Lock Delay 1 Sec. 1 Sec. ITravel Stop Delay 7 Sec. 7 Sec. Postpurge 10 Sec. 10 Sec. Heat Input Max. {20,247 Joules / Inch 16,800 Joules / Inch I l ! Layer 7 and subsequent layers if required may use any of the parameter sets j listed. l l l l l t v) _ . _ . _ 'N
un 4eJ SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION ALCQfio (PQMI (5ee QW 201.2.Sectisn IX. ASME 8 iler and Pressure VesselCatel Record Actuel Conditices Us:d to Wold Test Csustn. pan, ) of g m.: -
=
Companv Nam, New York Power Authortty Procoowre Osallftcet on Recore No EU ogie {' h _ N2 - Clad r
- U 4 Procniin)- SMAW -
Typn tVam v et. Autometic, temi Aato.) - Manua1 sotNTS (CW 402)
~
This PQR is comprised of 3 separata stages.
- 1) ID Cladding of SA508 E 3 0 %- -
- 2) Buttering 6 PWHT of SA50$
- 3) Groove Weld
',9)T~g~e,-bfM OWALA Y E30BL
-l y s y,
i Groove Cetion of Test Cowoon (For combination cwelitiestions, the concolted weic raetst tnamers snell be recoretc for es:n filler metet or crocess wsec.) SA8E METALS (CW403) SA508 PQ1 MELD HEAT TREATMENT (CW407 ceteriet se c.- _ 7,,n ,,,,, ,, See subsecusnt PQR Type et Qrece - C1 ass !I y ,n, , oaea 2 e f _4 p.No. I NA to P.No. ein,, W P $ # N Z -IM. (buT.E.Q
~ Thickness of Test Coucon I I/0" D cf Test Cowcon-- IW --
C A8 (CW 408) _ Type of Gas or Gue:-- NONE Composition of Gas Misture - O th ee-- FILLEA METALS (CW4041 Weld Meist Analysia A No. S Sus of Pittet Meut I/II" & I/0" 5 ELECTRICAL Cl*AA ACTERISTICS (CW 409) FIDer Metal F.No. 01reet Cwerent SFA soecifteetion 5k P oiarity - - Reverse OCEP Aws cusification E309L FIest Layee Amos, y o,,, otn,r _. EIO8L Ba1anee Tunssten Electroa. siae NA Otrer PCSITION (QW405) TEONNIQUE (CW450) Position af Orcove IO Trevet Scoed W;td Progression (Vont11, Dowanlit) Uoh111 sinn,or w ,,g,,, strineer other #1oe Re1Ied _ o,cist tion Multicats or Sietie Pass (per tical MUl?ID4sS Siegte or Mwit sie Electroon EIn;Ie PREH EAT IQW4061 Other Pr Temp. 3TY Te, . enn*r
.n.efo _ t.... >,m.. .... . _ .m . .r.. o.es...us.34. ...>. .<,n.. e,. coit: 1 I
s QW 483 $UGGESTED FORMAT FOR PROCEDURE QUALIFICATION REcortD (POR) (See CW 201.2e Sectlen IX, A8ME B;tter and Pressure Vauel Codel Mecord Actual Conditi:n Used to Wele Test couptn. Com enyName ev York Powr Authority fwre Owesificet on Ae:o a No,_ TC;
' t e ., ..
No. d 1,*.In- Bu w AR. car's ProctWes) . NW TvPee (Venwe . Awtor=at1c, $ew Aatt) _.Dt01_1 JC;NTS 104402) PQ F43 I Groove Des'en of Test Cowoon (For comb >nstion owsilf.cetions. tne concohed weid metal telckness s*sli be reto doo for seen fit'or mew or croc SA35 METALS (QW403) w ierd spec._ SA 50R PO47 WELD ME AT TME ATMENT gCW 407) ' Tempores .e 1150*F 50 F Type ce Grece CIRES 2 3 Time 10 heurs P.No. to P.No.3/A Qt e, Thiciness of Test Couoon-- l/0" _ I4" (Ger of Test Coween V) CAS (OW40el Two of Ces or Qases jn? Comoesttien of Qas MT re _ NOM _ omer - PILLEIt METALS 10W 404) - Wold Mete 4 Anolysis A.No. None saa of mer umi 3/32" 6 1/8" i FHIS* Wtal P her 43 stacTaicAi.cwAmacTcaistics tow cos) Cwerent - DiTOCI '
- P A toecmcation Sell Poi e,i,, Reverse Aws oomme. tion cNitrFe-3 Amos. _
Oats voii,_ _ Tungsten E.ect ode S'as M
.. Over POSITION (QW 405)
TECHNIQUE (QW410) fosition of Croove Z Trevel Scese weid Progreuien tunnue, cow,nin! Uchill oe:r steine or weeve need Stringer owmetion 2 tines the md dinneter Metteoen or sine e Pai, toer sidei Witipass Sieg e or Mattip's Clectroce Sif1El e FREHEAT (CW4061 og ,, Pieneet Temp. 3 50'F t.m;pa Temo. f 00*F ~ Ss4 .. This form (E00607) mov ce ootained from the Order Oest , A3Mt. 343 g,47 in 33., No. yera, g,y,1go37 . l
.c waocceelcen* . i ni.v* s V A ' W eninUS *CWSe en.nl e me 67 n t e - tota"VJ ^Wta:W*10 I ll* P -
~ . , = 4 QW.48J SUGGESTED 00RMAT Foa PROCEDU;t QUMIFICATION Af CORD lPQM
) (See CW.101.2,secti:n IX, A8Mt Boilee e e Pressute VesielCode) Reeced Actest Canciti2ni V :d to Weld Test C%psa. - -. n ~ . - . : , . .. _ _.
, e.,,,e j ev Yr"4 h er_AM*% *4 ty ,
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POSTYv t LO m L AT T Ftt AN#ENT LOW 8071 Att MtTiaL8 4QW403) ~ _Nnee we*(n pr.A Ctenal Spee.- M W tQ,,hdU y mpe,e,w,, _ ,,, ype er o: ee Cin n 2 to F347 7,,nc
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3 b of Test ca pon 1 1/8" --
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} ita mee G AL (CW4061) Type of 0:. . Geeee : Argen co-a.. mea e' coi eit.re - 99 9% hte s over 81L* 63 etTALS (OW404) Seis vient Aneiveis A Ao._ Nnno 1.se ef FlJer Metet _ 3/32" and 1/0" E LECTRIC AL CHAR ACTIRi& TIC 510W4001 sii:e, uetei 7.No. 45 curreat D4 rect l.d4 and 5,*.1. og er,,, __ C' TAW ="M\' SMyi'.1Y p _ IPMoesitiestica ._ _ EANitr 3 rmd ENicefe 3 gyne _ _ voi, Awa en ncetion 1/8" Nm.2 , Tseinn sei,oo. sisi ou cia er . T8 CHNIQvi (CW410) PottThoN (0.140M T'evet $0eed PDe'llon $f Oroove m weis Propeu on wonm, sowantil_ Uphill svy or Wo... stea _ Rtr4 nger ote met e ? ti~ne the mA A4 nmnter cteer _ uwit esis or sian'e reis toer nice) Withus 8:ag e o' cwitip's e actroces _ D Elf _ othe, PEN F AT (CW406) - Prpht Temp. 60'U Temp. MO E . - This f e1*i (6000071 me, be otta nee troen lee 0,per Leet., Aswt,344 3 et en gg , New y are. %.V.10017
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- Ae+kard?y Pre'cebre c.ewest ea mese o Ac 19? 7,,,
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- DM" E',t ;Tmic AL CH AR ACTimittics (CW4Cgi 51ee ef *mer Meie! _ D I ' '
Filter Metal F No. ., _ . AI Csreent _
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-- . . - . _. . - - ~__ .-.,. _ _ _ _ _ , - - - _
5,/ 3 = OW443 (Sees)
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Tenells toet (OR.160) [
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Toughness Tests (QW 170) See 2,S2.642 gM3 ) i Test impett lateraltwo l Daeo Weicht Specimen Notch hotch so g ,,, Type t,,n p ye,y,g g g w,,, J u n, ! g.,,, No loc atiem rittet Weld Test (QW.iB0) No Cesult - 8 atisf actory: Yes _. No Pometretion into Perent Metsi Yes MacWesAs Othe Tests Type of Test Deposit Analysie ,_ _ Other .EALAAMfgy (!LT) wd__ n , n h olun H.ngw 1 Clock No .
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WelfereName teDoratory Test No. ._ Tests conducted by We c3rttN tht.4 the staternents in this recortl are cortest and test the test welcs we's peopterne, we'ese sna toeted in accorconce the requirements of Section IX of the ASME Cece. v amu eetw,er hW T_Od_EECJ._Authqti1Y ._ -_ _ m er _ (v;f record of teste are IHwstrative only enr aney to mocif ed to toMorm to the type and nwerbe 16131 '
net 7 Yo;K Pot */ER AUTHORITY g tae 2 g JAMES A.FITZPATRICK NUCLEAR POWER PLANT t CALCULATION SHEET .L ., .7.
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\.s; . ~. ' ] i/y.y
STRUCTUM ingmyy Qi...Y: .-' - .' _._ ~' _
l Jix 6. A .vsf E Y t. m P L R,3 E A D " I croove ces'e* et ten cocoon tror some,i.ecen owennuneas. ire eeposite<r were mim mene. j
.*e i ce reco,see for enn tii:e, mem or e,neu wienj t cAtt METALS 60W403) i wterini si,se, SA SOB PC$7WILO HEAT Tat ATMINT to I vem,,,e,,,, _ nou MticN5t24 07)
Type or orece Class 2 l 7,,e _ P. N3. _ 3 t o *.N:,. - j
-4 Ce et_
Thhkmess of Test Cowson- 25* IA" Diameter of Teet Cowpoe- ., p>. V Q A5 (CW408) Tree of ces or ce.e, . Arron Comecouen of coi u,.we 99.9 % Pur.e_ Ctmer FILLER METALS (OWJ*Al Weld Wtal Anelve>s A.No.--. N^ae ~ 8;te of Pilier Waal W" Filter Wtal F.ho, a1 ELECTRICAL CHAAAOTE RI$ TIC $ (QW409l Corrent- Di T P f* t
$$ A Samfkstion I IA .
Po6erity StMi eht AWS C e:Cfication Ml N4l'?-1 ~ Ames. ' M - S In _ voiti 9_ A Other Tungsten E ntroce siae 1/ A" N 7 Otmer w P081T10N ICW4C51 TECHNicut (cwatos Poittion of G#oove- M Tre si speed - Weid Prog,ession (Venett, Downhill) hTM 1 I _ stria 0 or Weeve BW S * '" i M * " Other * Cecinetton 40't e ._.
~ Mvf ocais or Slap <e Pass (per . s'cel M 11 tim t t 8 ng+e or Mutsio4e EtHtrodel- NMIO 3
fat H EAT (Qwa other_ { M /,n_4 e un ga n FrenseiTeme.. O,T 2 laterpose Teme.1 4 S O ' T m 't' Osher - J.- ,, i.e. . .o e , m ee oe . .,e
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_= mar 1
3 QW 44 3 (bxA ) PCRho' 7'S - Temelle Te n (CM.1!.0) { vitimsie Vitim e t e T ,4. ,,i
$peonaen tetal(cas Unit Stress p.,m a Ne ! Wiet> ?>ichaes ps
,_ __ aree__ <e __
L x, , . .. T1 j . 50]" D14t's t e r 2019 1 71.600 . .10 7 , Q20 ,_.,_. }{ tig .,,, ,, , , , , ,, T2 --
.305_" Dieeter 2003 21.10p..-..- 1 0).i.3,Q0 ... L'ej d
' " ' " ' - - - ~ ~ ~ "
L= 1 ! . 502" Disene t e r .19B i 20,150 T6l'T66~ Gulded. Band Tests (OW.160) i Tvoe saa resee No. e s ,wi3 Side Bend ~~ ' p.,, ~' ~ ~ ' ~
~
Side Bend p',
~
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- Side Bund p ,
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Side Bend pg., Toughness Tests (QW.170) Specimen Notch'
- Notch Test lmpstt (tief el ( s e Deer We cht No. Leest;on Tvoe Teme Velvet % 5heer _I Mits t'est i _ No B'est
= - - . - .
l ._ __ Fillet Weld Tett (CW 180) Re wit - $stistsetery: Yes - No Penetratien into Pareet Meist: Yes Ne M 4 c rt>--A e wit: _.._ Other Tests Type of Test Radiography (Sat), Hardness Profile and Charpy's Caposit Anahrsis E.es At tached- Report s _. - . . ~ . . . . .... . . . . . . . . . . . . . . . Other - . - _ . . . . - - . . . . . . . . . - . . -
......................................................................... ........................ .................o'."oo Welders Name ---- Clock No. :""." ~ S t a m p h e. .~ . L Tests concustee by: PSI PTp__,,, ,,,,,,,,,,,,,,, , , , , , , , , , (spo,etory Y :: No ,23% 00_01.1. ......- 4 We certify inat the statements in this recore are correct sna test tr.e test welcs we.e proprsrec. welces and testes in accorcente wn* !
ine teauirements et section m of tu AsMt cose. . Memwlatter:P O N Catt U.l.QlI.0 __ _ ... _ . py u hh loissa or',e.o . .iiesi, s,e niw.t,.u.. oniv sna may es moose to convorm io ine iy.. anom no b oiinsi. ,siase or in ceen O q O im l l l
CW.483 $U00tsTto FotiMAT FoA PR00t0LRt OUALIF10Afl0N AE00RD (PCR) ($st CW 201.2, Settlen IX. A$ME Doiler aM Preuvre Vessel Ccide) Retof d Attbtl Conditi$es Use# 10 Weld Test C#wCon. como:avhems N"U "* ?k P" 1. h t %- 4 tv v2,e ove ivIcisioa seco,e No N6 ;e t, 6/1b790
,o Nr N*-luv
;eg Procenles) - N Types (Vanwei, Av to*st c. be ** A.te 1 DI F8IiC 4 JO t hTl (DW402) 1 1 __
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r/ omo eCo ino,toico. con lPo# co*bination tus14f testloes, t*e espes!tes wold moul thlehness shell t.e reectos 'l for eeth filler rettal er D'ocess w64dj BAS A METALS (QW4C31 PC$mtLD HEAT TRE ATMf NT IOW.4C7) Meterial foes.- _.SA 50B _ _ Tom,e,ety,, _ s on' r TypegtOrsee J JL55 2 Time 7AN"A P No. 3 _ to P.No. m /^ Otb et __ TP'kness of Test Cowpen . 3* - ter of Test Cowoon l'" [L )i . - _ _ _ G AS (CW40s)
- Tree of on or ce .. Amn comossation of on M., pre _ 09,9% Pure O th er- ____
PILLI A METAL 810W404) _ t*!*Id Mete! Anelve e A No.- N^* P 814e cf Pillet Meter W" I L t CT RIC A L CH AM ACTE RISTIC310W4091 Piller Metet P.No. Al Cureent __N ?*Ft
$F A Specification _ E 1A Peterity StYalfh t AW$ C;esiffication _ M
- MM?-I Amps. D h_7 t h y,1, = 9 A O(nor Tuneiten Iwtroce 1.4e _1/E" M* ?
.. Other ! P381 TION (QW408) TECHNtQgg (QW410)
Posit'en of Oroove C .. Trevei gases we.. ,< ,re..oniuen,,. oo. _ ,_ -sm , ,,, , o, , se .e , .e . x,,%.. ' Other - Oss stisi.on /10 4 I
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No. Wieth T>ietasse Ares 't L ,as tne e __ tr'
'l T1 .500" Diameter .2011 l 21.250 _. 196,92Q ,_ . _ y.fj1,, _, _ , . ., . ,,,
l 72 .$09" Diatieter .2^35 21,200 . ,,,},,0,4 1 Q QQ,_, . . Weld i I I I I L1 --. 5 05 " D i a rse t e r .2003 ! 20,200 101.000 Weld l Gwides Bend Tsite (QW.ito) tue .no n eu,e u. I s e s vi,3 Bide Mend Pass Side Band . Paes Side Eer.d Paen Side Llend Pass
* ~
Toughnete Tests (QW.170) l S pe cimer. Noich Notch Test impact ts' erst be Deco We.ckt l L No. we. con Tee te-e vessi ss e., ,n e e,e.. ~. v,e.. I Fillet. Weld Test (QW.180) Result a.- $stisisstory: Ye s No Penet,etica lete Potent Metal: Yes No westo stesAs n. Other Tests . Typs of Test Rediottaph (BAT). Hardnt.ge Profi1e_And Chatr.,y.'),. _ . , , , . . . . . . . . _ _ . . Oepeeit Anafyste .ite At ta ehg,4 Bigort a ,,,.. . , . - , . . , , . . , . . . . . . . , . . . . . . , . _ . - Othe, . - - - Wolser's Nema Clock No. ... - . _. Stemp No. . - - Tests conductec Dyt - ___ -__ . La tio,etory Te st No. _ . -- We certl*y that the statememe in thle ,eto,e era cortest and that the test weics were proces,es, welde. and testeg in setordance with the ,eewi,emania of Sect;cn IX of the ASME Coot. M a ng fe ggy,e, New York Power Authority este mmo ._ ._ __. iv M,/ hm teet.a .< ,e..,. .r i.si. .,e msires. .,iv .n. ,eer .e mous. io e.ei ,,, i. ies iv.e e,. Je.e, . iesi. ,e.vi,e. .y tne cuo r
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O i Appendix 3 Nutech Temperbead Quabfication Program for Discharge No7zle at the Oys:er Creek Nuclear Power Station (EPRI Advisory Committee for Temperhead Welding, November 2 3,1989, Charlotte, NC) O l i i I V SIR 90-063, Rev. 0 l
- ~ -- -
l4 lt 4 : l . O aozz a 2oa att t"o wtto ovta'ar !l
,i UNDEILWAIEfLBACKED_COND1110NS I i
[ DBJECTIVE e i]; ! f DEVELOP A WATER BACKED WELD OVERLAY PROCEDURE FOR N0ZZLE TO ' i SAFE END WELDS.
;i
'I
- DEVELOPED AS A CONTINGENCY PLAN FOR OYSTER CREEK NUCLEAR i PLANT.
P
- -GEOMETRY.0F THE N0ZZLE AND LACK OF PHYSICAL SPACE TO
[ ACCOMMODATE PREHEAT AND PWHT EQUIPMENT. ; O :
- APPLICATION OF NUTECH'S PROCEDURE WITH PREHEAT AND POST i BAKE (N-432) WAs DzrrrCutt.
