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Stand:rd Number i
MNS-013 Page 1
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Date issued Effective Date
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1/28/8, r
1rZM4Q Materials Technology Revision No.
Date Imoortant To Safety YesC No O R. B. Corbir
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TUBE /TUBESHEET PLUGGING STANDARD FOR STEAM GENERATORS AND/OR HEAT EXCHANGERS CONTROLLED DISTRIBUTION DOCUMENT SERIAL' NUMBER 17i Approval d
. Y ft.. I F. S. Giacobbe C. D. Cowf er Materials & Welding Mar.ager Manager Materials Technology Concurrence
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g 1/28/82 1/28/82 Revision No.
Date 1/27/82 Materials Technology Index and Revision Sheet Page No.
Revision No.
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Sttndard Number E
Nuclear MIWS-013 2
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1.0 SCOPE & PURPOSE:
To provide a standard which defines the necesrary requirements for i
i welded repair plugging of steam generator and/or heat exchanger tube /
j tubesheet. This procedure is based on utilizing the nanual welding technique.
2.0 APPLICABILITY
2.1 When plugging of tube /tubesheet is required to maintain steam eenerator primary to secondary integrity.
2.2 This procedure may be used for manual welding repairs of tube /
tubesheets on any heat exchanger with documented evaluation by Materials Technology.
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3.0 REFERENCES
3.1 ASME B & PV,Section II (Latest Edition).
3.2 ASME B & PV, 'Section II (1980 Edition).
3.3 Materials Technology Standara MTWS-012.
3.4 Applicable Site Procedure for Control of Welding:
3.4.1 AP-1042 TMI-1 3.4.2 AP-1063 TMI-2 3.4.3 Procedure OC-9-01 Oyster Creek
4.0 DEFINITIONS
4.1 GTAW - Gas Tungsten - Arc Welding
.4. 2 NDE
- Non-Destructive Examination 4.3 WPS
- Welding Procedure Specification 4.4 Interpass Temperature - In a multiple pass weld, the temperature ifh:
(minimum or maximum as specified) of deposited weld metal before Aooo11oS
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Standard Number Nuclear as-3 o'
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l The next pass is started.
4.5 Bore Hole - Bore hole is described,as the hole that exists after the removal of a tube and/or where.a tube has been cut off flush with the tubesheet cladding. Where the tube is cut off flush with the tubesheet. The I.D. shall be chamfered requiring plug to tubesheet contact.
4.6 Tube' Extensions - The amount of tub'e extending outside of the tubesheet.
4.7 Consumable Insert - Preplaced filler metal which is completely q,
fused into the root of the joint and becomes part of the weld.
5.0 RESPONSIBILITIES / PREREQUISITES:
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5.1 Prerequisites
5.1.1.
Positive identification of tube /tubesheet bores to be plugged.
TECHNIQUE #1 5.1.2 For tutesheet bores idc.atification shall be accomplished through the use of a wooden plug. The plug shall remain l
in tact to the point of exchanging it with the plug which l
will be welded in the bore hole.
5.1.3 It may be necessary to remove plug during cleaning and fit-up sequence, but care must be taken to insure plug is placed back into its proper location.
(Wooden plug may be used as interim narker.)
TECHNIQUE #2 s.2 "JG~
5.1.4 For identification of tubes to be plugged specially designed tube markers or a template shall be used.
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Standard Number Nuclear N8 4
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Date gg Materials Technology 0
1/28/82 5.1.5 All plant and component condition prerequisites shall be in accordance with the applicable site work package.
5.1.6 Responsibilities see GPUN Welding Program.
6.0 REQUIRDENTS
6.1 Materials identification shall be as follows:
6.1.1 The materials to be velded under this specification are specified in ASME Welding QualificationsSection IX as P-No. (Base Material) and F-No.
(Filler Material).
Refer to the applicable UPS assigned by Materials Technology Site Welding Engineering via welding documentation.
W 6.1.2 The plug base materials (P-No.) shall be identified i
by the serial number and as a minimum require supporting Certified Mill Test Reports.
(Record serial number as required by the welding documentation.)
6.1.3 The filler materials (F-No.) shall be identified by the applicable Heat Numbers /AWS Classification and controlled i
in accordance with Materials Technology Standard MTWA-005.
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6.1.4 Shielding gas s' hall be Argon commercial velding grade 99.99% pure composition.
6.1.5 All materials shall be QA approved / accepted.
6.2 Qualification of welders and procedures:
6.2.1 Shall be performed.in accordance with Materials Technology Standard MTWS-012. This Standard meets the nandatory
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requirements of ASME Section IX (I.atest Edition) and ASME Section XI (1980 Edition)'.
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7 St:ndard Number Nuclear MTWS-ou a-a' 16 i
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Revision No.
Date mp Materials Technology o
1/28/82 6.2.2 The essential and non-essential variables (Joint Prep.
electrical characteristics, etc.) needed to accomplish the welding shall be identified on the WPS.
(Reference MTWS-012).
6.3 Cleaning / Fit-Up Sequence shall be as follows:
6.3.1 The area to be cleaned shall consist of a 1/4" radius around the tubesheet bore hole and the entire extension for tubes.
(Extension is the amount of tube extending outside of the tubesheet.)
6.3.2 Cleaning shall consist of the removal of all grease, paint, or other foreign matters present. Oil and grease shall be removed by using one of the following accept-
,r able solvents.
(Reference MTWS-o07).
6.3.3.1 Denatured alcohol.
6.3.3.2 Acetone.
6.3.3 The tube /tubesheet bore' hole shall be wire brushed.
TECHNIQUE #1:
Tubesheet bore hole brushing shall consist as a minimum 3600 I.D. to a depth of 1/4" and 1/4" radius on the sur-face around the 0.D. of the. bore hole.
TECHNIQUE #2:
Tube brushing shall consist as a minimum 360 I.D. to a depth of 1/4" and the entire 0.D. of the tube extension.
(Reference 6.3.1) 6.3.3.1 For S/S and Ni Base alloys a S/S wire brush
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Stoncard Number Nuclear Pas-6 o'
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Revision No.
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Materials Technology o
1/28/82 6.3.4 During fit-up verify that burra do not interfere with the two base materials (Plug / tube and plug /tubesheet) thus preventing contact with each other (3600).
6.3.5 Any grinding perfor=ed on S/S or Ni Base alloys shall
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comply with the following requirements:
6.3.5.1 Rubber or resin bonded grinding wheels shall be aluminum oxide or silicon carbide grinding wheels which are either unused or have been previously used only on S/S or Ni base alloys.
TECHNIQUE #1:
6.3.6 For tubesheet bore hole plugging remove wooden marking plug (Reference paragraph 5.1) and insert tapered plug.
tEr Scribe a mark 1/4" up from the tubesheet on the plug.
Remove plug and replace with wooden marking plug. Cut off excess above the 1/4" scribe mark. (Reference Attachment #8.2)
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6.3.7 Once excess has been removed from the plug, reelean plug with an approved solvent.
(Reference paragraph 6.3.2) and verify bore hole was cleaned as in Step 6.3.2.
6.3.8 Insert plug into tubesheet and drive plug with one blow from a four pound mall to insure a good mechanical seal.
TECHNIQUE #2:
6.3.9 For tube plugging, plug shall be inserted into the tube positively identified to be plugged (Reference 5.1.4).
In cases where stabilizers are to be used the applicable manufacturers procedures shall be followed in conjunction acoctica r
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Stancare Number Nuclear P=s-of m s 013 7
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Revision No.
Date Maten. ls Technology 1/28/82 a
a with this procedure. Plug shall be inserted into the tube to the point of intersection between the consumable insert and the tube end surface (Reference Attachment
- 8.3).
6.3.10 If steam generator and/or heat exchanger has been open for a 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> or less time period, or flushed or flooded within that time, a cal rod heater and/or forced hot air shall be used to insure the tube / bore hole and surrounding surface are thoroughly dry. When tube extension has been cut off flush with tubesheet a cal rod heater shall be used prior to velding in order to dry the tube /tubesheet crevice.
If usage of cal rod and/or forced hot air are necessary as deemed above, the following sequence /
requirements shall be met.
6.3.10.1 Cal rod heater shall be inserted into the tube /
bore hole and maintained there for a ninimum time period of 15 minutes. Following the drying period the plug shall be inserted as described in Steps 6.3.8 and 6.3.9.
6.3.10.2 Forced hot air shall be blown through the steam generator / heat exchanger for a minimum time period of 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br />.
6.3.10.3 At the end of drying periods on both of the above methods, a thorough visual check shall be performed l,]
to insure the tube /tubesheet area to be velded is moisture free. If moisture still exists, e
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.J Standard Number Nuclear xras-013 e=a-s a'
16
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Reveston No.
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Materials Technology 0
1/28/82 the drying method used shall be extended until all moisture.has been removed.
6.3.10.4 The in.sertion and welding of the plug shall be acco:plished in a five =1nute maximum time period.
6.4 Welding Requirements:
TECHNIQUES #1 and #2:
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6.4.1 Preheat
A minimum preheat of 50 is required prior to striking an arc.
6.4.1.1 Preheat shall be determined by control room temperature indicators or on the co=ponent surface. Fifty (50 ) degree limit may be lowered with concurrence from Materials Technology.
47 6.4.2 Interpass temperature:
Interpass temperature shall be a maximum of 400*.
The procedure joints #1 and #2 are single pass welds with a 10-20:: overlap; verification shall only
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be required if repairs are made within 30 minutes after initial welding. Verification for Interpass Temperature shall be made with a calibrated contact pyrometer.
(Reference 4.4) 6.4.3 Postweld heat treatments: Postweld heat treatment is not required.
6.4.4 Position
The welding procedure is qualified for all positions.
TECHNIQUE #1:
6.4.5 Technique for bore hole plugging shall include the following:
(See Attachment 8.2) 1 j
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1/28/c2 6.4.5.1 The tungsten electrode to base material are shall start on the plug material and work its way downward to the point of intersection between the plug material and the tubesheet cladding. This is where the fillet veld will be placed.