J O i BC-3 , nutech i -I : f
,.-,.y,,, ,. n.,. ....,,,,,,,_.n.. ,.,......_,..-,,.,n,__-_-. , , . , . - . , + . , , , . _ ,
i O q 00*O D:ECHARGE I i *D* (Fgre it)
/ / / / /
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= =
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t l " NOTES:
'D* (Figure ib)
- 1. DIMENSIONS INDICATE MINIMUM CLEARANCE BCSHIELD OPENING TO EDGE OF CLADDING
- 2. DIMENSIONS TAKEN AT *E' DISCHARGE ELEV ATION . OlSCH ARGE Figure 1(a): OYSTER CREEK NDZZLE FRONT VIEW d 14 XGU-05-211 Revision 0 4 l
g ' 28'sntti - 1 I
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=<
Figure 1(b): OYSTER' CREEK DISCHARGE NOZZLE ORIENTATION e ? b 1 4 15 .' , XGU-05-211 Revision 0 . l- @ _...-...--_.,__._._._.-.._-..._,._..__.,.._,_.._.,_.......,..,..~.-,,,_.._._.--,...___,-.,_._._-,._m_,._.,...-,,._,
... _ _ - .. __ _ _ _ - _ _ _ . . _ _ _ ~ -
)
i EXPERIMENT o OBTAINED N0ZZLE OF SIMILAR VINTAGE (1975 MANUFACTURE), APPROXIMATELY 14" DIAMETER. O No22LE HAD SIMULATED POST WELD HEAT TREATMENT AND ALL REQUIRED MATERIAL TESTS. o NOZZLE WAS BUTTERED WITH E-NICRFE-3 oN END AND STRESS RELIEVID FOR 1 HOUR AT 1100 - 11500 F. s 0 STAINLESS STEEL 304 SAFE END WELDED BY B&W ON BUTTERED ' END. O o NOZZLE SET UP IN SG POSITION. o ALL WELDING BY GOLDTRACK II. o TEMPER BEAD. WELDS WERE MADE FOR BOTH:
- DRY, PREHEATED AND POST HAKE, FOLLOWING N-432 i
TECHNIQUES ESTABLISHED EARLIER. > UNDER WATERBACKED CONDITION. O WATER TEMPERATURE, HIN. 80 0F, o UNDER SMALL FLOW CONDITION TO SIMULATE LARGER (]) HEAT SINK APPROXIMATELY 1-2 GPM. BC-3 nutech
)
3--_--__-___ mern_na u.z_ m uarum Q LJ , [REMISTPJ 112._ V
._CE 111._
C EL fi._ P- ._E._._
.02 Ladle
.35 .83 .60
.28 .010 .009 .57 .01 Chech
.20 76 10 9 .33 .83
.75 .28 .015
.19 MrftT TPIATPIt{I
- Air Cool 1660'T i 15*F for B hours 1560*F i 15'T for 4 1/2 hours - Water Quen 1290'F i 15'T for 4 1/2 hours - Air Cool follows:
Test Specimens were stress relieved as
- Held at 1125*F i 25'E for 50 hours Cooling to 600'F at a furnace coc!..
1100-1150'T for 1 hour after Hottle-Safe End stress relieved at E-HiCrFe-3 buttering. TENSILE PROPERTIES (P.T) tE SRA_ M .u __ Y S . _ 73.1 70.52 26.0 Axial O' 92.62 24.0 73.1 92.84 70.75 180' DROP WEl M _ 4 no breaks per forging. $ at 50*F to qualify an NDTT of +40'F. 2 each at 180* apart e RTNDT = +40'T pMAP_PY __ t shear _ Enerav_Tt-Lbs Lateral Ern f ini_ 100-100-100 206-192-203 .087 .100 .090 100-100-100 Axial +40*F 180-182-191 .093 .093 .096 100-100-100
+40*F .090 .080 .076 100-100-100 T ang . +10 0
- F 121-120-100 .079 .086 .079
+100*F 113-112-110
{ HNP ' I l
O EXPERIMENT (CONT'D1 O WELDS WERE MADE TO APPROXIMATE DIFFERENT WALL THICKNESSES (1/2 AND 1 1/4 INCHES) AND OVER N0ZZLE TO SAFE END WELD. O TEMPER BEADS OF 5 LAYERS WERE APPLIED 0 FIRST 0 WITH PREHEAT ON HALF SIDE OF N0ZZLE AND POST DAKED AT 450 F - 550 F FOR 2 HOURS. O HOCK-UP MODIFIED FOR WATER BACKED WELDING AND TEMPER DEADS PUT ON OPPOSITE SIDE TO BUILD UP TO 5 LAYERS. P o BALANCE OF WELD TO FILL GROOVE DONE UNDER HORMAL WELD PARAMETERS. O AVERAGE TEMPERATURE FOR WATER BACKED WELDING WAS 70 - 750F. O Bc-3 nuteC1 .;
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f o O O , t yx mC , <: c ye ! i mo ww 0 8 TENSILE-L i' nue FWOF oe , MICRO- 1-5 l SIDEBDiD-1 f '; ' 1 "' l SIDEBEND- \ l ! - 35 ! OVERLAY SIDEBEND-1 ts - l C11ARPY-1 - .,' 4 ray l' OVERLAY SIDEBEND-2 l CilARPY-3 a CilARPY 3
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-GROOVE BOTITH HAZ BASE METAL Tigure 8: POSITIONS OF TENSILE AND CHARPY TEST SAMPLES FROM THE OVERLAY AND 1/2" GROOVE
> V XGU.05 211 nutech , 22 Revision 0
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- O xa;-os-212 23 nutech Revision 0 ,
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BASE METAL GROOVE BOTTOM HAZ rIcvP2 los POSITIONS Of TEN 3!LE ED CHARPY TEST SAMPLES FFCH 1 1/4' THICFMESS GP.OOVE. XGU-05-211 24 gg Revision 0-E
a r Oauuus DPMJ1EliEALED_AND POST BAKED _EROCEDDRE MLTIMATE T ENHLL_$T RENGT111 91.1, 88.0 (P ARENT MET AL) AT 1/2 INCH GROOVE 84.9, 88.5 (PARENT METAL) i AT 1 1/4 INCH GROOVE SIot Britan ALL rouR (4) SAMPLES SATISrACTORY AT EACH OF THE 1/ INCH AND 1 1/4 INCH GROOVE LOCATIONS. O WATER _DACKED PROCEDURE ULTIMATE TENSILE STRENGTH 1 91.0, 91.3 KSI (PARENT METAL) AT 1/2 INCH GROOVE 88.8, 86.5 KSI (PARENT METAI.) AT 1 1/4 INCH GROOVE $ 'if,i T g"
'y SwE BENos-ALL rouR (4) SAMPLES SATISrACTORY AT EACH OF T INCH AND 1 1/4 INCH GROOVE LOCATIONS. l 10
- 1 BC-3 ded l l - - - . - . ._
\
DASE_tiEIAL CHARPY C0!iEARISONS ('J
)
EtiffGY fT-ldh [AHEAL_D.P__(llf1 ,,_.kbliEAfL_ CMTR. AXIAL 206-192-203 .087 .100 .090 100-100-100 00 180-182-191 .093 .093 .096 100-100-100 1800 Nozztr - SArt END AT 1/2 INCH LOCATION 178-151 .090 .078 100-79 DRY 175-150 .088 .078 100-79 WET QCATION 122-120 .081 .066 76-100 DRY 104-97 .065 .060 76-76 WET bJ 8C NteCh !
l f BOCKUP N0ZZLE CHARPY COMPARISDNS i DRY I REI I , ENERGY LATERAL i ENERGY LATERAL FT-Les_ EXP (IN) A SHEAR I FT-Los Exp (in) ' 1 SHEAF I 9 1/2" 178-151 .090 .078 100-79 175-150 l .088 .078 100-79 9 1 1/4" 122-120 .081 .066 76-100 104-97 1 .065 .060 76-76 . I
'HAZ OVERLAY toe I ,
160-158 .092 .088 100-100 1 148-164 .084 .089 79-100 i HAZ Sror i 9 1/2" 112-111 .065 063 100-100 138-130 1 .070 .061 100-96 0> 1/4" 102-100 .063 .063 84-87 l 115-94 .060 .059 100-82 i NA2 BTM. I 9 1/2" 168-156 .084 .082 100-100 l 73-57 .050 .043 I 66-58 9 1 1/4" 70-60 .056 .049 61-42 53-57 .043 .040 1 54-56 I l l l lO - .I ( BC-31 mMch '
- I ;
. . . _ _ _ _ _ - . . _ _ _ . . . . _ . . _ . . _ . . _ _ . _ . _ _ _ _ _ _ _ _ . _ _ . . . . _ _ _ . . _ _ . . . _ . . . . . _ . . - . _ . _ _ . _ m_.-____. _.m
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- 80. 40 034 vacer leg 33. 41 034 c;*eer of Itr 28
- 46 5, 44, 46 5 034, large greens 34
.034 074
.096 33 174 32 196 34 5
.274 25
.296 34
.339 31 in-e*, $
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.004 31 34 .303
.104 33.5 30 .203
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O Appendix 4 CB&l Reactor Nozzle to Safe-end Temperbead - Structural Overlay Test Program (EPRI Advisory Committ:e for Temperbead Welding, November 2-3, 1989, Charlotte, NC) O 1 I SIR-90-063, Rev. O I
1 l i 1 l 1 I O l Reactor Nozzle To Safe-End Structural Overlay Test Program O
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_ _ . . _ _ _ . _ . . . _ _ . _ _ _ _ _ _ _ . _ . . _ - _ _ _ _ _ _ _ _ . _ _ . _ _ _ . _ _ ~ _ . _ _ _ . _ . . _ _ _ _ _ _ _ i AESTRACT Program Reactor No :le to safe-End Structural Overlay Test l lding This report details the SA568 C1. 2 no::le mock-up, weions i et Code and instructions and the results of non-destructive exam nat mechanical testing to qualify an overlay procedure to meAddition Case N-432. , without preheat or post heat was performed to compare data toTne ov that of the Code Case qualification. condition and a non-water backed both a water backed (teat sink) condition. dure The results of the test program yielded welding proce i l t results for i al (non-qualifications meeting Code Case N-432 and equ va ena techniques it. the heat Code case) Additionally, a random occurring f weldability e quality, problem conditions. was observed and traced to filler material sur ac i ( pviding additional infcrmation to prevent weld defects. , t i f i l
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-( )._ ceContract - FileN61122 8500-1 February 4, 1988-REACTOR NOZZLC TO SAFE-END STRUCTURAL OVERLAY CEST PROGRAM BACKGROUND INFORMATION: ,
In the mid:to late 1970's, intergranular stress corrosion cracking (IGSCC) was found Thisincorrosion existing nuclear processpower was toplant be ' reactor. piping' systems. 1 mitigated by several means, one of which was the applying of a overlay over the affected-joint area with the piping system full - -of water. The application-of.the overlay performed two functions; (A)-to effectively double the wall thickness at the
+
3 joint location and (2) due to weld shrinkage, place-the inside surface of the pipe in compression which would close the corrosion _ crack openings and/or reverse the tensile stresses present to "ow down the IGSCC process.
~
The-IGSCCoproblem was-due to the selection of type.04% 304 stainless carboa or _higher steel va-lety. material which was of the high carbon, i.e._This material was easil g' upon and IGSCC cracking was=found in_the HAZ of this piping materials. Additionally, stainless steel safe-ends were attached . Some of F to the? reactor nozzles which had similar chemistry. these safe-ends'were later replaced-with Inconel or with low carbon grade stainlessEsteel. However, even some of the replacement safe-ends exhibited IGSCC as well'and had to be
- replaced after..being in service. .Inconel 182 filler materials (nozzle weld prep _ butter)'also has exhibited IGSCC, plus. furnace 1 sensitized-Inconel safe end forgings. -
As anLalternate to replacement,.a full structural overlay across
~
the nozzle to safe end foint was deemed possible-after The=EPRI funded research had'.been performed 1by the EPRI'Foundasion. =
- program was designed to_ find an alternate 1GTAW-mechanized technique'that would give_the same equivalent results-(metallurgically)Jas the half bead repair technique This alternate would on the technique reactor was neededsteels.(SA533B.or so that-repairs SA508-C1.
to reactor2).shells and/or nozzles could-be done remotely under-high -ndiation '.ields, i BWR core spray / inlet _ nozzles typically hcva high radiation fields h due to the crud trap nature of theTwo. smallplants,annulus space formed by. Hatch Unit 2 and
-the~ thermal sleeve and nozzle.
, h -Vermont Yankee had IGSCC~UT indications in the core spray safe < v -end to nozzle welds. 'Rather than change these safe-ends out, s h v up g -, ~ ,mn~-- - - . , . , -- ,-.
')
y February 4, 1968 Page 2 he the Utilities opted to go with a structural overlay utilizing tin order to do so, Code alternate half bead technique. was passed by the ASME Code to allow this alternate mechanized GTAW technique. CBI As this was just another method to fix the IGSCC problem, necessary to have this method qualified and Services deemed it availabic this problem. for future repair alternates to offer utilities withPresently, procedure, one being GE and the other being CBI. ' This report deals exclusively with the actual Code Case N-432 qualifications and a proposed alternate method which will Codegive Case the Utilities more flexibility in performing this fix. N-432 requires both preheat and post six layers heat during deposited. Thethe welding alternates process for the first ;
' investigated in this report are a non water backed, nonnon post he s_,rcheated, heated condition to compare with the Code Case qualification.
The water backed qualification allows the Utility the greatest flexibility in that the reactor annulus and recirculation piping system could remain full and/or flowing which allows in vessel operations to be performed simultaneously with the remote overlay operation. It also eliminates the need for the attachment of ing and p thermocouples and preheating devices or for the preheatEliminating the ne post heating would minimize cycles. outage time required to perform the structural overlay. THE TEST PROGRAM The test program was designed to qualify welding procedures i in the SG position utilizing existing SA506 C1. 2 no::le forg ng As - it was material which had been procured from a scrapped reactor.th assumed To to be meet typical of what would be found in existingthe Code Cas reactors. weld heat treat time applied to the no::le prior to the repair,T at j the reactor no::le was given an additional 24 hours of PW 1150 r. reactor. It is dassumed during thatoriginal the at leastfabrication cycle.) The shad been applie ( Stresschosen jno::le also had Improvement been (IHSI) utilized mockup. forinduction This an Induction Heating heating was I
- y. s._ .
./
i 1 February 5, 195E Page 3 i l 1 1 concentrated in the stainless steel safe-end area rather than in the no::le forging. This induction heat treatment is thougnt to have no effect on the actual no::le properties in the regions tested. Please refer to the work orders in Appendix IV which show test specimen location. The purpose of the test was threefold:
- 1. Produce a welding procedure qualification meeting the ASME Code Case N-432 which would establish base line material properties.
- 2. Produce a non-water backed and a water backed overlay which, when tested, the material properties could be comparea to the base line established in the Code Case qualification. :
n ( ) 3. Provide sufficient technical data to allow in-service
repairs on no::le to safe-end welds by overlaying with and without water in the affected no::le/ safe-end.
To do the comparison, a Code Case groove weld was made in one region of the no::le forging and a full thickness structural overlay was built-up across the no::le to safe-end joint. The overlay was blended smoothly into the 45 slope region of the no::le forging. Please refer to Appendix II for the no :le assembly drawings for details. As the Code Case requires the procedure qualification to be done utilizing the equipment planned for the repair, the use of fiberoptic video monitoring was used to produce both the groove and overlay welds.
.; Code Case N-432 Groove Weld A 1" deep, 60 , with a .25" root opening groove was machined 360 in the nozzle forging after trimming excess material from the no :le forging and PWHT for 24 hours at 1150 F plus or minus 25 F. Once machined, the forging was nondestructively tested and positioned for welding. Preheaters were installed inside the bore of the no :le, and thermocouples attached outside in the "3T" band of the groove. After preheating of the no::le to the required 300 F, it was allowed to " soak" for one hour prior to I , ~3 start of welding. Welding was performed per the instructions in
) W.O. H5173 (Appendix IV). Using ERNiCr-3 (Inconel) filler.
(G I I
[Udebruary 5, 1988 page 4 It was interesting to note that during the first six layers deposited, no real prcblems were encountered. It was feared that the sidewalls of the groove could not be easily welded (especially using remote video). Because the torch was motori:cd, it could be easily positioned to have the arc impinge on the sidewall. Additionally, positioning of the filler was also easily done with it being motorized as well. These features are necessary for ease of operation in a high radiation field. With these featares, the six layers required by Code case N-432 were deposited easily and the 60 groove shape was r.aintained allowing conventional split weave beading to complete the joint. (See photos 5 thru 7, Appendix III). During the welding of the groove, some difficulty was incurred on passes 53 and 54 at the 90 location. The passes exhibited poor watting into the side walls and heavy oxides were produced. The location was ground and liquid penetrant examined. No indications were found. As the spool of wire being used for another filler spool was used for the I'_ '2xt filler was almost passes empty, without incident. Upon UT examination after groove (_lompletion, this location exhibited indications of non-fusion. This location was marked for further examination by sectioning and microscopic examination. This exam revealed inclusions between beads and internally within the beads. This defect was caused by an intermittent filler material quality problem. (See weld overlay for additional details and photos 25 and 26 Appendix III). Upon completion of welding, the no::le was post heated at 500 F for 2 hours minimum prior to cooling to ambient. After cooling to ambient for 48 hours
- minimum, the groove weld was liquid penetrant and ultrasonic inspected. With the exception of the UT indications at 90 , no defects were found.
Weld overlay In order to do a wet / dry overlay, the nozzle was re-configured to have a partial thermosleeve detail. (See No::le Mock-up Drawing Appendix II). With this configuration, one half (0 180 ) would be filled with water (both stagnate and flowing at +40 F) and the other half (0 -270 -180 ) dry. This configuration would allow the welding to be affected by a severe (water backed) quench rate and a moderate quench rate (steel mass effect - both conditions without the ('_ '2nefits increasing interpass temperature), of preheat or post heat. \_/
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! )
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February 5, 1955 Fage 5 The no::le assembly was instrumented with thermocouples at the 90 and 270 center lines at the I.D. surface of the no::le bore. Additionally, an O.D. surface thermocouple was placed en the 45 slope of the no::le and both the flowing water and stagnate water were monitored. (see photos 10 thru 17 for plumbing and thermocouple installation.) To do the overlay welding, passes were alternated from clockwise to counter-clockwise to eliminate the variable of pass direction so impact specimens could be taken from the highest heat input (vertical up) locations - wet or dry. Welding was performed per the instructions of W.O. H5224. Temperatures were monitored to determine peak temperature per pass and location. It became evident that the stagnatecouldwater not (which was to represent water in the reactor annulus)
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(_- be maintained at +40 F due to its small volume. Therefore, tap water was allowe d toreflow at the minimum rate which would allow contacting the I.D. surface of the noctle the water temper reach equilibrium. Cold water (+40 F) was circulated in the thermal sleeve to cool the annulus water to the equilibrium point. The actual water temperature contacting the steel ranged from +45 F to 65 F, for the majority of the overlay welding. During the first two beads being deposited en the first layer, As the heavy oxides were formed and wetability was very poor. beads were being deposited on the stainless steel safe-end, wetability should have been very good. A review of the weld parameters, equipment se'-up, Argon supply, etc. was made prior to proceeding. At this point, it was noticed that the spool of filler material had seams or laps present on the exposed wraps. The spool of wire was replaced with another which did not exhibit this condition. Welding resumed using the same parameters, etc. with excellent results. )
\_s I
m February 5, 1955 Page 6 layer, a liquid penetrant exam was Upon completion of the firstbeads exhibited several indications. performed. The first tw7 These indications were ground into and additional ones found. The entire volume represented by these two beads were then ground out, (See photo 19, Appendix III) and replaced with good material. Now that the weldability (poor wetting - heavy oxide) problem had been traced to wire surface quality, a stepped up visual inspection of wire surface quality was instituted to preventThis inspection not additional repairs. same heat / lot to have this surface problem where as the majority did not. The surface problem was very intermittent without any pattern. An entire spool might be defective or only a few inches, a few wraps be defective and those cross inchesoforgood sections wraps would and bad be found any where on the spool, wire (same heat / lou) were cut, mounted and polished for(See photos 7 71croscopic examination which confirmed the problem. Q S and 26, Appendix III). = In order to produce a smcoth transition from the no:tle shape to the safe-end, it was necessary to " step" each layer into the , existing radius joining the This 45 sloped no::le reinforcement and the weld prep extension. transition is necessary so the overlay will not induce piping reactions into the radiused region of the nozzle causing fatigue. This meant that the last layer would have to have a temper bead technique which could soften the Temper beads were deposited 1/32 to 1/16" from , toe tie in area. the use of filler and decreasing heat the toe This tie intechnique without is the same as " Flame Softening" except i input. (See W.O. H5224, ! thru the use of the mechanized GTAW process. Appendix IV for details). Upon overlay completion and grinding for ISI UT inspection, No the overlay was ultrasonic and liquid penetrant inspected. defects were found. Test Results: Code Case Groove Weld: PQR 7673 (Appendix V) lists all mechanical results including hardness, The resultsnilmeet ductility temperature, the requirements tensile strength levels, etc. A 1" deep 'or less) weld repair could be (~Nof Code Case N-432.hade utilizing a welding procedure which incorporates these (
techniques.
73 February 5, 1985 page 7 Weld overlay: pcR 7718 (AppendixpOR V) list7719 all mechanical results lists the results for for the non-water backed overlay.Both FQR's exhibit good notch the water-backed overlay. This tou7h ness level is similar to toughness levels in the HAZ. strength of the code case Groove. that of the HAZ impact The non-water backed overlay exhibited lower hardness levels in the toe tie region than either the Code Case groove or water backed overlay, which exhibited hardness of 380 to 410 from the toe tie. In general HAZ at a location slightly removed This area became suspect when this region was 400 to 435 Hv-10. As the welds were made etched for determining the HAZ region. orbital and no similar condition 360 backed hardness samples, it is thought that the interpass temperature may have allowed a greater portion of the HAZ to 7s transform into a harder microstructure. (< ') As the Code Case groove had also exhibited hardness in e 400 Hv-10, A supplement to W.O. H5173 was prepared to of this technique. After temper beading, the ! perform this technique and testing. 10. l toe of the groove hardness dropped approximately 30 (See W.O. 5173 increased in hardness by the same amount. Appendix IV). In reviewing all hardness data, it appears the HAZ will range 2 These hardness ranges areForgings, probably typical especially in of the SA material when welded Specimen this shape, are notedinforthis manner. properties. non-uniform location may account f or some of the scatter seen in the hardn but at a depth of results, but the fact f
-the toe of the weld within imm of the sur ace
.3/16 to 1/4" within 1 to 2mm of the fusion line.
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February 5, 1933 page 8 conclusions:
- 1. Mechanized orbital GTAW welding can be performed on SA'08-C1. 2 nozzle materials with and without preheat or post heat and achieve / maintain material properties which are notch tough and ductile at NDT plus 60 F.
- 2. An additional heat sink of water backing during welding '
appears to have no adverse af f ects and may be more beneficial as lower hardness (ave) was achieved versus the with and without preheat conditions.
- 3. Equivalent results were obtained in comparing the three conditions which should allow the use of any method
'z~s investigated to overlay the no::le to safe-end joint.
) l
;/
- 4. No HAZ cracking was observed in any cross-section, tensile, i or bend specimen despite hardnesses exceeding 425 Hv-10, indicating a lack of sufficient hydrogen being absorbed ,
during the welding. The use of the GTAW process provides ' the lowest hydrogen levels of the commonly used process (SMAW, SAW, GMAW), plus the use of Inconel filler allows any remaining hydrogen to be absorbed in the weld deposit rather than into the HAZ.
- 5. Notch toughness at +20 F in the HAZ that equaled or exceeded location and depth.
forging base material toughness at (Base material toughness varies with depth from quenched surface and location within the forging cnvelope).
- 6. Filler material can vary within a single heat / lot and within a single spool due to drawing process control problems.
Wire surface quality has to be smooth and without laps, tears, seams, etc. or weldability problems of poor wetting, heavy oxides (slagging) and inclusions will occur. Full structural overlays covering the no :le to safe-end j
- 7. I weld can be temper-beaded at the toe tie in points without l
-s the use of filler and obtain similar hardness and impact strength levels to that of Code Case N-432.
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1 r^N N. February 5, 1988 page 9 achieved
- 8. Hardness levels or 350 Hv 10 mean average were not using either stringer beads or weave beads with temper 380-400 Hv-10 mean a techniques. Typical is probably more realistic than the 350 Hv-10 levels desired.
- 9. Code Case N-432 requirements to use stringer beads does not yield superior HAZ impact or hardness levels when compared to a weave technique.
gecommendations: Welders
- 1. These techniques should be used with caution.
should be trained on mock-ups to assure the technique used
~N can be done under simulated plant conditions prior to doing
(,,)
/
the actual work.
- 2. Even though in-plant dry well conditions are usually hot
(+80 F) and dry, reactors filled with water tend to have Surfaces to be condensation form on the outside surfaces. welded upon should be wiped with Acetone to remove surface moisture prior to welding, when using the non-preheated 1 condition.
- 3. These water backed and non-preheated conditions filler only. Theshould use of be of done using ERNiCr-3 (Inconel)etc. is not recommended due to the coefficient ER309L, linear expansion of the austenitic stainless steel filler materials. Overlay deposits of these types can cause thermal fatigue.
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I July 15, 1957 I LRS
,M C BI Services. Inc.
l O NO:ZLE TO SAFE-END
^TRUCTURAL OVERLAY QUALIFICATION TEST PROGRAM 1.0 Purpose of Test:
l The purpose of this test program is to qualify a non-water-backed and water-1 backed strue.tural overlay procedure which could be utilized in the reinforce-ment of ASME Section III, Class 1, reactor nozzles and safe-ends which have l in-service generated flaws in the weld joining the nozzle to the safe-end. 2.0 Objectives of Test _: il l The cbjectives of this test program is to: i 1) Produce a procedure qualification meeting ASME Code Case N-432 to f l establish base-line material properties. 2) Produce a non-water-backed and water-backed overlay, which upon l destructive testing, will yield similar material properties. Serve as a model for future qualifications. l l 3)
- 4) Provide sufficient technical data to allow in-service repairs to l
' nozzle to safe-end welds by structurally reinforcing the affected area by overlay welding with and without water in the affected no::le/ safe-end. j 3.0 Reference s_: l 3.1 ASME Code Case N-432 i 3.2 ASME Section XI,1986 Edition, No Addenda 3.3 ASME Section III,1986 Edition, No Addenda ; ' 3.4 ASME, Section V,1986 Edition, No Addenda 3.5 ASME 5ection IX,1986 Edition, No Addenda l I 3.6 " Alternatives to 1/2 Bead Repair Technique (GTAW)" by P.J. Alberry and J. G. Feldsten - Maintenance Welding in Nuclear Power Plants /III, conference paper November 1985. I l 3.7 Test Assembly Drawing , 3.8 73-Cl24 Nozzle FN2-1-5 Certified Test Report iO : l p*r*-e g etw-wc.7-ygari y.q-u-g. g r m y n,s.m1irw-.gv are-g q,-ta ger,y g-.y yyw.,wwa4* '--*mes w= rw- 'we=Nw-reww - m - wwe-+wwwe- a-* -- ar y e+-m+ - +4 w-*-- -- '=- -WP'--*--w-*"w *r 7- =d* ---
CBI Services, Inc. O Nozzle To Safe-Enc Page 2 3.0 Re fe rence s_: (Centinued) 3.9 Dra..ing ER420 Rev.1, Contract 34541 - Safe-End Details 3.10 Nozzle to Safe-End Weld Sequence and Parameters. 4.0 Test Materials: The materials to be utilized in this test program are: l
- 1) An SA508 Class 11 forging which was salvaged from a can ;
boiling water reactor. history: a) Weld prep buttered by the SMAW process using Irconel 182 electrodes. Nozzle to shell welded complete into the shell reg. b) c) The nozzle and butter have (Fabrication been records PWHT'd destroyed - at il50*F Q time of 10 - 14 hours. ; V Typical time for manufacturing cycle). - Additional SMAW Inconel butter applied and new weld prep d) made (20*J prep). Safe-end to nozzle weld made by orbital GTAW process using e) Ir.conel 82 filler. Weld joining safe-end to nozzle has been IHSI treated for f) test / qualification purposes. An A312 type 304L "B'uilt Up," " Tuning Fork" design safe-end. 2) Inconel 82 filler materials, .023", .035" and .045"0 3) 5.0 Post Weld Heat Treatment _: l As most reactors in operation to which this test program tl coul have PWHTnozzles time, thewith fabrication test assembly shallhistories be PWHT which at il50*Fhave 20
! 25*F I mininum prior to any welding.
induced stresses by the IHSI testing. O I E ;
)
CBI Na Con. Inc. O-- zzle to Safe-End Pace ? 6,0 Consideration o' Restraint: Both Code Case d-432 and ASME Section III,The NS-4321(c) require co.: sideration location of the groove weld of restraint in procedure qualification. meets C.C. N-432 requirements for self restraint by having sufficient material thickness surrounding the cavity to be welded. Code Cese N-432, para. 2.1(e) allows the assembly to qualify weld buildup procedures provided the cavity is notAs less most than the thickness safe-ends are i to of the weld 1-3/16" buildup or 1 in whichever is greater. thick, and standard designed overlays are slightly less than wall thickness (for thru-wall cracks -360'), A 1" minimum depth groove shall be used. As the overlay will be applied to a full scale mock-up containing actual materials and typical geometry, restraint that will be encountered on nozzles in service should be similar. To minimize any stiffening effects of the wet / dry interface divider plate, the plate shall be made from thin guage material which allows (See the nozzle and safe-end to band in cue to the expected weld shrinkage,
,G Assembly Drawing).
() 7.0 Test Specimen Locations: All destructive test specimens shall be as located on the test assembly drawings. It must be noted that test specimens may or may not comoly with ASME Section III, NS-4334.2(a) due Fortopurposes the orientation of this of testthe groove program, weld and overlay reinforcement weld.the test samples are taken at sim forging and transverse to the axis of the welds. ! 8.0 Reference Nil Ductility Transition Temperature RT NOT: l i For the forging involve'd, the actual nil ductility transitica temperature Per notch impact testing as established by the nozzle forger using drop weight te shall be (RT NOT +60'F), +30*F. 9.0 Remote Sensing: As most in-service nozzles and safe-ends are in hig pulsed GTAW welding equipment with remote A Dimetrics Gold Trackviewing of the arc and depo 11 welding using closed circuit "G" weld head and video color video systems. system utilizing system shall be used a to p deposit all welds. Q I
C BI Services, Inc. M im (v ) No::le to Safe-End Page 4 10.0 Test Program Operation Sequence: 10.1 Test assembly preparation for Welding: 10.1.1 Burn excess shell material from forging. 10.1.2 Machine excess forging material to required dimensions. 10.1.3 Machine Code Case cavity in forging hub to required dimensions. 10.1.4 FWHT assembly for 24 hours minimum at il50'F ! 25'F. 10.1.5 Clean all surfaces of scale, rust, etc. by wire brushing or sandblasting. Care must be taken to protect the Inconel weld and stainless safe-end from iron contaminatad brushes or sand-blast effects. Use only stainless steel brushes on the safe-end and weld. 10.1.6 Layout reference lines for specimen removal and dimensional In)
'w/
checks. 10.1.7 Take as-builts of test assembly prior to welding. l 10.1.8 Install wet / dry divider plate and thermocouples. 10.2 Code Case N-432 Welding- l l 10.2.1 The groove shall be welded with stringer bead welding with l heat inputs ranging from 20 to 40 K Joules /in of deposit. : Additionally, the wire feed speeds shall be controlled to allow deposits to be made within the 1.25 to 2.0 megajoule
~
range. 10.2.2 The groove shall be filled with the required layer sequence of C.C. N-432, Fig.1, using parameters meeting the Kilo Joule / Mega Joule heat input limitations. 10.2.3 As more than 6 layers may be required for actual overlay, a minimum of 8 layers shall be deposited in the groove, I }. L.o) . I
C BI Service s, Inc. b
+
le to safe-Fnd Page 5 10.2 Code Case N 432 Welding: (Continued) 10.2.4 Preheat and post heat requirements shall be met using electrical heaters and recording instruments to monitor Thermo-preheat, interpass and post heat temperatures. couples sh 10.3 Non-Water-Backed And Water-Backed Overlay Welding: Af ter completion of the post heat operations, the assembly 10.3.1 shall be filled with water internally and cooled to +40 F
+ 5'F by circulating the water and/or adding ice.
10.3.2 Once the assembly has been cooled to +40*F, water in the annulus space between the themal sleeve and nozzle wall shall be allowed to become stagnent, water may be flowed maintain +40* *. 5'F for the water backed portion only during welding. using a weave A V 10.3.3 Overlay welding shall be accomplishedtechnique and hea Additionally, wire feed speeds shall be controlled to make Weld beads deposits within a 1.25 to 2.0 Megajoule range. Clockwise, counter clockwise shall be alternately deposited.360', to allow impact specime position. Cere shall be taken to deposit the overlay in such a manner 10.3.4 to produce a smooth transition in the crotch section of the forging. 10.3.5 Temperature monitoring of forging shall be done during all welding. 11.0 Required Non-Destructive Examinations _*
- All nondestructive examinations snall be perfomed to meet ASME Se V,1986 Edition, No Addenda Techniques.
11.1 Code Case Groove Weld: 11.1.1 Magnetic Particle: MT inspect the groove surfaces and l" either side of the m groove prior to welding. I
7 C BI Services, Inc. M Nozzle to Safe-End fage 6 11.1 Code Case Groove Weld: (Continued) 11.1.1 Magnetic Particle: MT inspect the groove surfaces and 1" either side of the groove prior to welding, 11.1.2 Licuid Penetrant: a) PT inspect the groove surfaces plus 1" either side of the groove prior to welding, b) PT first layer deposited in groove. c) PT final surf ace of completed weld prior to destructive semple removal. 11.1.3 Ul trasonic: a) UT inspect the groove and machined hub area to a depth of 2" from the machined surface using focused longitudinal inspection techniques. b) UT inspect the final weld. 11.2 Non-Water-Backed And Water-Backed Overlay Weld: 11.2.1 Magnetic Particle: l MT surface of SA508 Cl 11 forging wnich is to be overlayed plus 1". 11.2.2 Licuid Penetrant: ; a) PT en' tire sur. ace of forging and safe-end to be overlayed plus 1" prior to overlaying. i b) PT first layer deposited plus 1" additional.
', l c) PT final surface deposited plus 1" additional. l 11.2.3 Ultrasonic:
a) UT inspect the volume to be overlayed using focused longitudinal inspection techniques. f, l f UT inspect the final deposit. l b) . l J l 11.3 Surfaces to be inspected may be ground, cleaned, buffed as necessary l to obtain meaningful; examinations. 1 l
@ C BI Services, Inc.
( v l Nozzle to Safe-End Page 7 11.4 Acceptance critaria for the examinations shall meet ASME section III, Subsection NS-5000 for the rethod used. 12.0 Destructive Examinations: 12.1 Code Case Groove Weld: 12.1.1 Tensile Tests: a 2 transverse .505"0 tensiles, b 2 all weld metal .505"O tensiles 12.1.2 Bend Tests: a) 4 transverse side bends 12.1.3 Drop Weight Tests: a) 6 - P-2 specimens for base metal (assumed to be -30'F per CTR) 73)
' 12.1.4 Charpy "V" Notch Impacts:
All ime- . specimens shall be removed from the maximum dep' . actical and tested at T NOT +60*F temperature for HAZ ad unaffected base material. A minimum of 3 HAZ and 3 base metal specimens shall be tested. 12.1.5 Hardness tests (Vickers Hv 10): a) A minimum of 3 cross sections shall be cut and prepared for hardness surveys. i b) Each cross section shall have a minimum of 3 hardness transverses in the HAZ, 2 at the surface (lef t and right of groove centerline) and I at the deepest point of the
- repair.
'l 12.2 Non-Water-Backed And Water-Backed Overlay Weld: (Tests required for eacn condition) 12.2.1 Tensile Tests: a) 2 transverse all weld metal .505"O tensiles of the overlay deposit. v
CBI Na-Con, Inc. Nozzle to Safe-End O Page 8 (Continued) 12.2 Non-Water-Backed and Water-Backed Overlav Weld: 12.2.2 Bend Tests: 4 transverse side bends. Centerline of bends to include a) the HAZ of the SA508 Cl. II forging at the toe of the overlay. 12.2.3 Charpy "V" Notch Impacts: All impact specimens shall be removed at the maximum a) depth possible and tested at T NDT +60 F temperature. A minimum of 3 HAZ and 3 base metal specimens shall be tested. 12.2.4 Hardness Tests (Vickers Hv 10): A minimum of 3 cross sections shall be cut and prepared a) l for hardness surveys. b) Each cross section shall have One shallabeminimum taken nearofthe 3 hardness transverses in the HAZ. I toe of the overlay, near the surface of the overlay. [ One shall be taken near the bottom of the overlay,One shall l in the curved crotch section of the forging. l be taken at random at the bottom of the overlay near the HAZ of the nozzle butter. 13.0 Metallurcical Examinations: I Random microstructure examinations of the SA508 Cl 11 forging shall be i performed on the HAZ of both the Code Case groove and weld overl The examinations shall be done tionson pereach crosscross sectionsection prepared is required. The for hardne i testing. A minimum of. i Magnification exams shall be located,3 exam nanear the required hardness transverse shall be sufficient to identify the HAZ micro-structure present. Photographs shall be taken of the typical micro-structures. I 14.0 Acceptance Criteria of Test Program 14.1 Code Case N-432 Welding: l 14.1.1 Mechanical Testing data shall meet the requirements of l g C.C. N-432 applicable Section III and IX welding procedure .I . El [p qualification requirements. N 14.1.2 HAZ hardness shall meet 350 Hv10 or lower, as measured and Peak hardness shall calculated for mean hardness level. tu gg> p. not exceed 390. j
~ - - - - - - . . _ _ _ . . _ _ . _ _ _ _ _ , _ , , , " '"*"AM__m2., A C BI Services, Inc.
, M
' Nozzle to Safe-End Page 9 P
14.2 Non-Water-Backed and Water-Backed Overlay Welding Mechanical test data shall meet the requirements of 14.1.1. 14.2.1 HAZ hardness shall meet the requirements of 14.1.2. 14.2.2 O \ 1
. M !