6.4.5.2 When the point of intersection is reached and the two base materials start to break down, filler material will start to be added. The addition of filler material will continue 360 to 370 around the plug.
6.4.5.2.1 The welding process is not to stop until the start and stop point meet a
G wir.h 10% overlay to assure 3600 weld length.
6.4.5.3 At the point of tie-in (Start meets stop 3600) the are lengtit shall be gradually lengthened and the are extinguished on the plug base material.
(Do not break are on the weld).
6.4.5.4 Upon arc extinguishment gas coverage shall be maintained on the veld point of completion for approximately 5 seconds.
6.4.5.4.1 ' Replace argon bottles when gas gauge.
pressure is reduced to 25 psi or less.
6.4.5.5 For bore hele plugging only one stringer head
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shall be used to complete the fillet veld.
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Standard Number Nuclear r
m S-013
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16 Revision No.
Date gig Materials Technology 0
1/28/8.,
e.y TECHNIQUE #2:
6.4.6 Tube plugging shall include the following:
(See Attachment 8.3) 6.4.6.1 The tungsten electrode to base material shall start on the plug material and work its way downward to the consumable insert.
(Reference 4.7) 6.4.6.2 Once the are has reached the consumable insert the angle of the tungsten shall be directed towards the point of intersection between the plug base material and the consumable insert.
This step *is necessary to prevent tube blow a -
holes created by direct are contact on the tube wall /end.
6.4.6.3 The breaking down of the consumable and the adjacent base haterials is to continue 360 to 370* around the plug / tube extension.
6.4.6.3.1. The welding process is not to stop until the start and stop point meet with a 10:: overlap to assure 360 weld length.
6.4.6.4 At the point of tie-in (Start meets stop 3600) the are length shall be gradually lengthened and the are extinguished on the plug base material (Do not break the arc on the veld).
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6.4.6.5 Upon are extinguishment gas coverage shall be maintained on the weld point of completion for Acco11oS I
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Stancard Number Nuclear i
arWS-013 e se 11 of 16
,4 Revrsson No.
Date Materials Technology 0
1/28/82 t:g.
approximately 5 seconds.
6.4.6.5.1 Rep 1 ace argon bottles when gas gauge pressure is reduced to 25 psi or less.
TECHNIQUES #1 and #2:
6.4.7 There shall be no peening allowed.
6.4.8 The-completed weld shall blend smoothly into the adjacent base materials.
6.4.9 Gas: The gas used for shielding shall meet the following requirement.
6.4.9.1 Argon Type.
6.4.9.2 99.99% pure co= position 6.4.9.3 During we1 ding a flow rate of 15-20 CTH sha11 be aw maintained.
6.4.10 Electrical Characteristics: Electrical characteristics shall meet the following:
6.4.10.1 Cptrent shall be direct current 6.4.10.2 Po1arity shall be straight.
6.4.10.3 The Amps and volts ranges sha11 be covered under the app 11 cable WPS.
6.4.10.4 The travel speed range shal1 be covered under the applicable WPS.
i 6.4.11 Filler Materials: The filler materials and size to be used shall be addressed on' the app 11 cable WPS/we1d record sheet.
6.4.12 Joints: The joint designs to be used are shown on attachments 8.2/8.3 of this procedure and the applicable WPS.
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6.5 Inspection
The fo11owing inspection requirements shall be met.
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Standard Number
_ $UCl$$7 MTWS-013 Page 12 of 16 s
Revision No.
Date 5g Materials Technology 0
1/28/82 6.5.1 Lighting shall be sufficient enough to distinguish a 1/32" black line on an 18% neutral gray card.
6.5.2 No visual cracks and/or linear indications shall exist in the weld.
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6.5.3 No visual porosity and/or blow holes shall exist in the veld.
6.5.4 No visual cold lap shall exist at the points of intersection between the weld and base materials.
6.5.5_ verify the weld is 3600 single pass minimum.
6.5.6 Any indication proving to be relevant shall be removed and repaired as outlined in Section 6.6.
6.6 Repair welding shall be as follows:
6.6.1 Grind out defective area using acceptable grinding wheels j
G as outlined in Section 6.3.5.1.
Care shall be taken not to grind into intersecting base materials or surrounding tube welds or tube extensions.
6.6.2 Perform visual inspection'of grind out to verify defect is removed and that no adjacent tubes or adjacent tubeseal welds were damaged during grinding.
6.6.3 Once defec.tive area has been removed filler natarial shall be uniformally added as described in Section 6.4.
6.6.4 Upon completien of welding, repaired area shall be visually inspected as described in Section 6.5.
7.0 RECORDS
7.1 The weld records used to control and document velding shall be (bg considered service life plant records.
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SLandard Number Nuclear m s-on mu a
16 Revision No.
Date Mater. ls Technology o
1/28/s2 s__
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7.2 Retention shall be in accordance with appropriate p1 ant record retention procedure.
8.0 ATTAC1 DENTS :
8.1 Tube /tubesheet veld record sheet.
8.2 Plug to tubesheet joint design.
(Technique #1) 8.3 Plug to tube joint design.
(Technique #2)
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StandarJ Number e
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1/28/82 u-T w... n
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