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- IO
- I
O . Appendix II List Of Drawings
- 1. Recirculation Inlet Nozzle Mock-up code Case N-432 & Weld overlay Qualification Assembly
- 2. N2 No :le Asse:nbly Contract 73-6124 Dwg. ER420 Contract 34541
- 3. N2 Safe-End Details O
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.tppendix III List Of Photos l
Photos
- 1. As Ma:hined Tcrging Prior to NDE
- 2. MT of Code Case Groove
- 3. Remote Video Set-up Fct Code Case Groove Welding
- 4. Preheat / Post Heat Equipment I.D. of Netzle
- 5. Code case Groeve As First Layer is Being Deposited
- 6. Code Case Groove After First Layer Completed
- 7. Code Case Groove After 6 Layers Completed
- 8. Code Case Groove Partially filled (2/3 complete)
- 9. Code case Graove After completion
. 10. Mozzle Bore Showing Thermocouple Layout
- 11. Detail of Thermocouple Attachment
- 12. Thermal Sleeve / Water Box Detail Showing Annulus
- 13. Detail of Thermal Sleeve / Water Box & Thermocouple Routing
- 14. Detail of Thermal Sleeve / Water Box & Thermocouple Routing
- 15. Final Assembly and hook Up cf Water Box
- 16. Multi-Channel Thermocouple Measuring Instrument O- 17. Insulated Larrel and Water Pump Assembly
- 18. Overlay Layout Scribe Lines and Punch Marks
- 19. First Lay 6r, First 2 Beads PT Indication removal
- 20. Set-up to do Nozzle to Safe-End Joint overlay
- 21. Completed Nozzla to safe-End overlay 22.
Cross-Section of Forging and Safe-End Assembly
- 23. Typical Code Chse Groove Cross Section
- 24. Typical Crcss Section of Nozzle to Safe-End Overlay
- 25. Cross-Section of Filler Wire With Surface Defects
- 26. Cross-Section of Tiller Wire Without Surface Defects
- 27. HAZ Micro Structure Code Case Groove Right Side
- 28. HAZ Micro Structure Code Case Groove Left Side
- 29. HAZ Micro Structure Code Case Groove Lef t Side Bef ore Temper Becd
- 30. HAZ Micro Structure Code Case Groove Left Side After Temper
, Bead
- 31. HAZ Micro Structure at *ce of Overlay
- 32. HAZ Micro Structure at Toe of overlay at Peak Hardness Location (v
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e 7 r' - P Sm i~ Photo 25: I Cross section of GTAW filler metal which caused unacceptable wela beads (heavy oxide, bumped bead shape & inclusions). We believe the rough surface prevented sufficient cleaning of the wire during manufacture. The wire is ARCOS Type 382, Heat Y4875N382, .045"O on 2 lb. spools. 3 200X , No etch
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Photo 26: Same heat of filler metal as above but from a different spool which had acceptable welds. Notice smooth surface. 1
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s Photo 27: Typical HAZ microstructure near the surface of the code case repair groove weld (Identified as "right side" in hardness report). Weld /Fusionline is in upper right corner. The vickers hardness number of the impression in the photo is 408 HV 10kg. f f+ . lWk it.f NY[
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l 4 Photo 28: Same as above but on the other side of the groove (ID as " left side" in hardness report). The vickers hardness number of the impression in l the photo is 356 HV 10kg. , 1
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i I. W/0 H5173-Supp. I Specimen A - 1 (Before Temper I i Bead) 4 l Photo 29: Typical HAZ microstructure near the surface of the code case repair groove weld (!D is *leftside" 1 in hardness report) before welding the temper i
- beads, The weld /fusionline is in upper left corner, ,
The vickers hardness number of the impression in the photo is 401 HV 10kg.
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Same location as above but af ter welding the Photo 30: temper beads, The vickers hardness number of the i M m impression in the photo is 345 HV 10kg. O l
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- Photo 31: Typical HA2 microstructure near the surface of the SA508-CL2 at the toe of the overlay weld (Identified as" toe"in the hardness report), <
.; Weld /Fusionline is in upper left corner. Hardness I number of the irrp;ession in the photo is 350 HV 10kg. l i A s Nital Etch 400X
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4 i . W/0 H522' , l l Specimen 02 l l
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[ j (h d hi .. n l Photo 32: Same as 6bove but at lo;ttion "i-1" which has ) a harder HA2. The vicker hardness nur.ber of the impression in the photo is 434 HV 10ke. { \ \ t
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1 J l Appendix IV i l I List of Data l j l 1. Material 'Iest Report For No::le FN2-1-5 ) Contract C73-Cl24 (2 pages) ; I
- 2. Material Test Report For ERNicr-3 Electrode (Arcos) (1 Page)
- 3. Work Order H5173 Code Case Groove
- 4. Work Order H5224 Norrie to Safe-End Overlay (Water Backed and Non-Water Backed) 4
- 5. Non-Destructive Examination Reports 5.1 PT of overlay area prior to overlay.
5.2 MT of Code case groove prior to welding. 5.3 UT of Code case groove prior to welding. UT of overlai' area prior to overlay. 5.4 PT of finished groove and overlay after welding and blend grinding. 5.5 UT of Code Case groove after welding and grinding . UT of overlay after welding and grinding. 9 l I l
- 6 i
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Purchaser's ord.r tio. M10 312- 3 73-012h re,e n,, B I Huclear Co. Distramio, *s Order tio. o w,,tmt or L/F approved precedure IIT-12, Req. 'l',11*c'O,"$' -- utar on c oncino
- o. tarvntavutor In!bd- 3 ! ,,, ,,,
raoo;ct secc. ceot no. un ov v. I SA508-2 & Q2QIlN $73C 3650 F +25*F for7 brAir Cool
? 2 H2 !!onzle Mat-k: M12-1-h & R12-1-$
CPIN Specs. 1&2 1560 F ~25,F for7b hrw ater Quenct,
- 12")0 F ~425 F for7h brAir Cool MS-$2.1. Test were stress rel hed as fo11ovs:
Rev. 7 & Qr 1150 F +25 F for 60 hrs.
-$1, Rev.12 Supplier ,
Fev., is L/F appro red proceduro SPWirf-101 tit. la. 212000 V Cl4CMIC At. AN A4.Y$15 AMD *AT CH ANIC AL PROPE f17tES Grain nor nseoats
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.012 .28 37 82 .63 .02 Ladle I I Fcer (h) specinen: -
.20 .69 .007 973C Q2QIliW
.008 .015 .276 37 855 57 .017 check 7 T* C21 '"th 100 -
-1 .1 33 .720 .01 8 Check 70
.720 .008 .01 h .276 37 .86 57 0-10_
-2 .183
.01 h .276 37 .855' 58 .018 Check 7E cprt.No-brea)t,g:c2, to quality -20
-3 .192 .730 .008 7-O
.276 3B .86 57 .018 Check Testing in acecrd:n*:e
-b .180 .720 01 0 .01 5
- Minkmn R INDT 6 - 30 F "Ilh OPETUV*d 188D FI G73C-1
- 19% O') Rev. 1, 473C-2 _}inim, f NIJr @ - 30 F Irpact Testing V-Notch @ *!to F to Qualify -20"F "'UDT YtE LO Eloff G. % n. A. L att H AL E PP. f ra ") %sutsa
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% PSI a 9000 PSI . 1000
\*d O No. TEut, Bh-91-73 .066 .068 .060 80-70-70 H.T. 0 86,190 6h,389 26.0 70.7 70-70 60 573C-1 Q2QI):V -
26.0 67.6 83 82-73 .06h .063 .059 180 82.625 65,000 e
.050 .053 .06h 55-60-75(v 0 +30'F) 0 Actual UnTT @ - 30 F 62-65-92 69-73-87 .055 .057 .062 60-55-75(v a +30'F) 180 Actual TWrT a - 30er .c62 .057 .or/, 70-co-90 0 91,767 70,980 2h.0 70.0 72-68 82
-2 67-79 83 .0$$ .060 .0/4 7c-80-90 180 88,$00 68 0 25.5 67.9 60-70-70(v 9 .)[r) 66-80-S? .0$h .053 .050 0 Acl.ual in rrr 4 0030"F .05h .057 .058 60 6< 65(V H *?,0*F 1
*80 Actual ID;TT 0 - h0 lF 70-7h-75 1.cnare Forr,e certifics that, all ripp11coble requirerents of SA5C8-2 & CEIN Spec. MS-52.1-nev.7 4 QAs-51, Rev.h have bcen complied with.
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i E"* A DIV. OF Hd5K1!:S VJG. CO. Ortete+ 23, }964 p ,e P.O. DR AWIR 308 ' M1 C ARMil. P A '78 51 np 533.;6 CERTIFICATION OF TESTS 43701D Customer's order No A'tes 5. O No. ._ If313 Ort:ter 23, 19P4 Lnicago bridge & Iton Shipping Dete c/o Copper 1uelear Station A!!Z CECITICATE CSC-4 4 6
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- 2 tiiles South of Erovnville Expiration dete: Octeter 2:/s1 E r ownv ille . Ne t:r a sk a $6321
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sige 64% v % f e r _ Grade _ Y4675N3F2 / ~ La No./ Alloy No. 430t lbs 3No. Pieces ~~~" e' ASr1 SFA 5.14 Clar.s EF.N1Ct-3 / AttE Section II, Part C 1551 MM15 _
^ " ASF2 B 6 PVC Section III,
/ 10E3 Editien, Suysectfen .02 / ~~
srbon .NB2400 and 10CTR21 erplies. 2.0 / , mengenese .15 /. ' V WS-4N (43700) Eev. 0
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/ OAS-311 Rev.15 .00 /
,lphur_
. .tesphorus 1b /r Chromium 74 3 /
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elybdenum '3I / 2.3 ,, Titonium ___ _,_
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' 'e hereby certdy thet the cbove meteriel hos been tested in occordonce with *he 1bied tre:d.co with equirements,
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I Cc1T Yf o i h/ORK OR D92. M ## "'- "I i l !i i 3 I \ i l . l l l l . i
. Pulse Frequency = 1.5 i Pulse Width = 60" Pulse Arc l Volt:ge control Continuous ichronization 11opa time 3 Sec. l 0cwnslope time 10 sec. .-
5 Sec. l Travel Start Celay 4 Sec. e Start Delay p yber 1-4 5-6 7-9 10-11 12 13-16 17-18 19-20 21-23 2( 2W ' 200 200 200 200 200 200 200 200 200 imt ) Weld Current (ames.) l 100 100 100 100 100 100 100 1
- kground Current (amos.) 100 100 100 _
@ ell (primary)(sec. x 1)
- ursion time (sec. x 1) -- -- --
Onell (primary) (sec x 1) -- -- -- -- -- -- -- --
- 111ation (in.) -- -- --
~
31 imary Wire feed (IPM) 31 31 31 31 31 31 31 31 _ 51] 2I I 2I 2I !
- koround Wire Feed ilPfi) 2I " 21 2Il 2I 2I 2I 2I 4.14 4.05 3.97 4.23 _4.14 4.05 3.97 4.14 3.97 ivel (IPMMTesfijgeed) 4.23 9.0 9.0 9.0 9.0 9.0 9.0 9,0 9.0 9.0 9.0 imarv Arc 1g1t. . 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 l8.5 S.5 l
- koround Arc solts 20.58 21.02 21.48 20.58'21.%
Qout (Kilo.. sl es /i n. ) {20.16 20.58 21.02 21.48 20.16 gy Oensity (7tJ/in3 ) l1.93 l 1.93 1.93 1.93l1.93 1.93 1.93 1.93 ,1.93 1.93! , E 2. (J ? (- r- 3 . 046'M Ft LL cI:. r%TA (,, - w;M k- 2.-
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- - ~ _ . , _ ,, _ , _
j Q 4% Nci? : i I V/O R,K ORDE.R bdd i I 1 l l i 29 30 31-34l35 36 37-36 39 :. 2 . [ Pass Number 25-2'!2S ' 210 200 200 200_ 200 200 2r Primary Weld Current (amps.) 200l210 215 110 100 100 100 100 100 1 C ;__ , '! Background Current (amps.) 100 110 l 115 ~ ~ - -
- - ~
~
IOut Dwell (primary)(sec x .1)
~
l~ <
- - i- - - -
Excursion time (sec. x .1) - - - - - - - '. l In Dwell (primary)(sec. x .1) - - l-f Oscillation l i n . l_ 31 31 31 3! ' 31 31 31 31 31 31 i Primary Wire Feed (IPM) 21 21 21 l21 21 l 21 21 21 l 2.L_L 21 Background Vire feed (IPM) ' 4.05 4.25 l4.92 I 4.92 4.92 I4.74 - 4.92 5.09I4.92 54.I_ Travel (IPM) (Torch Sceed) 9.0 9.0 9.0
, ' ' ary Arc Vol ts f
- 9.0 9.0l9.0 l 9.0 9.0 9.0 9.0 l 8.5 8.5 8.5 8.5 8.5 8.5 8.5 l !.5 8.5 8.5
, Acround Arc Volts 16.74 fl 7. 3 3 16. 7(. Input (Kilojoules/in.) 21.02 21.31 18.94 18.41 17.33 17.96 17.33 1.93 1.93 1.93 i1.93 1.93 ll u 9.1._. t 1,93l2.05 2.12 2.05 Energy Density (MJ/in3 ) 60 61-62 63 6a 43-48 49-56 57 58 59 42
! Pass Number 220 220 l220 200 210 200 210 200 220 210 IPrimary Weld Current (amps,)
110 100 110 100 110 l100 110 l :0 l 110 .np _ Background Current (amps.) l- - l0ut Dwell (primary)(sec. x 1) - - _,
- - - I-l- - - - __
Excursion time (sec. x 1) in Owell (primary) (se: x 1) - - I- - - - - - - b__ I l-Oscillation (in.) 30 35 35 15 t 38 31 31 l 31 31 35 _
- iPrimary Wire Feed (IPM) '!
21 25 20 25 L_ 2.5_ _2.5 2 !. 21 21 jackcroondWireFeed(IPM) ' 4.48 l4.92 4.64 4.91 4.64l4.54 4.74 4.92__4.92 4.48 l iTravel (IPM) (Torch speed) !c.C' 9.0 9.0_> 9.0 9.0 9.0 9.0 i 9.C t o.0 2 rima ry Arc Vol ts _9.0 l 8.5 8.5 8.5 l 8.5 8.5 ! E.' 8.5 8.5 8.5 8.5 Jackaround Arc Volts 19.0620.18ho.!!j 17.33 20.18 I 4e ,out (Kilojoules/in.) _ 19.0? 17.33 18.41 19.00 20.18 1.63! 1.93!2.05 1.93 1.79 2.00 1.84l 1.Sh 1.84
}gy Density (PJ/in3 ) _
2.05 I l l l
+ - - * < - ~ . _ . _ . , . . , _ _ _ , _ ,
-vyrvw ,.y, _
":.W E C T 2., o* ,
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i
'J 65-68 69-76 77h2 83-90 j ss Number 220 225 225 220 _
imary Weld Current (amps.) ' 110 115l115 110
- kground Current (amps.) '
t Dwell (primary)(sec x .1) - cursion time (sec. x .1) - - - , Dwell (primary)(sec . x .1)
- - - l -
- illation (in.) 45 45 40 40 ___
mary Wire feed (IPM)__ 30 35 35 30 kground Wire feed (IPM) j 4.56 4.47 4.38 4.64 yel (IPM) (Torch Soeed) I 9.0 9.0 9.0 , 9.0 Art Volts ' 8.3 l er 8.5 8.5 8.5 ' und Arc Volts l 20.57 21.58 22.02 20.18
- at Input (Kilojoules/in.) l 3 1.39 l 1,44 l 1,44 1,59 tergy Density (FU/in ) _
- Passes 78 & 79 - 2/3 of circum. downhill side.
iss Number imary Weld Current (amps.) ackground Current (amps.) , t Dwell (primary)(sec. x 1) l . i f[cursion time (sec. x 1)
. Dwell (primary) (sec x 1) f
_heillation(in.) imary Wire Feed (IPM) ekcround Wire Feed (IPM) - _ _ _._ . l avel (IPM) (Torch Speed) _ I i 1 imary Arc Volts _ i i W round Arc Volts _.____ f aput (Kilojoules/in.) , ,__,,_, 3 l ergy Censity (MJ/in )
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METALLURGICAL LAECR ATORY HARDHE55 TEST REPORT p,, g g 7 L C.F T
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Backoround Wire Feed (IPti) - - Travel (IPM) (Torch Speed) 7.4 24,_ Primary Arc Velts 4o 9.0 $ Backcround Arc Volts 95 f. 6 Heat input (Kilojoules/in.) 31.4- 20.93 Energy Density (PJ/in3 ) _ _ ; e O I
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METALLURGICAL LABOR ATORY HARDNESS TEST REPORT ypg 3EFQR_E net.0IMQytpER, (~'u r y Ric.sv Work Order No.: N503 TOPE ( j C dub SibC , 7 : --> < v
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! Primary Weld Current (amps.)
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- Background Current (amos.) //0 //0 ! //4 l /M //o //o //0 l //0 //d l //C Out D.vell (primary)(sec. x 1)
Excursion time (;ec. x 1) 4 4 4- 4 4 l$ G G A .7
.3 2 .2 .2. .2 2 .? .2- .? I .2 In Dwell (primary) (sec x 1) l 4 I 4 9- .3 .3 .3 3 .3 .3 4 Oscillation (in.) l.20 .24 . 24- .2 4- 24 .24 . 2 9- .24- . 24- .2C 5imaryNireFeeL(IPM) 90 40 l35 35 33 .35 '35 I35 35 l 35 Backcround Wire Feed (IPM) 20 l30 l 2.s i 2.5 2.5 2.5 2.5 25 2.7 l 2.5
-Travel (IPM) (Torch Soeed) 2.C6 I 2.fi 256 25C 23T 2.42. 2. /. 4 . 2. /,4 2.G ? 2.65 Primarv Arc Vol ts 90 9.0 9.0 9.0 9.C l 9.0 i
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. mary Arc Vol ts 9f___94 [9h 90 ,
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- PEAK TEMPERATURE DURING WELDING I
T/C e *F [ LAYER 9 3 Pass 8 7 l 2 Pass g 1 -- 7 1 l Pas s 2 231 -- 352 19 -- 246 356 3 221 27 -- 331 53 -- 230 356 45 4 125 222 322 220 37 56 215 5 335 65 213 123 281 1 6 293 87 181 295 80 72 204 292 106 238 73 93 187 7 285 100 99 l 199 280 118 120 181 343 112 94 242 198 106 107 8 l 186 , 267 jl26 174 , 274 I i 136u 88 , 208 140i O 3 1 3- _. 1
Y.//D _ $2 2 A Record OF T/c. tem p . DUR UJ G VJELDUJ G _ :( I tv T /C.
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, 5 !-
e so
%f M Electrode- ESU5C"~3
\Tot . to PWHT: Uow l:
Pos tion
- bM RA2 h4 f 7,3 3 y:
.[
1-osie:
*t
. v 3-ID-87
,4 .s tom,on; >J w sro u PL,
__ [miw e. ,q u s.m V'tr k.tr_t.s 10 k.c-, AREA , toc Minue t Ee r s, % ! I I l 247 29c iE Z. I 254- 3If l ac t agi 3 274 l 240 )l 1 4
~5 240 2.33 i 19 7 299 150 I
l 171 2. 2. t l l 191 l #91 l 19 9 I l 7 l 17 7 ! lYf 193 9 l- i t c. E 'l 9 1 167 IM 4 1 7 2. l I 177 l j i' (7/ l r i G ,% I lO /.d' ,I t77 t
- g zos I l L E l j I l ,
I I
' I I I i l l
llll 1 - I 1 ' l 1 I . l l l l Tiavec.se boncioc, I l
- II i i ro s =l v: - 1 I '
I I l S r. a d 1 - I i .) j ll- I l
., e to 9 :I A vm e - ~. 1 1 i ;
b E.WM A To C. /k To l m% l ( l , l l ' l l l I i j l i 1 ; . l, I b I l 1 O f
"'j {
METALLURGICAL LABORATORY q- HARDHESS TEST REPORT
, j I
3 p Q C,1 M E d h C \ work Order No.: 1-152.2A-
'")
i Materist: 54608 cuz
, , ,..( as r' ; 5#~
- Thickness:- l7 T* I75 5
-~_s \
A)
- Electrode: U N 8 C " ~3 1
- PWHT: U O O l'
*8 Position: $b'
*f HA2 ff \ 7,,i s y: ACH
,t o,i,:
3-h-K7 Loca tiorn B Qi T O d 7 PL, .7 (Mitne _ t Bc.rTo w Vic h E ns 10 k G (REA *{~,q ! pd t bb W 30TTom k l __ f 341 I 19% 172
'l 4 t t. l 23f 331 1M -
l l 3- __ _ ML 2.61 2M - l A. 175' 'E7 2. 2.5 - I t7l 177 E_.f6 - - tol 179 l 7 (7) I l tv i 176 - i E' T (ed i ro v 176 l 202 l 'l 'l I i I a l I I i q l I t I l J 1 i i l l l l l 1 ! l I l T l I I l i 1 1 '- l 1 I Y T a v s .s e s e c. ~ c , I I
/D *ITo-tr,% I I
) r c. E t e/ t % e l l l S rlL 1 e- i 'l l
! c. r m , 6 4 r- a - I
$ I l I smbs,2b t r& h Vt ~ ~. 1 l
l
. E c. n. c L i ~. _
1
! Cre q b4 L P, - f 1 i n B c p ris Sr TJr L- h to J4 ,
! _- ) _
l l i { ! i m_ e==+ 4
~~~^~~~__ - - - - - - - - - - - - - ~ - -
= . ~ = - - ~ ~ ~ ^ ' - - ~ " ~ ^ ~ ^ " ' ' - ^ ^ ^ ^ " ~ ~ ~ ^ ^ ~ ~ ' ^ ^ ~ ^
HARDNESS TEST REPORT S P E.c1 M.E d 31 I work order rio.: N 5 2. U- ) Material: SA508 0.t E
. . . . Thickness: 5'E D !'
T ' 4 Electrode: M di d"~ 3 1 *7 N "O #
,7 PWHT:
I _ Position: b_C' 4 N A'7. Test By: Rcu) I ~'
,g Date: 3 *ID - -
Location: N105 W I
*w gacott ' *O t B vr ~
bcFERS 10 KG
~
AREA - Tp f ,_ N ID E C. hm^ - t 38_7 3/J, , 300 I 7 2 56, 273 3/4 I 3 pp c., 227 274 I
~
r .(90 203 234
/82 /84- /86 (72 I?4 /77 16 4 \ i95 203 .
p(") I l . i I
- - 1 I I __ t I
l^ 'Tinv c.g.s el SP A c.10c'- i 1 - c, ei- d V7 - - l
- 4. n C --
I -
- 5 Tc 6 r 4% 8MM i
l ! be.9TR Ai Toc =__b _Te i-I7)
- ~
s l ' 4 i !
W METALLURGICAL LABORATOGY HARDNESS TEST REPORT I
$?CC l % E d b v.ork Order No.:d6 2 E d u,ie ;,i; SA508 Ct E n ,, ,,, i . 2. - n i. 75 ..
j" #. s... y$)
- w t( \{ ,
.'l
~
HA2
\
Elecrode: r.v,m Position: 7,,, s y; E R h)i d "" 3
-c 5C WA 5 cate: 13-D
. Location: NM 5 to *J
[m.oca. EL- 6 E % r.~ ' Vic KE E S 10 KG
!EA ! '
To t Po e ea L y re m It 307 J/o 329 426
,4 l I
I 348 3/4 t 272 l - l lt - 1 239 26,5 l 2 79 - l 20/ I 2 /4 1 234 - l
/79 I /Ro l /% -
i
/7'7 I / 7/,
/77 -
I - 7M !.b_8 l 190 l Rom I - I I 't I i i ! I I l i L l I l l 1 l i I
~ l I l l
I l I ' ' l
! i TR AVE RS$ SPActAG l l
/v , 4 cl vt e- l I i 4 r, s el 1 --
1 I I rc6=l sroni \ l l l be p r u A l i~ c = P't k i - 1 I ' I i l I l n I l ( ) l I l I i
Wb ' METALLURGICAL LABORATORY j I HARDh'E55 TES T REPORT - f
', ' a i
-E i
work Order No.: N5E2 4 [k> '* ~ m31.,m: SA508 Et 7_ 4 .
/.KA Thick ness: h 2- T~2 I 76 "
l I I '. '
- 4 Electrode: ER 0;de- 3 W N o d' e7 PWHT:
i l .' _ Fosition: bC7 Nk2 Test By: MO f MN 5 Date: 3*l3' !l Location; A tM TO d l g L [+*e ou. EL- *6 L 9,r.~ Vjc KEC.5 10 KG AREA l yt l Plinetc 7,orro_ 8 360 1 30 B gt 264 434 q._ 1 252- 30 7 ?*:d- 4r, a 3 L93 P &. 7 24 R 3/6 i E+ 189 2 24- z33 2-70
~
'IS R I183 l96 25b
[G '
/y,j_. l /R/ I /72 / F F_
SfM /63 ! /90 / 9 '7 I - I a l I E I l I lE - I I . l t i a I E I _ l I l l l L I 1 I i . E hv e we spacms I u l iy, 4 2 1 yt__ l _ l e r, 6 :I 1 - - ~ l I ,E g To 6 - 2 re s _ I I I I i 4 m !F i l l i I
- - i i i i ,
I . is
'N M AGNETIC PARTICLE EXAMINATION REPORT Il wsw ms D re,d
,. g j
VOL'S@V WX/91 L OC ATION
'Ssnap 'Wh$ 0 CONTRACT REPORT OR SEQUENCE NO.
l[(7^V Customer Descript on and stage of items enam.ned I ))fC 6 G}f00VZ Nff AC'C8 W WSMWh Outside kl snside C1 - L ) stems Procedure and Rev No U"d M'E d M C Prods
. N 0 l sffV).C/p W Y Y***
?e 0,y Prod Unit ID Prod Unit Raung Prod AC Yoke Mfg & Color
@ AC M A M 4 W u,X Amps Mod O HWDO Mode l /1 O DC DC IA DM Location of Defects or Unacceptable Cavities Not Repaired During Enamination.
ID Location From Reference Point Date l Ile ( q R marks cr Sketch Check Applicable Bestes): Weld repairs were made during esamination and have been re examrned and found acceptable lancludes repair cavity). No welded repairs made during examinati rt Final surf aces requiring blend gnnding during uamination have bee , co . 3ieted per GR Rev,. . re examined and found acceptable. Examinations were performed and ailindications evaluated in accordance with the referenced procedure. Ostects not repaired during the ex amination are listed ey location above. All other examiner areas included in this repori were found acceetaole. b 3 av __W ?-- lO b OPE RATdRIEVALU ATOR ' LEVEL DATE R2 port results reviewed and accepted by-LEVEL DATE
,[\iview.ed and accepted by -
NY I e CUSTOMER'S INSPECTOR DATE AN6 OH At DATE Pneted m USA WL 244 REV AUG 81
Ll0VID PENETRANT LX AMINATION R[F' ORT E tyfw u?B Dr.ia ; i pf uc, M 6//22- __negy, _[7*cw Y.1 **
'c e 9 gwncM c e .,
7EydJ t Oc A sic >. cc w ac, ou,a GB-C S. I
. ._ i -
E l,e,.ci.roonanditaaeo io - e.s ~ ea e ai . , g cv.m sr c.mcur Ma.9 AnM v v n e u ust 'i de - c ' stems - Prot tdu'e and Fe v No. UN ffw.wk 3 . E ~ u san iaciu,e,.. e,andunma , et,a ,i t T,re and cauh Numbe, eiesee,a,e.no,e. o,,e, ope, 5lYaf W/W CFR a2-c c> ^ ,6-soo wcwungro M -r0 5/f'- D'+ S28-GS ___ Location of Defects or Unsecettable Cavities Nc.t Siepaired Dunng iseminat.pn. ID E I Location F#0m Pe't'ence .'oint Date P@ II u Ramarks ce $~n etch 8 Check Applicable Bostes):
] Weid repairs were enace curing es smanation and have teen re ea am.ed er a founc acceptable (inci , *: repair cavityL h No welded rerairs made during esaminatIon-,
Fieel surf aces requiring blend grinding dunng es aminas.un have been completed rer GR Pev. - re esam.ned ani found acceptable. E. Enem. nations wera performed and allindications eva'vated in accorcance with the referenced procedure. Defects not repaired during the esamir.ation are listed by location above, All other easmined areas snclucec in this report were found uceptable. 49_ - a N lC h OPE R AT Q4t V ALU ATOR LEVEL 'DATE Report retufts reviewed and accepted by. ' 4 LEVEL DATE IR* viewed and accepted by -
~
l ~ CutTOvtP's iN5PECTOR DAf f ANi OR At DAit ,
*rraita in U$A WL 2a6 PEV AUC 51 euer at . - . ~ ,
ULTRASONIC EXAMINATION REPORT I O uwez CONTHACT F ei,10 6e d'U'7 u Nhve(e ho "1 ~ VO'b~[~Id {j 62 f fE M CT k P,4rtiag Het 1.e.eIJ E to
*** '~
Cocomer (, Q- - - m
,, l I Description and stapt of itemt en ama.ed I I I j I /) CVf/ftRy (2fPr5/ 7' Mf9 /W/#tt ~7c w/alw'h IC i f fl j ;
r) nroe circeav r.r.co s.nex -rc wruv.m sl1 i i l i l ! !! l i1 .* I Procedure and Re, No Coupf ant EWL '
- l' : -
l . Iran 6dwcer Mfo g.afee I !
' ! J
.l i 1
l ! Sae . 5
- X /
- 1 t In s t r u m e n t M f g ,,pp, y,,,,,A,,,) ,y,o, gno;, 3 7 _
l Model # l$l*)& Stesal N 2)UOW r. h
- l J
l b
) l
- l Location of Unacceptable Indication 6 or other indications Atovired by the Procedure to be Recorced l l Depth from I 10 Location From Reference Point Defect Sier Outside O oai, f
, Length l Depth inside O .l I - -
- I l l l . . - - .
i I l l l I I
.O Remarks or $ ketch 1
I I I Enaminations were performed and evaluated per the referenced procedure. Unacceptable Indications found Yes O No 3 Unacceptable and other indications fecuired to be recorded are hsted with tneir location above. I All other esamined areas included in this report were found acceptable.
' M d --- 0 lb / 9/ $$ ll /b CPE R AT OR Liv (L DAfC (V ALVATOR L(y[L Dayg beviewed and accepted by~
( k. (vgl oset R'S st[YCf0R DATL Art s b an A4 DaTE I. _ ... .. _ .. 1
.--__-.. -.~- ----- - --
i l
<WS / O r 2 ULTR ASONIC E X AMifJATIOPJ REPORT k' 2'dal?
i I
- CONTRACT f (!c C I'e00't2T c' Iew_eln6I e i Ff98 61 ~dCjl(%f. 7#
l, IN' }2 Primary Aef L e et b te . i
- !c=
CS/ "' o u c .. . . . . ,. 3 i s a l i i j , , i i q , te ' i ! 1
' Delc'>Cla n an0 atJif o' 'It" l e t ave d I I I l l i I I i }
l }) CVffM" N/C.5"/ T bY/A $ Y/f* t O W*NEW$* 8
\ s } \ l
~
i k 1
& jdfC*,
- CWWW N/P Miraf ?C' We"$O/Wi'- 8 h; g 6
l ; l 1 l f
-br l l !
Pect edste and Fev fm l Courtant l l { Tr 'i j i } j i ; ji } 2 l./L 7n M G /4 % t."g sp*Srsc '{IL!' l !. t i ii' i Instru ment Yf 9 l S a c_'f */ nlL i i I i iiil ;1 l st*,ppp7'ggg4&Le n ?A.s*cA./ #"9 '- U. l l t n{ { ; 3-- l-f Model # M(( *M ber al ** hdMf[ a fA l j ' 0 $ locat+on Cf Un4CceDiable Indicatton$ or other 1r cbcat.cel HeQuired by th, Proctdure to be Recordtd. V l i DtOthfrom h ID f location From At erence Po:nt Defect Sire Outste C Date I length f Cepth innde O l l h l l l l l l ! E I . I
! t i l
l _. i l l 1 I l l j l l i
~
i Remarkt or Sketch l iI 1 i 6 i
!I E
r Enaminations were perf ormed and evaluated per the referenced procedure. Unacceptable Indications found Yet O rao E Unacceptable and other indications re sired to be recorded are listed with their locat:en above All other examined areas included in this report were found acceptable. (Yd.a &h$N< C8'f A A T O R _ )U~ tiveL
//ltcAG CATL
&;{a% hk7(2- nbc/pg
(/ALyATOR ggygg pagg g ) Neviewed and accepted by- !l
- C V 5 f C,vt. V b #N but C T O b OAT 8 ANi OR A6 cafe j
l
... i. . i, us A we e., or no, ,, .
,[', ,Qf .$ t'f $
ULTRASONIC LXAMINATION REPORT '
.o Il i WGUC3 UT
~7 e por t cdE e nt e N o "2 ~
l CONTRACT F eld C ((49 (d y 'i N bh0p N p,, mpy p , f L ,, e t ,__f_, pg, i o m. . . . ., . . 4 a , q Cuttemer (g/ 3"
" j j j j l j ; )
f Despipt pn sad stage e-f ,te" e n aw e d i i I f i i ~i~~ <
}} eV?fs&Y' ('f f N / T
- -) Gircov: wrip prreur n.w.two wtw
//A' mfd Wil O $t
"* T iN j Rl lll- l l l O '
i i7] i QCfM M/Tf4 GoTa4%?/WJ .) H
~ j -- ~] ;; j l Frocedure and Rev No Couplant i ()'T*S " A'fn 0 bit ys,.qggt f se I' l L l u yg ggy, o h"e ne'-"!?!
Site .f"X . 5', n- ! ! I !
?----%l!=- I i
'O'U**' 5
,k'fgpfxyg,efggggt,y,e,vf ps,,o Angie_ 3 7'" _
I l , I ! , l Model # v.56,"4f' Senat # $/?pydf' Freovency.S~q],
,ygg ,
a j3 j' j ' j 8
/ ,
i location of U-acceptab!c rnai,uions or other indications Reavited by ths Procedure to te Recordet n j Depth from ; l ID Lout.en Fra n deference Point Defect $ ire Outside O cat, ! j Length Depth innide D i 4 ._ _ . . 4 1 l l l l $ .h l I I I Remarks or Sketch j M'DM7MY M4595 ^M74'4'50 OA' Gn'ao yg : l Wft.D l j ! !s l Esaminations were performed and evaluated per the teferenced procedure. Unacceptable Indications found Yes @ No O ! Unacceptable and other indications required to be recorded are listed with their location above. All other examined areas included in this report were found acceptable, !
'b 24 l 6 $ _$ Y&
J i et..tw.d .n c<...e. amep,ed ,_ om e.1c e m a,on mm e.,, i _ _ . _ _ _ , ,c .
- e. .r . . ._ a . -.:_,a k
1 J
+r--eerwg,- -m..,*-,-rw.-v+r,,--+y.---..,__ ._m.,,.-----,--,,-e.---,.e. . . - - - , . . _ ,-===--=-*==-~n - - . - - -
Ll0UlD PENETRANT EX AMINATION REPORT ' g was MS O ou j anysrc% z;om LOC AT ACN k,, /vDl2 e _ 17
- e ,
CONTRACT Customer Pf eOni C N floulidi ho CS/ l Descr rt on ene stage of items eaawee l C
' nV/SN!O M44,05 o f W <1' f & ' U O Y f o,,,,g, y 0f i '
i l $ ic e C ,i, r.. . Vrocedu*e and hev No fue o ..j , EfV/sww 3 l Manuf actu rer's Ts re and Fetch N;mser i B'and Name Fe ne trant i Cleaner /Re.nover Oesetope, lI .5NE,f W/W Dh W l f)N =50 [)#/00
&VCDRPMMfD /E823 )
l S/B-DY SCB-GS Location of Defects et UnacceptaVe Cavities Not Aeraired During f aamination.. ID tocation From Aeference Point I Date I l 4 .
/VO (AV/?CCSP 78866 /A4/C# T/GWS /GtwD i
nemeni or neien Check Apphcable Boalesi:
] Weld repairs were made during e aamination and have been te esamined and found acceptable bncludes No welded repairs mace during e aamination.
] Rev. Final surf aces recumng blend gnnd,ng during e remination have been completed per GR re-eaamined and found acCtDiabie.
(samination$ were performed and allindication$ evaluatedin accordance with the referenced procedure. Detects not repaired during the esaminat6en are b$ted by location ebove. Allothee taa%ned arealIncluded in thiS report were found acceptable. Y p ? [ OPE R A T OR/E V ALU A T 5t il LEVIL DATE Report results reviewed and accepted by:
- l
# LEVEL DATE Reviewed and accepted by -
e
~
{ CUSTOVtR 5 6NLPECTOR DATE ANI OH Al DATE PsmteQ m V$A l WL 246 R(V AUG 01 \
=== .~.._-.-____.-.-.,_,__,___,.-_..,_-.._._,,_.-_...,_..-r-_- _ . , . . .m . .,,..r,. . . _ _ _ , . , _ . . . , _ - , , - - .
- -.l 3
h, - !W Appendix v
~
,' Procedure Qualifications ,6 J
- 1. Code case N-432 Groove - PQR 7673 ,5 ,
' "P '
?. Water Backed Noz 10 to Safe-End overlay EQR-7717 W 3. Non-Water Backed Norne to Safe-End overlay-POR 7718 s
J L N
. r.
1 4 M* e l
, N P ..
N l ~ l l l 5 l E i
- . ,1
h/5/' c? cv &' dE ULTRASONIC EXAMINATION REPORT A%jn3 CONT 4ACT r eia O EE R 6 Ncue M o ur "e -~ Shop C ft? t AG_ f'qt'JfsW'TX Jt Prtmary Ref Lese Y__Du l C8/ "{""" Customet 8" , l ; Driced ton va uay v itera eommes l l j y l} CbML A)" g) f#xt / Ws.o Crn14 H"u a e ff/CJW /VMJA'fd WitD i+14O Ct Y ; l
't l Q l Prxedure and Rev No.
[ey n r.cr Coup: ant
/,w.~.wp a U
; jx ;
g y ,yy, p Transduce' y I
\. I l
[g ggy Q U b Yr W l $ $ $ Mf g N/T* /LWO y l \ I S tel'r._.y W ,,
\ >
Instrument Mf9 Angle _ Co e .l t d'$&*TKfA Mxl$/4<sse As Freovency S S'n e L_ _ ne s-Modd w VJL *)? St[el # '&/ w ff" p g, y yf , e { J jk \'] *l Lccation of Unateeptab81 Indications or other Indications Required by the Procedure to te Hecorc'ed. Depih from 10 Location From Reference Point DefectSire Outside O osie Length Depth inside 0 l l I I I I: . g riemarks or $ketc*i l l<WlC 'i 7/W OSA.S A fst y/j y' f p pA/ gg 9pj,g WSt.D Enaminations were performed and evaluated per the referenced procedure. Unacceptable Indications found Yes 2 No O Unacceptable and other indications teauired to be recorded are hsted with their location above. All other enemined areas incluced en this report were found acceptable. Ghv
*ERATOR 2 LIVEL nb/n Daft c1(VALUw L =D C OR LEVEL
!%k DATC 9eviewed and accepted t>y-J 4
4 CUSTOMLR*h INSPECTOR DATE ANs 04 Al DATL "I # 'I Printed in US A _ _ . . _ . . ._ , . . . . . _ _ , . . . _ _ . . . _ _ - . . . _ _ _ .. ._, .- . - - - . _ . . , . _ . , _ . _ , . _ . . ~ , . . _ _ _ . . . . _ . . . - . _ . _ , - . , _
u r,p C or ti s ci FROCf DURE QU AliflC ATION RtCORD lo A S M E Se: tion ix FART !!! WI LDING V ARIABLLS f0*
- - - ~~,
p I i xv:iNWwNIN, = - - , t,,3,s,c , 7 < > ;
t 's , " j n .s .. , ;
s ,,
*) . ;N o , - 61 f g ; _ $ IN 9 J. I" 1.1 j/s 5-3/10"
/'
r 07)F y/ Vn/ #
\ te /* /
(Safe End Side) 'ssf d_ s
. /4" .
1 k r SG P051 TION OvaHUcation No. 2/18/87 7673 _ gy hm IAlan E. Hudson u/x~ Date. _
/ 's -
g ..,.
.Y, FROCCDUHF to A 5 M !. ItCTicN n
- OUAllTICATION RICORD Comrect r a n u _._ _ PART U L SSENTIAL VAmADLis n
u.n .EG lr
- dLW ? Ort i t a l i_ _ _ _ u.n v.,,, ,, u ,
,e.,
fA!O3 CI355 2 v.i[]>.*,em . [R,e,.au []raie ILIM 7 AIMER ec 3* C' 3 To A5vt r nce __Z_ t.
.m.m.a []
18 aren u p 3 e e . ,ne
.n ts.cu f6 i< ace na , FLUN OR AlMOSFHt Ht' s.n , r.i.i s,e r no r e
f 3 / I6 "_ None Ee:;ui red 43 . r . i p i o,.u u r e w . o m e i,i ,,.., ,- i IUU #'90"
- r. A ERNicr-3 . t 4.,.i......
_ 40 CFH A sMt u-um or en no. 5TA 5.14 _ i.t.o m ,u,, e No Aws . u n s.o n.n no. A 5.14 . _ r im.ie pe , ,n.n r , i,,n+,ni
, , ,, ,on . , ,., No ,,, , , r g , 300'T-450'T(
ne*" I c.nsie e,m v r:e o a _ I Multio1e WELDING PROCEDURE ! filler Metal ERNitr-?** _ s m,,, ,, mo n y, ,,, 51ngie g ,, n ,,,, _ ,,,,,g,, 5G EWiH-2, 0 1/P tyn et tuung _ None _ na,, ,;,, ,,, ,,,,, _ k .045" Coaswa PART in w*LoiNo VAntAett5 fo, somt o me nsions enc .e'eing ,y,,,n, _Dicurreni re c t Curren uninst_ t , El w,ie,ng ec t rode Neg i ~ (Pound Specimen) TEST RESULTS (5tratght Polarity) Fulsed) p.evue z,o.en T,no, n ovni ! I 5 " i"' ' " " 5 L ca.n .on. in i~ I w,ois ] un m.i. I 1 Ts.on nI l ^'" I 2 I" '"' { vn m.i. uno ! A 'Trarsverse -- in un
'"'" en,,n,, e t r.ao,. I
! B kTransverse)) (ll 0.504 l0.200 --- l 0.506 l 0.201 17.6
.!6
. E B .O EL_L M* .no too oon k
C ( All We ld Me t A l ) --- 17.5 7 Ductile in c,M ( 87.1 600.5
~ D ( All Weld Me t(1) --
0.250 l 0.049 5.1 Ductile in EM T04.1 TFTT~ { 0.253l0.050 5.2 - 3 nds ' 1re. ( (104.0 717.0 - I puun 1 I 4 Transverse Side l ( \ l OK T.c. Jerry t l ! w,1ce, . n.m. _ Jnkn Uehay n... Matth_eys
- r4 nun 1
w se dy sino. . in l so W Cr3779 n in a m..ii w iee, reform.nu ..._un ,e,,i s,,,,,,y no. _301 1 19 3 JP Week 0,0,,(0,,gs WPfl No. _ v .nii. _ w,3,,, , s y,n eo, M _ Rev, _ _ _ oa t e ,,,_ Qvietmenit of tstCi4on tx of he AsME codw. c.ns, in.nn. nven. nu :n in . ,ee e. eini ..ie w n c.. n..o. ..io.o .noo,e.nu u.i.ein .cc...
..in is.
s,gn.e ces e, _ Alan E. Hudson .
~ ( / de o,,. _ 2/18/87 e,m.a.:._Ilshhgito a ?2"O 00. $ 11 5/6" e N-432 using a SA508-2 nozzle forging 10*) Qualified 360' lHT forarr'und 24 Hrs, at the 1150*7 OD. priorGTAW to rnachine
, with a 1" det2 welded rmit 4;rmtmr110tL. ui s no a remote video monitor.m*, The forcin
* * }_ Arcos type 382. Ht ..xamiteed by Pi & UT af ter the completed v w Y4875N382.
)*)PostHeat: 2 Hrs 9e.ee n UU at 500*F immediately after weldinoeen a t em Wt200D(VWOiil
i E r e ;, i Centeon PROCEDURE QUAllFICATlON RECORD To A.S.ML Sectien IX ) i* PART (11 WELDING VARIADL ES ll
)ss Number 25-27 28 29 30 31-34 35 36 37-38 39 !40 41' 3 imary Weld Current (amps. ) 200 210 215 210 200 200 200 200 _200 200 ekground Current'(amps.) 100 110 l 115_ 110 100 100 -100 100 !
t Dwell (primary)(sec x .1) ' ' ' - - 300 300 pursion time (sec. x .1) - - -
-]
!gu Owell (primarv)(sec. x .1) l- _- - - - - - illation (in.) I mary Wire feed (IPM) 31 31 31 31 31 31 31 31 kground Wire Teed (IPM) 31 31 1 21 21 21 21_ 21 21
'ej (IPM) (Torch Speed) 4.05 3L__ ll_ I 21 . lLl 4.25 4.92 4.92 ary Arc Volts 4.92_ 4.74 4.92 s.09 4.923dLo_
9.0 9.0 9.0 I 9.0 9.0 ' 9. 0 9.0 9.0 9.0 9.0 g, y round Arc Volts 8.5 8.5 8.5 8.5 I 8.5 8.5 8.5 8.5 _8.5 l 8.5 ' LHeat Input (Xilojoules/in.) 21.02 21.31 18.94 18.41 17.33 17.96117.33 16. 74 H. 33 l16. 74 l Energy Den:;ity (MJ/in3) 1.93I2.05l2.12 2.05 1.93 1.93 1.93 1.93l1.93 l1.93, J Pass Number 42 43-48 49-56 57 58 59 60 61-62 63 64
'rimary Weld Current (amps.) 210 200 210 200 210 200 220 220 220 220 <
iBackground Current (amps.) 110 100 110 100 110 I 110 'lut Dwell (primary)(sec. x 1) - - - 100 110 110 .np, ; 1 - - - - - -
. ;xcursion time (sec. x 1) l l
- !nDwell(primary)(secx1) - - - - - -
{_scillation(in.) - - - - - - ' rimary Wire Feed (IPM) 31 31 _31 iackground Wire Feed (IPM) 31__ 35 30 35 ' 35 1s 38 21 21 21 21 25 1 20 25 29 ?s 2R l-avel (IPM) (Torch Speed) 4.74 4.92 4.92 4.48 4.48 4.92 4.64 _4.91 4.64 4.64 ! *imary Arc Volts 9.0 9.0 _9.0 9. 0 9.0 9.0 9.0 9.0 9.0 ; 9.0'
****1round Art Volts 8.5 8.5 8.5
__ 8 . 5 8 ._1 8.5 8.5 8.5 l 8.5]85 l ut (V.ilojoules/in.) 19.0P 17.33 18.41 19.00 20.18 17.33 20.18 19.0N20.18 20.18 . ergy Density (MJ/in ) 3 2.05 1.93 2.05 1.93 1.79 2.00, ! 1.84l 1.84'l.84 1.68 ( ,,,,, QUALIFICATION NO. 7673 DATE 7-1A-A7 av , , , n ,g ,,, n g
j Page t cc-vect PROCEDURE QUAllflCATlON RECORD ' I To A.S M E. Sectien lX l PART 111 Wf LDING VARIADLES ! \ i i l \ o - Low Pulse Frequency
- 1.5
! Low Pulse Width = 60% i jSynchronization Pulse Arc l Voltage control } IUpslopetime Continuous 3 Sec. Downslope time ! @ ire Start Delay 10 see. 5 Sec.
. . _ _ _ - - Travel Star +. Delay 4 Sec.
i . s Number 1-4 J 5-6 7-9 '10-1 1 12 I 13-16 17-18 19-20 21-23 m erimary Weld Current l amps.) 200 200 200 24 l 200 200 200 200 200 [BackroundCurrent(amps.) 9 200 200 l 100 100 100 100 j 100 100 100 ' 100
!0ut Owell (primary)(sec. x 1) --
100 100 { Excursion time (sec. x 1) -- -- -- -- - -- -- --
~
'In Dwell (primary) (sec x 1) -- -- -- --
l . Oscillation (in.) < -- -- -- Primary Wire feed (IPM) 31 31 31 31
-- l 31 31 31 31
) lBackaround Wire feed (IPM) 21 ' 21 21 1 21 21 21 21 21 31 31 l 21 21
! Travel (IPM) (Torch Soeed) 4.23 4.14 4.05 3.57 4.23 4.14
[ Primary Arc Volts 4.05 3.97 4.14 3.97 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 Backaround Arc Volts 8.5 8.5 9.0 l 9.0 8.5 8.5 8.5 8.5 8.5 8.5 Heat input (Kilojoules/in.) (20.16 20.58 21.02 21.48 20.16 20.58 21.02 8.5 l 8.5 l ' 21.48 Energy Density (MJ/in3) 20.5821.cde l1.93l1.9311.93 1.93 1.93 1.93 1.93 1.93[ 1.93, 1. 9.i ovahl: cation No, _ 76 73 l Date: 2/18/87 Ly ( A MN Alan E. Hudsen !i O l ( *"8
- N wg 1 $4 hf v seOV f t 1
1
m VQH140. J L !A 1 W.o. tso. H5173 3 T ra ve rs e ] PHOCEDURE QUAUFICATIOfJ RECORD __ Spacing 4 1-5 = 1/2nn VICKERS HARDNESS TE57 5-6 = 1m
- 6-7 = 6 to 10m
- ; 10 KG LOAD 1W (Safe-end side) tin star 7 s i i
k
, e i s s , pl/2 to 1 n N- n ur a n ..
g~ .
- g SPECIMEN A art
,. I
. 1.
(Safe-End Side) LOCATION LEFT SIDE RIGHT SIDE ROOT
.I 386 408 315 f 2 362 417 300 ;
l! 3 255 312 227 4 224 1 261 198 j 5 183 188 180 l, 6 184 184 181 7 179 185 184 8 177 183 222 'I . e ,10 " " c & om 2'>8'87 - U5a
- . _ . . . - . . . . _ _ _ _ _ _ . _ _ . _ _ . _ , . _ - _ . _ _ . , _ , _ - . . _ . _ _ . . . , _ , _ . . . _ _ . _ - _ - , . . , - ~ , . , , _ _ _ , _ . . . . _ , , , _ _ . - , _ _ , , _ , , _ _ . - - _ . - , -
- I
- r. . i ;
ccetrut , 15 - i PROCEDURE QUALIFICATION RECORD i10 c S o A.S.M E. Section IX l -l , t PART til WELDING VARIABLES ( 4 i i fPass Number 65-68 69-76 77-82 83-90 Primary Weld Current (amps. ) 220 I 225 225 l 220 I Background Current (amos _. ) 110 115 l 115 110 -
#0ut Dwell (primary)(sec x .1) - -
,M - - '
j In Dwell (primary)(sec..x .1) - - ! - i - i _ Oscillation (in.) - - - l - '. Primary Wire Feed (IPM) 40 45 45 40 i Background Wire feed (IPM) 30 35 35 30 l Travel (I[M) (Torch Sceed) 4.56 4.47 4.38 4.64
'ary Arc Vol ts 9.C 9.0 9.01 9.0 i i
koround Arc Volts 8.5 8.5 8.5 8.5 hdt Input (Kilojoules/in.) 20.57 21.58 22.02 20.18
- Energy Density (MJ/in3 ) ,
1.59l1.44 1.44 1.59 l l ) _
- Passes 78 & 79 - 2/3 of circum, dovnhill side.
! Pass Number l
(PrimaryWeldCurrent(amps.) l l ! ,; fBackground Current (amps.)
.Out Dwell (primary)(sec. x 1) - _,
[ Excursion time (sec. x 1)
' J ;
'In D4 11 (primary) (sec x 1) _I (i0scillation(in.)
! Primary Wire Feed (IPM) l I
lBackcroundWireFeed(IPM) fTravel (TPM) (Torch Speed) tPrima ry Arc Vol ts '
- I
!Be '*around Arc Volts !
h (nput (r.ilojoules/in.) i { ,t _ y Density (MJ/in3) QUALIFICATION NO. 7673 1 DATE 2-18-87 BY [2A_ 5" /1Ae "'"'"""**" 1
. - - - - - , - - - - - .r,w-,--m,e,,-v m%,.~.w,-- w.--,,.w_.y. , , , , . --..% ,-,.-,w- . . , _ , - . - , - . _m,--- - . - - . -
POR 80. 7673 W.O. NO. h6l 73 PROCEOURE QUALIFICATION RECORD Traverse I _ Spacing VICKERS HARDNESS TEST
," I )h*
10 KG LOA 0 6-7 = 6-10m
' un erst (Safe-End Side)
I3 - 7 s s
\....
i
, a i
5 6 f-- 1/2 to im i l- n ,n et I s. s. I * : SPECIMEN O * ,. 1. IS (Safe-End Side) LOCATION LEFT SIDE RIGHT SIDE ROOT I ; 1 384 390 308 2 400 395 336 3 327 300 264 4 230 243 211 5 211 200 183 6 185 183 187 l 7 187 180 189 8 175 175 208 [ A-Alan E. Hudson DATE 2/IO/07 i
.. usa
~=m~ ~)
i C rect l nev l W.0. (H5173 l PROCEDURE OUAllFICATION RECORD DROPWElGHT TEST DATA I SPECIMEN TYPE P 2 SPECIMEN LOCATION TEST TEMD 'F , RESULTS I ! PLATE H5173-1 Longitudinal
-30 No Break
) I H5173-2 Longitudine1 -30 No Break H5173-3 Longi tudi no , -40 Break i .l . PLATE TNor = -40'F l- HEAT AFFECTED ZONE i l l0 HEAT AFFECTED ZONE T NOT l WELD METAL ! l WELD METAL T NOT i .l 1 i CHICAGO BRIDGE & lRON COMPANY Qualification No. 7373 o,i 2/18/87.. MAlanf~E. Hudson 4- ; gy ; WL,2 0 G R EV N SV 76
onn.ci PHOCEDURE QUAllFICATION RECORD TO A.SME. SECTIOtJ P. V Water Sacked: Weter contained in arrulus space of the thermal sleeve and nozzle wall. Water was considered to be stagnant with 20 feet of head pressure yet allowed to circulate (2 GPM maximum) at the welding heat input was absorbed by the water. Circulation l did not start until the water temperature had risen to approximately +60'f. The water temperature ranged from +41'T to 62*f peak with the majority of the welding being performed with the water temperature in the range of +45'T to 65*f. I 0 (~') I A i3 -- N IISI kAll ]
$tA*NAnt (Anttr.3 CytRLAY hAf tR W l ' . N AX \\ 4:Wh
/O/A}Y/////YJ////w>
.=
- f. terarAt strtvt d l
A
- , y r -
j yjp p yj,i,/,j/j ////td
/ mxwwww WATER BACKED N0ZZLE TEST ASSEMBLY CROSS SECTION !'% l./ " .
i ,311fication No. 7717 By Alan E. Hudson Date 5-15-87
l POR fio. { , W.O. No, __W U l
- \
PROCEDURE QUALIFICA710N REcono Traverse 9 acing VICKERS HACNESS TEST ' f,~f," l 10 KG LOAD 6-7 = 6 to 10m (Safe-End Side) u rt wt 7 5 5 ! 1
- 5 '
s....
. 1
, j-1/2toImr i
/. . . .
_r
- a ut et l
l s. } 1 SPECIMEN C
- 1.
t (Safe-End Side) ' LOCATION LEFT SIDE RIGHT SIDE ROOT ! l 379 306 297 2 396 292 288 3 281 239 248 ) 4 241 208 208 l 5 194 - 177 179 I 6 179 177 178 7 178 174 177 8 174 172 213 l I
- Alan E. Hudson 2/IO/07 DATE.- ,.,--..,-..,y-~., ....--..y..._wmm-, - . , - . - - . . . , . ~ . . . . . , . _ _ . . . - _ . . . . . _ _ - . . . . - - . - - - . - - - , . , ~ , - . - - - . - - , , _ . ~ ~ ~ .
PROCEDURE QUAL!f! CATION RECORD To ASME Section IX PART Ill Welding Variables b' i . 1 I I I chronization Syn Pulse Voltage control Continuous lope time 5 Secs. Downslope time 10 Secs.
.e Start Delry 7 Secs. Travel Start Delay 6 Sees.
.ss Number N23 5 146 147 Primary Weld Current (ar.:os.) 220 220 180 120 Background O' rent (amps.) 110 110 90 60 Out Owell 5, eimary)(sec. x 1) .3 .3 .3 .3 I Excursion time (sec. x 1_) .2 .2 .2 .2 In Owell (primary) (sec x 1) .4 .4 .4 .4 Oscillation (in.) .24 .24 .24 .24 Primary Wire Feed (IPM) 35 35 -- --
Backcround Wire Feed (IPM) 25 25 --l -- Travel (IPM) (Torch Speed) 2.71 2.72 2.72 2.72 Primary Arc Volts 9.0 9.0 9.0 9.0 Backaround Arc Volts 8.5 8.5 8.5 8.5 Heat Input (Kilojoules/in.) 35.47 35.19 28,79 19.19 Energy Density (MJ/in3 ) 1,g7 1,87 .. _. l ,Q ualification No. Date May 15, 1987 7717 By g g/ Alan E. hudson I- 1
_ _ _ _ _ _ - -- - ~ n] tes j c r o.o PROCEDURE QUAllflCATIOf.' RECORD l l TO A s 8.1 (. $(C TjQN is i l j \ PART 11 ESSENTIAL v' A Rit.Bils ocn t.o U17 , Ftecess ci " (F;ite*"
*L'0" trbit3I) rue _5 E l Manw Iays; M,
- ne rT~ r-J A vt:<r at.g Se mi,9,e,mp t g gl i
1 ev., c are:n o.e, S A603 CI + 2 E A312 IP E4l* I 3, G;. 3 FLUX OR ATMOSPHERE f esuse ,, b 4tur s no E' UN I s u t,ne n.- e _ t.cre Required in.cinen u e4 e. <: . .me o.1 mu 13 9 "0 X 1 2C" ine ,i s s -,.u s.t 4., _ 100t Ar, con - 43 ) Finer reetal g> csp to f , _ ficev f oie 40 CFH 4 ,Jtiir-a tr . _ _ Weld metal analvs s nc A . . . . Is t sc 6 ng si,ip vs#0' - M i ALMt srec,#, cat.on na . SIA 5.14 rieneet iemrero.,re ange 500 Pace 2 AWS srecif, cat on no
- N000 **
Fest a eld be st t'est'r ent 1 l WELDING PROCEDURE s,n e o,ensit#epass Multiple 3,,, ,, ,, m y m g , , ,, Single , ,,n _ SG l Filrler Metal ERNiCr-3"* tiectroce EWTh-2. 1/8"O r ,ne, * ,,e ci.m. e , .045" ! Type of tecong None w,,,,ng ,,,,,s, Di rec t Curre nt , E l ec t rode"Nega t i i Con:vri PART !!! WELDtNG VARIABLES for io,nt c,mensions and nocing cur <ent settegs. ! l TEST RESULTS , (Turned Specimen)n,oucea reci.on t,ns,:, p, suns - Transverse All Weld Metal : o ensiont in vu m.te vn mue ua Srn*en No w ,, , , Arn lto<aiLoen 5""' cnerocie, et reau,e y,,, ,,,, g ,
.ne toe t;,,
n,s sii uce _., H5224-A -- 0.253 0.0502 4.77 655.C ' l c5.0 ---- l l H5224-B -- 0.250 0.0490 4.86 l99.2 684,q , ov.ees tend Tesi
, - . ..s, ,-. , .es, ,
i 4 Transverse Side OK ------- --- l l Verry t. vehay,M an i, nus:,an
~ ~
64 7pt3M7-4996 5H1 ,20 , 4!H. We#cer's name M i h MntihPwt 1 Who ty vince of tnese tests meets welcer pertorrr.ance reov,itmeats socro security no. 30l
- 50-1193 woeecs s,mou &
Work Orcer torig WPSI No H5224 g,. O e.,, 12-9-86 We certif y that t*-e statements in this reco<d are conect and that tre test wcld was p<ecared, weiced and testec in erecreance witn the re-overements of section tx of t*>e AsME cece
/ s>gnea CBI
,y M _ [~ / 4 j h- _. _. Alan E. Hudson ,,,e 5-15-87 j E -
n,m ,,, _ Water backed - see page 2 forf teils. , GTAW n ehine weided usir.a a remote video monitor. _)* SA508-CL 2 nozzle neck welded to A312 Tp 204L safe end with a ENiCrFe-3 butter and GTAW ERNitr-3 bett weld. (SA508 C1. 2 Heat No. C124 FN2-1-5)
**) The nozzle safe ena assembly was FWHI a t 1150 4 t o r 'ia h r s . p r icF t o we i d i n g .
***) Arcos Type 382 Ht. Y4875N382.
e.,, vs. m so o .t. ac. n _ ~ _ . - - - - . . - . . _ _ - - _ _ - - _ _ . . - - - - ~ . - -
I I #!h 1., N tv W.0. th5224 PROCEDURE QUAltFICATION RECORD DROPWEIGHT TEST DATA t SPECIMEN TYPE P iI a I SP E CIM C- N L OC A TION TEST TEMP 'F PESULTS l PLATE H5224 I longitudinal -30 tio Break H5224-2 Longitudinal -30 fio Break H5224-3 Longitudinal -40 I Break ' PL ATE T NOT * -40*f '
=
HE AT AFFECTED ZONE I i t._ O ~ ~ m e " " ~v, I ._1 < l ..
- WELD METAL T NOT I
il 9 I CHICAGO BRIDGE & IRON CO iPANY Quahfication No 77I7 .I o,i, 5/10/07 ' E' ' . BY- Alan f. Hudson wt se a atv Nov M i l
FRO'EDWE C #Lif!CAi!O'4 FEC: ? TO A.S.M.E. SECTION lt FMT 111 'nELNN5 V RI AELES l t
)
/ 1461 147 (Taper f ead:.) 1/32" tt 1/10" Passes 142 thru R Frc- t:c cf pass 124 fcr fillirg in u ':11er retal ad cd. l N I N spots.
IN % - EFNiCr 1 L
&d M ,. .
/ k- D7&&,. %---<-
NM
,o 4 __
I
- g,.. .-:us - r -m". r.,. - ->ENM l [
u, p NSY$$fENN.[fMN.-M* N,v.,._% . r%;jf.-# 0 ,- . C --- -
~ -
-;d.~ts c- 9 %
',9 I .
f rjgn M t?.&' l;7G G ? = X M S ~; - M = 2 & % 'e
,s .
,s N ,
- - i i
i k l i
/ (
, I i
, , i t
e / ..
; S A!OS-CL2 -H \ ', '
N- Safe End
~
\
'; ',l, f ,' A312 Tp 304L 1.20'
__4......- i i p [NICrf t: 3 J LERNiCr-3 ~ Synchronization Syn Pulse Vol tage control Continuous Upslope time 5 Stc5e Downslope time 10 Secs. Wire Start Delay 7 Secs. Travel Start Delay 6 Sees. 1
.s Number _,, [J 24 5 6-18 19-3fl37-54 55-72l73-89 90 l 91-1CE 1 1 l f Imary Weld Current (amos y ) !220 220 220 220 220 220 220 220 220l220 i Back round Current (amps.j_,M10 9 110 l 110 110 110 110 110 l 110 110 l 110 ]
Out Dwell (primary)(sec. x 1) .4 .4 .4 .4 4 .4 4l .4 ( .4 .3 l , Excursion time (sec. x 1) - . l ,. 3 .2 i .2 .2 l .2 .2 .2 .2 l .2 .2 { l in Owell (primary) (sec x J Ll_.4 .4 .4 .3 l
.3 .3 .3 .3 .3 ; 4 !
Oscillation (in.) .2v .24 .24 .24 .24 .24 .24 l .24 .24 .24 Primary Wire Feed (IPM) 40 40 35 35 -33 35 35 35j 35 l 35 l Backcround Wire Feed (If 30 30 l 25 l 25 25 25 25 25 25 l 2El Travel (!PM) / Torch Stet.g l2.55 2.55 l2.55 l2.55 2.38 2.62 2.64 l 2.66 2.68 2.6S sl i Primary Arc Vol ts J 9.0 9.0 l 9.0 9.0 9.0 9.0 I 9.0 l 9.0 9.0. .J,. - 9.0 l ' , Backcround Arc Volts - S.5 8.5 - 8.5 8.5 8.5 8.5 8.5 l 8.5 ! 8.5 l 8.5 l
- . _ _ . _ . . - -1 Heat Input (Xilojeules/in.)
_ - l36.04 3C.39 38.39 37.64 40.33 36.72 36.38 36.08 35. 76 l35. 76 l' Ener9y Density (MJ/in3) _ 1.57 1.64 1.89l1.67l2.00. 1.87 1.87 1.87 1.57 1.Dl O" IFICATION NO. 7717 N Yu!w l [. 1 ATE 5-15-87 EY Alan E. Hudson e l l l 8 I
l Pon 140. _ 7717 W.O. tJo. _ h5224 FHOCEDURE QUALIFICATIOfi RECORD i YlCKERS HARDNESS TEST Transverse
" "9 10 KG LOAD l 1 to 4 = 1/2m, '
I 4 to 5 = 1rnm l Specimen B 5 to 6 =' 4 to 8m i i Depth at toe = 1/2 to Iren
, j i., t -
,.-Q + .. n .
* :* \
- l .
\ 4 l
\-
hf , r ) LOCATION TOE HIDDLE BOTTOM 1 400 310 305 2 291 322 286 i 3 204 249 267 4 191 192 226 5 181 179 182 6 171 174 179
)
7 163 195 200 8 r5 ..
~
$g [. .
Alan E. Hudson- May 15, 1987 DATE .
5 PCR 7717 ] IMPACT TEST DATA tvrt orNotes VEE
] g.,4
{ gj g g7 i O srt e. l r.rt e i strc wotcw inst teve W RCY latinal ri , no caut s t 4 sat tocAucN cto r
, (
- rgt;'o rd sui f
! A-1 4 l LONG. i - FULL HAZ {
+20 95 l 129 l 60 l 50 j A-2 LONG. l FULL HAZ l 420 76 l 103 57 40 A-3 LONG. ) FULL HAZ l 4?O 95 l?9 65 55 l l!
! B-1 LONG. l FULL I PLT +20 43 l 58 36 40 'l B-2 B-3 LONG. l FULL LONG FULL PLT PLT l 420
+20 48 60 65 81 45 40 50 E0
- l l
l1 .I l l
- 10 l
! i il .l i i i 1 1 1 l l l Il l l l l l l l ! l ;
! I n gyang r, HAZ specimen taken at maximum practical depth of overlay weld on the i end of the overlay opposite the safe end at AZ 90', PLT specimen taken at 1/41 i depth from 0.D. of SA508-2 adjacent to the HAZ specimen.
l ! fD M M !. i l eY: Alan E. Hudson Jerry DeHay i
- 1 Laboratory Technecian wt 2%)9(y NQW $$
f.me a usa
fby9 c oeu sa PROCEDURE QUAllflCATION RECORD 10 A 5 M [, $[CTION lx [3 PART 11 CSSENTIAL VARIABLES r;n se '71E e ,, E-15-87 p,cc,s s _ GTu' (rulsed - 360 Crbita1) v,,,,J lu , m , W , m ..,,,, [~ ] 3,,,, ,,,,,,,, O unte,.ai n ec,# c ai.on SAEDE C1. 2 & A312 Tp 324L* FLUX OR ATMOSPHERE j Asut e no 3. Or.1 to Asvg e no 8. GP. I ry, i,aet name hone Recuired Th.cknesi u v.c, o.a and wau ih.co _lLCL 1. 20" ine.t s es c ompos.i.,, _ 100!, Argon r n e, ,,,etai g.oup no. s . 43 rie ,ai, 40 CFH weid ,netal ana4ys,s no A, ERNitr-3 ,,ty6,,,,,,, ,,,,, No Asur spec.f. cat.on no. SFA 5.14 p,,s,,,,,,ng,,,,,,,,,n,, acer - 350*F (IPT) A 5.14 resi,,eid he ,,t,,,i,t.n, None ** AWs necificanon no. WELDING PROCEDURE b Pf nde p , , , t ,, n single or mult*ple pass 5.ngie or mutt.ple arc Filler Metal ERNiCr-3*" (12ctrode EWTh-2. 1/8"O r ,ne, .,, d,am,,,, _ .045" None ,y,,, n, Direct Current, Electrode Negat.ve type of decking w,,d,ng Consuit P ART lil WEL'.HNG VARIABLts to, joint dimensions and welding current settings-. TEST RESULTS Transverse All Weld Metal Q (Turned Scecimen) neduced e,et,on 7ensae neso,ts - C '" ' Dimensions in Ultima t e I '*' L 'd Ulumste Umi gg,,,,,,, ,,y ,,g,, and Location Width Th ckne ss in 2 kies b il ! MPs ) H5224-C -- 0.252 0.0498 4.85 97.4 672.$ l H5224-D - ,, 0.247 0.0481 4.70 97.7 674.h Gweed Bend Test Type Re s u't Type Resutr 1 Transverse Side OK Alan E. Hudson 464-76-3339 455 66-6391 JED, AEH I Weicer's name Jerryi..DeHa{p,wt John D. Mate social secunty no. 301 60 11 3 Weider's symbot 10" Who by virtue of these tests meets weider performance tesvi,ements. H5224 n,, O c.,, 12-9-86 Work Orcer lovig WPs) No. We certify that tre statements in this record are correct and that the test weld was prepared. welded and testedin accordance with the re-guirements of section IX of the AsMt coce s.gned CBI l 3, (( g . Alan E. Hudson n,1, 5-15-87 n,,,,,,,.
*) Non water backed structural overlay test assembly consisting of SA508 CL. 2 nozzle welded to A312 Tp 304L safe end with a ENiCrFe-3 butter and GTAW
) FRNiCr-3 butt weld 1 a thermal sleeve inside the nonie. (5a509 C1. 2 Heft I(m No. C194 FN9 1 M .
**) Nozzle / safe end assembly was PWHT ra 1150*F for 24 hrs. _ prior to welding.
"*) Arcos Tvoe 382 Ht. Ya875N192. GTAW rnachine welded usino a video monitor. ,
e..... v5 woo o eiv ov s.
POR f40. 7 'l 7 W,0. N O. HI?" PROCEDURE QUAllFICATION RECORD g VICKERS HARDNESS TEST Transverse L spacmg 10 LG LOAD 1 to 5 = 1/2m Speciren A 5 to 8 = 1m 8 to 9 = 4'to Sm
. Depth at toe = 1/2 to 1
) ,,
< ns .
,, .w_
. t >t 1C' i
i .,
.M!il h1 O LOCATION TOE M100LE BOTTOM 1 257 295 302 2 254 315 h 331 3 236 240 '298 4 240 197 250 5 233 181 222 6 191 181 183 7 177 181 183 8 164 177 172
- 9. 167 177 171 10 163 178 -203 d4 E. /- l 6
,)
Alan E. Hudson 5/15/87 DATE , l
~ _ . PP,0CEDURE QUAllFICATION RECORD To ASME Section IX PART Ill Welding Variables I I I I I I
- hronization Syn Pulse Voltage control Continuous
' ope time 5 Secs. Downslope time 10 Secs.
. Start Delay 7 Secs. Travel Start Delay I .Tss Number IU/-
123 14 *+ - 145 146 147 6 Sees. l Primary Weld Current (amos.) 220 220 180 120 Background Current (amps.) 110 110 90 60 0ut Dwell (primary)(sec. x 1) .3 .3' .3 .3 _ 1 Excursion time (sec. x 1) .2 .2 .2 .2 . g In Dwell (primary) (see x 1) .4 .4 .4 .4 - l0scillation(in.) .24 .24 .:4 .24 fPrimaryWireFeed(IPM) 35 $5 -- -- lBackaroundWireFeed(IPM) 25 25 -- -- l Travel (IPM) (Torch Speed) 2'.71 2.72 2.72 2.72 l Primary Arc Vol ts 9.0 9.0 9.0 9.0 w lBackorcund Arc Volts 8.5 8.5 8.5 8.5 heat Input (Kilojoules/in. ) 35.47 35.19 28.79 19.19
$EnergyDensity(MJ/in) 3 1.87 1.87 -- --
l ,Q ualification No. 7718 g g [)Date May 15, 1987 By Alan E. Hudson v l
~
l j POR tJo. 71 i W.O.14 0. _ J.Q l PROCEDURE QUAlfilCATIOtJ HECORD 1 VICKERS HARONE55 TEST Transverse "9 10 KG LOAD 1 to 4 = 1/2nn 4 to 5 = 1m i Specimen 62 5 ' o 6 = 4 to 8mm l Depth at Toe = 1/2 to 1 I t c.,,, ; . l a19Al f
; none l
. p \ i
- ] ) I
. 1
\.
At . l ) ' O - LOCATION TOE MIDDLE BOTTOM ; i 1 387 216 300 256 273 31^ 2 l 206 227 '274 3 , 190 203 234 4 182 134 180 l 5 l 172 174 177 6 ..- l 7 164 195 203 i l,
~~
l .-- , b [/ , y Alan E. Hudson 5/15/87 DATE , ' ,.....,,---.------,--..--._~,.-.,....,_-._-n._,._-.---,,,.._.n,---r,.,-n,,,,,,-
._wn, , , , -
I g?\ L nn PROCEDURE QUALIFICATION RECORD DROPWElGHT TEST DATA SPECIMEN TYPE P SPECIMEN L OC A1,10N TEST TEMP'F RESULTS PLATE H5224-1 Longitudinal -30 No Break l H5224-2 Longitudinal 30 No Break H5224-3 Longitudinal -40 Break HEAT AFFECTED ZONE I I _ HEAT AFFECTED ZONE Tnoy WELD METAL , I I WELD METAL TNOT I E . I CHICAGO BRIDGE & lRON COMPANY Qualification No. 7738 [ e cate 5-15-87 gy Alan E. Hudson wue o acv nov n 1
l l FROCEDURE CUALIFICATION RECORD ! TO A.S.M.E. SECTION IX l f 7 PART 111 WELDING VARIA5LES s 13 & 147 (Temper Beads) 1/32" to 1/15" Passer 142 thru 1 7 I , From toe of pass 124 No filler metal added. for filling in Iow spots.
,c ERNiCr-3 ,, u I 270&WWQWM%
~-
I ,,, QQ:>9 30 ynw% 36ctsq [ k'8b M k s ji s h k N N h h .5/8"[
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l ', 1
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', Safe End .
f 57,50S-CL 2 -H s _ _ .2 4 , , , A312 Tp 304L->l 1.20' y ,,
,\. 9
- o J L--ERNiCr-3 ENicrFe-3 Synchronizacion Syn Pulse Voltage control l Continuous Upslope time 5 Secs. Downslepe time 10 Secs.
ire Start Delay 7 Secs. Travel Start Delay l 6 Secs.
,s Nunber 1 2-4 l5 6-18 19-36 37-54 55-72l73-89 90 l91-1C ~
Primary Weld Current (amps.) 220 220 l 220 220 220 220 220 220 220 l 220 Background Current (amps.) 110 110 l 110 110 110 110 110 l 110 l 110 l 110 l Out Owell (primary)(sec. x 1)' .4 .4 .4 .4 .4 .4 4
.4 l .4 l .3 l
.J .2 .2 .2 .2 .2 .2 .2 .2 l Excursion time (sec. y 1) la Owell (primary) (sec x 1) .4 .4 l
l .4 .3 .3 ,3 .3 .3
.2 l
.3 4 Oscillation (in.) l .20 .24 l.24 .24 7 24 .24 .24 .24 l .24 .24 l Primary Wire Feed (IPM) 40 40 l 35 35 33 35 35 l 35 35 l 35 25 25 Backcround Wire F :d ('Ptd 3'O 30 l 25 25 25 25 25 l 25 l Travel (IPM) (Torch Soeed) , 2.55 2.55 l2.55 l2.55 2.38 2.62 2.64 l 2.66 2.68l2.6Sj Primary Arc Volts 9.0 9.0 l 9.0 9.0 9.0 9.u j 9.0 l 9.0 9.0l 9.0j i Backcroond Arc Volts l8.5 8.5 ~8.5 8.5 8.5 8.5 8.5 l 8.5 l 8.5 j 6.5l Heat Input (Kilojoules/in.) 36.04 38.39 38.39 37.64 40.33 35.72 36.3836.0835.76l35.76 Energy Density (MJ/in3 ) l1.57 1.64l1.89 1.87l2.00 1.87 1.87 1.87l1.87 1.87l
" 1FICATION N3. 7718 g
" *" I DATE. 5-15-87~
l
d PQR NO.
W,0. No, HS?? * :
,O PROCEDME OUALIFICATION RECORD
( ) TRAVERSE VICKERS HARDNESS TEST SPACING 10 KG LOAD 9 Bottom 1 to 5 = 1/2 r:n
\ 5 +o 6 = 1 m f 6 = 4 to 8 cm
! SPECIMEN D 9 - 2 Middit.
I tc 4 = 1/2 mm i s' i uo . / 4 to 5 = 1 rm i .. 5 to 7 = 4 to 8 cm
,mi Depth at toe = 1/2 to
\
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- i
^' ,
I _ cO V T0E A M:00LE BOTTOM LOCATION i 341 416 282 272 2 235 -- 331 267 . t 196 - 261 249 3 4 185 -- 187 225
~
i 177 'al i ; 5 171 .- ;
- -- - 179 6
181 -- 166 178 7 8 168 -- 176 202 a 4
. [V)Alan0$n E. Hudson[/ DATE 37 4
e4 - usa a
POR 7718 l l IMPACT TEST DATA
}.0.45224 nrt or Noicn Vee 5/15/87 !
sof c. setc srtc. NoicH 7tsiitup IAIRGY LAffRAL l No. cmiNr set LOCATION Of G F. iXPANSloN I" E ggg ri to l .i Mats l l l 0-1 l Long i Full ' HAZ +20 111 151 75 l 50 D-2 l I g Long full HA2 +20 1 89 121 63 [ 5 D-3 Long Full HAZ +20 99 134 72 70 i f C-1 Long Full PLT +20 43 58 33 40 C-2 Long Full , PLT +20 51 69 42 35 Full C-3 Long eLT 420 45 l ! 61 37 35 'l 1 9 I { O - i l l l 1 l
~
l l 1 I l l I l l f a REMARKS: HAZ specimen taken at maximum practical depth of overlay weld on the
- end of the overlay opposite the safe end at AZ 90". PLT specimen taken at 1/4T i
l depth from 0 - of SA508-2 adjacent to the HAZ specimen. i l l BY: - {. / h Alan E. Hudion t,%,,, 7, Jerry DeHay WA213REWNCvel _ -. . 30
l l i i ( O l l l Reactor No::le To Safe-End Structural Overlay Test Program t i Index i Section
- 1. Abstract
- 2. Report
- 3. Appendix I Test program Instructions II No::le Assembly Drawings l III Photographs l
IV Work Orders Instructions and Data
-1 l
V Welding Procedure Qualifications L[ t-iI
Id:JR PROCEDURE QUALIFICATION RECORD VICKERS HARDNESS TEST TRAVERSE SPACING 10 KG LOAD I to 4 = 1/2 cm a to 5 = 1 em S to 6 = 4 to 8 mm ! Depth at Toe = 1/2 to 1 cm
'l SPECIMEN C
- 1' 's ~ c 's 1
1 nlaa t l N "..nr ( l us ic \ 1 i nr , l < i s - _ , i 4 l . i8 LOCATION TOE A MIDDLE BOTTOM l 1 307 426 310 329 2 348 - 314 272 : 3 239 - 265 279
< 4 201 - 214 234 l 5 179 - 180 186 6 177 - 176 177 j .:
7 168 - 190 203 l l l l I f b Alan E. Hudson 5-15-87 l n DATE l nv . usa i I
YoHNO. L k W.o. No. H5224 FROCEDURE QUAL!flCATION RECORD VICKERS HARONESS TEST 10 KG LOAD TRAVERSE SPACING 1 to 4 = 1/2 mm I / SPECIMEN D2 4 to 5 = 1 m 5 to 6 = 4 to 8 mm e l Depth at Toe = 1/2 to 1 mm l
\. . . ,f, ' ' f,
/ : - '
r m i 1 4\
. - g
/
-s m, f E
l 1 li - LOCATION TOE A MIDDLE BOTTOM 1 350 434 308 284 1 l 2 252 417 307 274 3 196 316 267 248 4 189 270 l 224 233 5 188 256 183 176 6 174 .182 181 172 l1 7 163 - 190 197 l l l I
#1c./A Alan E. Hudson DATE e-.4 usa
I I i 1 Appendix 5 Mechanical Properties Test Reports in Support of PORs 395,745,746 I I h I I I E g 4 4 SIR-90-063, Rev. 0 3g ,
E' :. .= == v O7 Professional Service Industries, Inc. --
. [ .t 2-d.l_j Pittsburgh Testing Laboratory Division Lab No. :PHY-00851 E330 I Order No.:828-06214 Date 5/16/90 FIIISICAL TEST REPORT OP WELDING PROCEDURE QUALIFICATION TESTS Client New York Power Authority. JAF Nuclear Power Plant. PO Bgx 41. Lycomint. NY 13993 Specification No. POR 395 Date E Material Specification SA508 Cid_to SA182 F347 of Group No. 3 P3 to Group No. 1 PB Thickness (if pipe, diameter and vall thickness) 1-1/8" Wgli Tiller Metal Classification Groove ERRICr-3/
ENiCrTe-3 Butter ENiCrFe-3 I WELDING PROCEDURE Single or Multiple Pass Multiole Single or Multiple Arc Single E REDUCED SECTION TENSILE TEST ULTIMATE UNIT I SPECIMEN NO. DIMENSIONS-INCHES AREA Top T1 Dia.
.506 THICDTESS 50. IN.
TOTAL LOAD LBS. ULTIMA 72 UNIT S'; RES S . PS I CHARACTER 05' PAILURE AND LOCATION l
.2011 20600 102000 SA182/ Weld Too T2 .505 .2003 19500 I1 97500 Weld 9 Dottom B1 Bottom B2
.507
.507
.2019 18200 90000 SA182 l
.2010 17300 56000 Weld Center Lin _gf,3f i d GUIDED BFND TEST i
Center Line of Buttering TYPE AND TYPE AND FIGURE NO, RESULTS FIGURE NO. RESULTS Side Bend 7/32" Defect - Pail Side Bend No Defect - Pass Side Bend Pinhole Defect - Pass Side Bend No Defect - Pass Side Bend 1/8" Defect - Pass Side Bend No Defect - Pass Side Bend 5/32" Defect - Fail Side Bend Pinhole Defect - Pass I PR SSIOf ERVICE NDUSTRIES, INC. -lI s-gear allagheg Division ManaYer Physical Testing Services cc: 1-Client /Neil Chapman I etn lO 850 gociar street l . %sm pu5m .. meumm m
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E r P . .o ds. . Professional Service Industries, Inc. I g./ 9 Jg' Pittsburgh Testing Laboratory Division 0ser No. 82,_ce21, Lab No. : PW-00!Q_ Page 14 P.O. No. :_90-081 j Date . 5/10/90 ' T OF TENSILE TEST OF *ar*4aed Weld Precedu re POR ?95
~ P New verk Pewer Authoritv. JAF Nuclear Pewer Plant. PO Ben 41. Lveomino. W 13093 ORIGINAL YIELD P%XIMM YIELD TENSILE DESCRIPTION AREA REDUCTION STR _ LOAD STR STRENGTH ELOW.W ION OF AREA m $0. IN. POLNDS DOUN05 LB.PER SO.IN. LB.PER SO.IN. IN 2 IN. PERCENT FRACTURE PEPCENT
.a Diameter
- t. lacht-E1 .507 .2019 10650 1 B h ;_ JQpg.S .76 3B 69 SA 1er l
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Lea ,m I Ig 92 .507 .2019 10000 11100 40500 56000 .12 6 22 Weld Dia. 449 Area .1593 hStren0th Dete -4 red at 0.2% offset. I i HETH00 ASWE See. IX-1999
' MENT USED (Control NO.) TM 220 EXT 163 MICS 385-112 WITNESSED BY: (if required) Not Deovired PRO SICRAL 'EP .E IND ES, INC,
(!CIAN Mike Arrara. Leve' II Earl Ga lagher, M ger
- t. ;- Jim Gallacher. Level II PITTSBURGH TESTI o DIVISION 1 lent /Neil Chapman S50 P00 tar St eet e P ttsuurgn. PA 15220 '
- Phone 2/922 000 -
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P31/PIIT50.i4GH ftsilNG LA80(t,40Ry M. l
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l-- Q) 9]/ Pittsburgh Testing Laboratory Division Lab No. :PHY-00914 Page 1 Order No.:828-06214 1 Date :$/16/90 PHYSICAL TEST REPORT OF VELDING PROCEDURE QUALIFICATION TESTS IClientNewYorkPowerAuthority. JAF Nuclear Pever Plant. PO Box 41. Lveomine. NY 13093 Specification No. POR 745 Date Material Specification $_A508 CL2 of Group No. to Group No. Tiller Metal Classification __ FLUX OR ATMOSPHERE Flux Trade Name or Composition eld Metal Analysis No. A Insert Gas Composition IW(ASMESec9Only) Trade Name Flow Rate For Oxyacetylene Welding-State if Filler Is Backing Strip Used?
- Preheat Temp. Range 200'F None lMetalissilicon-oraluminumkilled.
WELDING PROCEDURE Postheat Treatment Position SG Single or Multiple Pass Multiole (For plate, flat, horizontal, vertical, or Single or Multiple Arc overhead; if vertical, state whether up or
.l I Type of Backing:
- Weld 1" Det2 down, for pipe: Axis of pipe vertical, horizontal fixed, or horizontal rolled).
I
- For Information Only -
bpoveinformationbyPTL[] Client (x) Other eparation of specimens vitnessed by PTL Yes [ ] No [x] REDUCED SECTION TENSII2 TEST I ULTIMATE UNIT CHARACTER OF SPECIMEN NO. DIMENSIONS-INCHES AREA TOTAL ULTIMATE UNIT FAILURE Dia. THICENESS SO. IN. LOAD LBS . STRESS. PSI AND LOCATION T1 .507 -
.2019 21600 107000 Weld T2 .505 - .2003 21100 1053_00 Weld GUIDED BEND TEST TYPE AND TYPE AND I FIGURE NO. RESULTS FIGURE NO. RESULTS Side Bend No Defect - Pass Side Bend No Defect - Pass Side Bend No Defect - Pass Side Bend No Defect - Pass Did welder by virtue of these tests meet velder performance requirements? [x)Yes Re etful y bmittedvby,
/
~
Results of Tests do meet requirements of
/ ^ \SE Sec. IX-1989 EarlGallagher[DivisionManager
- lV Physical Testing Division i l cc: 1-Client /Neil Chapman _ cen - \ 850 Poetar Street . - Amseurgn: DA 15220 : . Prone. 412/922:4000-
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< n :D 7 ' Professional Service industries, Inc.
(3 ( 4' >V 1 / Pittsburgh Testing Laboratory Division o g,, u,.. ers-ur,4 Lab No. : PW-00914 , Page 2 P.O. No. : 90-091 Date : $/16/90 RT OF TENSILE TEST OF Machined Weld Precedure _ _ _ PO# 745 gT. New York Pever Authori tv. JAF Noelcar Power Plaat. PO Ben 41. tycomina. WY 13093 ORIGINAL YIELD MAXIMJM YIELD TENSILE REDUCTION DESCRIPTION AREA SIR LOAD STR STRENGTH ELONGATION OF AREA FRACTURE
- 50. IN. POUNDS POLNDS LB . PER SO. IN . L B . PE9 50. IN . IN 2 IN. IPERCENT PEPCENT 1e Diameter
- t. Intbes we1d .502 .1979 14550 20150 73500 101800 .74 37 62.9 w /3 Dia, .306 Area .0735 svene
.507 .2019 16200 21600 80200 107000 52 26 60.9 w/3 Dir .317 Area 0799 d Stremoth Determined at 0.2% of f set.
METHOD ASTM A370-82a PMENT USED (Control NO.) TM 220 REC 202 EXT 163 MIC 385-112 t'ITNESSED BY: (if required) Not Decui red P - SSIC e ICE IND' IES, INC. 41CIAN Mike Arrara. Level II -'
,s Earl Ga11agter, nager Et" J:,,)imGallacher. Level II PITTSBURGH TESTING DIVISION l\~ dient/Neil Chapman 850 Peptar Street
- Pmscurgn, PA 15220 *
- Phone: 412/922-4000 -
sir i lt - I { i ! !
~
I l 1 t : I l 1 ' I i SINGLE RANGE EXTENSOMETER #. Xf I '" '
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CHART NO,1010 SATEC Systems. Ine C.rova C.t3
l a N:= ~O d. Professional Service Industries, Inc. l ('s [/r{_3f] Pittsburgh Testing Laboratory Division 0ro,r u .. sa_0ns,
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l'J Page 3 P,0, No, ; 93-0B1 Date :_i/jfLCO FORT OF TENSILE TEST OF wachined wald Drecefu*e VOR 745 I rvf . New Yerk Pever Authority. 3AF Nuclear Power Plant. 43 Ber 41. Lycomine. W 13093 REDUCTION t%XIHJM YIELD T ENSIL E ORIGIMAL YIELD 0F AREA FRACTURE STR LO/,D STR STRENGTH _ E10NGATION _ AREA IM.? IN.!PFDCENT PERCCNT DESCRIPTION POUN05 LB.PER 50.IN. tB.PER 50.IN. I SO. IN. MYJNDS em 3 ample Diameter
- ent. Inches
.E5 27.5 52.2 MO 16000 21100 79220 105300
.505 .2003
*ad Dia, .349 mied. t.rea 0957
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5treneth Determined at 0.2% of fset. E S4de Bend - No Defect Pass Side Bend - No Defect - Pass Side Bend - No DM eet - Pass Side Bend - No Defect - Past i t i TEST METHOD ASTM 4370-89a TH 220 _ EXT 163 MIC 325-112 MC 202 EQUIPMENT USED (Control NO.) PPENSSIONAL S) ICE INDySTRIES, l' TEST VITNESSED BY: (if required) Not Pecuired Y w 4/8
.ager TECHNICIAN Mike Arrara. Level _ II Earl Gallagher, PITTSBURGH TESTING DIVISION Jim Gallaeer. Level II 89EWED n BY:
1 - Client /Neil Chapman
- Phone; 412/922 4000 E 850 Poplar Street
- Pittscurg'1 PA 15220
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?7dL/ Pittsburgh Testing Laboratory Division Page 15 Lab No. :PHY-00851 Order No.:828-06214 Date :$/16/90 PHYSICAL TEST REPORT OF VELDING PROCEDURE QUALIFICATION TESTS Client New YorkNo.
Specification Power POR Authority. 746 JAP Nucitar Power Plant. PO Box 41. Lycemine. NY 13,p03 Date Material Specification SA508 C Q_ of Group No. 3 P3 . to Group No. Tiller Metal Classification TLUX OR ATMOSPHERE eld Metal An-lysis No. A Flux Trade Kame or Composition W(ASME Sec 9 Only) Insert Gas Composition I Trade Name Flow Rate For Oxyacetylene Welding-State if Filler Is Backing Strip Used? 1" Deco Reoatt Veld Metal is silicen or aluminum killed. I WELDING PROCEDURE Preheat Temp Range Postheat Treatment 300*P 500*P/Tvo Hours Position 5G Horizontal Fixed Single or Multiple Pass Multiole (For plate, f3at, horizontal, vertical, or I Single or Multiple Arc overhead; if vertical, state whether up or down, for pipe: Axis of pipe vertical, horizontal fixed, or horizontal rolled), I - For Information Only - Above information by PTL [ ] Client [x] Other Preparstion of specimens vitnessed by PTL Yes [ ] No [x] hV REDUCED SECTION TENSILE TEST I SPECIMEN NO. DIMENSIONS-INCHES AREA ULTIMATE UNIT TOTAL ULTIMATE UNIT CHARACTER OF FAILURE Dih THICKNESS SO, IN. LOAD LBS. STRESS. PSI AND LOCATION TT (2) .500 -
.2011 21250 106000 Weld Metal TT (2b) .509 -
.2035 21200 104000 Weld Metal i GUIDED BEND TEST TYPE AND TYPE AND FIGURE NO. RESULTS PICURE NO. RESULTS Side Bend No Defect - Pass Side Bend No Defect - Pass i Side Bend No Defect - Pass Side Bend No Defect - Pass Did velder by virtue of these tests meet velder performance requirements? [x]Yes Res etfull bmitted,by,
,,,, 4 Results of Tests do meet requirements of #
ASME Sec. IX-1989 Ear llag er ivbienManager Physical Testi g Division f' : 1-Client /Neil Chapman Q]tn . . - 850 Pootar Street e Pittsburgh,' PA 15220 e Phone: 412/922-4000
a - E -- Q_ / '; Pittsburgh Professional Service Industries Inc. Testing Laboratory Division om,e, No.. ,2,.0s2,4 Lab No. : PW 00B51 Page 22
~5 P.O. No. :JQ QB1 Date : 5/16/90 PORT OF TENSILE TEST OF MacM eed Weld Procedure POP 746
.Nw York power Authori ty. JAF Noelear Powr Plant. PO Bev 41. tverino. NY 13093 ORIGIMAL YIELD MAXIMM YIELD TENSILE DESCRIPTION AREA REDUCTION STR . LOAD _ qR STRENGTH ELON@ TION OF AREA
- 50. IN. POUNDS POLNDS 1B PER 50.1N. LB.PER 50.IN.
FRACTURE IN 2 IN.! PERCENT PEPCCNT v.;.np1 e Diameter Ident. Isthet l E weld .505 .2003 14250 20200 71000 101600 . 7.L 36 59 M/3 s.d. Dia. .329 Red area .0850 5Iransverse ' iQ6 .2011 16200 21250 80500 106000 56 29 45 we ld Dyd. a rea .1097 E T rans ve rse tiem Test .509 .2035 16050 21700 79000 104000 .52 26 47 we ld
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Eid Streneth Deteminod at 0.2* Of f set. E T MET 100 a5=E See. D' 1999 IPMENT USED (Control NO.) TM 220 EXT 163 MICS 385-112 _ stST t!ITNESSED BY: (if required) . Not Deaui red PRO $10NAL JER,/dE INDUSTRjES. INC ICIAN . Mike Arrara. Level Il s Earl Gallagher, M ger BY: . lim Gallacher. Level II . RE&. - Client /Neil Chapman PITTSBURGH TESTING DIVISION ' 850 Poptw Street
- Pittsburgh, PA 15220
- Phone: 412/922 4000
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