ML20127B992
| ML20127B992 | |
| Person / Time | |
|---|---|
| Site: | Waterford  |
| Issue date: | 02/20/1980 |
| From: | J.A. JONES CONSTRUCTION CO. |
| To: | |
| Shared Package | |
| ML17198A241 | List:
|
| References | |
| FOIA-84-455 W-SITP-14, NUDOCS 8506220111 | |
| Download: ML20127B992 (14) | |
Text
-
( ,,, , ,
1~
-' , h ' t.; . ;- -
_ Q. . , ..- .
..-.r.. .
.. .- ,= . Procsdura No. U-SU
\*
EBASCO SERVICES
. -~
INCORPdRATED
- OAl-g ,
A. J0 iESJSTRUCT1ON COMPAtlY e
ENGINEERING
- SITE INSPECTION AllD TEST PROCEDURE This Document is:
d *" 'C****"'-
.- F0R .
dOa. 'i'.w* .a w.en comments .i Noted. Incorso,-te Coments.
WING n;SPECTION .aa anwomet; eroc..a wita O /
'T e
NOTE:
RGV a.* of thit docuM.*tt, wit"t Dr wi?noJt Comm. nil, i s
- 3' f *" t'.8 Confor,,.ac. ..in.in. .. ..c.o..
.. ..... en. m.i .e.: ,,., or Con.
5
". ra' 'F,ce, '* * ' *n"c.*.".
n' .','.* "". c'o'. '.
WATERFORD SES UNIT NO 3 ,.
=*ct. =,ma .ae ac c-.atst.ca CONTRACT NO. W3-NY I+ en 6t,*C1 .CCoro. meth Eng F M.S. C ,
By: i >
D .tz: 3 // W 78 I sf .
Q.UALITY ASS.URANCE DATE CONSTRUCT ION APPROVED BY Et1G iriEERING DATE DATE REVIEWED BY REV. DATE REVIEUED BY 2Aka a/S/76 WAa 9/J- t.b (d$w $Y elehn WWg k-27-76 (A.') W ' 8 )}
( y k ,l7.c
'llt,7ln rAhtu.bb2dN9/ 7/14 /
IO t N~ ~ 9. Il r.h8?
I
-.;"r)s./f.
/ w.yd n > r.!,s b .,a hf a a &G/x la3o~2VW h d L Ia~W
/z/u/rs $/iffe16 3 l>ln/7b 0.Y{&r= a2-#
& d s b p oir o I.c 6 % w d'24-9$W% u ~.
A- 4JefM 1 f
.. l FREEDOM OF INFORMAIGON ACT REQUEST SWC e/sq Y 5 L Y
%W 8506220111 850222 PDR FOJA GARDE 84-455 PDR
-s pr
~
. ~ ~
PAGE'1 0F 10 J. 'A. JONES C05'STRUCTION'ChfPhi
- l. .
PROCEDURE NO.
SITE INSPECTION AND TEST PROCEDURE: W-SITP-14 REV. NO. 4 DATE: 2-20-80 TITLE: WELDING INSPECTION PROJECT TITLE: WATERFORD SES UNIT NO. 3, CONTRACT NO. W3-NY-4 1.0 PURPOSE To delineate the inspection activities that J. A. Jones Qualiry Assurance /
Quality Verification personnel will use to assure that welding performed by J. A. Jones personnel is in accordance with contract drawings and speci-fications, applicable welding procedures and AWS D1.1-72, " Structural Welding Code".
2.0 SCOPE This procedure covers inspection of Seismic Class I structural welding for Waterford SES Unit No. 3, Phase I Concrete Construction. Wald repairs shall 1-2 be inspected utilizing the same criteria as specified for original weld.
t 3.0 REFERINCES .
3.1 J. A. Jones Work Procedure W-WP-3, " Qualification of Welders".
3.2 J.. A. Jones Work Procedure W-WP-10, " Welding Material Control". .
3.3 J. A. Jones Special Process Procedure W-SP-4, " Welding Procedure".
3.4 J. . Jones Site Inspection and Test Procedure W-SITP-3, 'Terif,ication_
of Walder_gualification".
l J. A. Jones Site Inspection and Test Procedure W-SITP-10. " Welding
(
3.5.
MateriaMoneral VJerification"_
3.6 American Welding Society AWS D1.1-72, " Structural Welding Code".
l l 3.7 Ebasco Specification LOU-1564.723, " Structural Steel, with Addendum for Class I Structures and Components".
! 3.8 ANSI N45.2.5-1974, " Supplementary Quality Assurance Requirements for Installation, Inspection and Testing of Structural Concrete and l Structural Steel During the Construction Phase of Nuclear Power Plants".
i R-4 3.9 Ebasco Services Incorporated Procedure No. ASP-IV-26, Current Revision .
4.0 RESPONSIBILITIES 4.1 Ebasco_ Services Tncoroorated is responsible for receiving, storage and issue of all weld filler material.
.. . . p. -
s ,
. ( __
J. A. JONES CONSTRUCTION COMPANY PAGE 2 0F 10 PROCEDURE NO.
SITE INSPECTION AND TEST PROCEDURE: W-SITP-14 REV. NO. 4 DATE: 2-20-80 TITLE: WELDING INSPECTION i .
PROJECT TITLE: WATERFORD SES UNIT No. 3 CONTRACT No. W3-NY-4 a
f 4.2 J. A. Jones and Subcontractor engineering and construction personnel are re:ponsible for the requisition, pos_t-requisition control. prop _er use of, welding filler material, qualification of welders and the use of only qualified welders for any welding.
4.3 J. A. Jones Q9_m_ Hey Ver.if.igtiqn. personnel are responsible for verifying compliance with this procedure and with References 3.1 through 3.8. ,
5.0 INSPECTION .
J. A. Jones Quality Verification personnel are responsible for pr-forming
, R-3 .
i 100". inspection on fit-ups prior to welding.
5.1 Prior to welding:
f 5.1.1 Verify that proposed welding procedure is approved.
l 5.1.2 Verify that proposed welder is qualified.
5.1.3 Check proper configuration of joint to be welded. This e' inspection shall include, as a minimum, the following
?
items where applicable:
> 5.1.3.1 Included Angle 5.1.3.2 Root Opening on Joint Fit-Up g,g 5.1.3.3 Root Face
{
i j
5.1.3.4 Joint Alignment 5.1.4 Check that weld area is cleaned and free of oxides, mill scale, cutting slag, paints, oils, greases and other foreign contaminants. ~
h, , 5.1.5 Check that required material certification.s are available
- and correct.
i -
J
- , .-m . - . . . . . - . , , _ _ . _ . _ . , _ , _ _ , _ _ _ , . . _ . , , _ . , .. ,_m,._ _ . , ,.,,,, , _ r . . _ _ . _, ,.~..,c._,,,,._,.,,._
\
o
..'u,-
~
( -.
~
.., .,,,r
' J. A. JONES C0dSTRUCTION C0MPANY PACE,3 0{ jo PR0(.': DURE NO.
SITE INSPECTION AND TEST PROCEDURE: W-5 eTP-14 RE'. NO. 4 DA'?C : 2-20-80 TITi.E: WELDING INSPECTION s
PROJECT TITLE:
WATERf0RD SES UNIT NO. 3 Contract No. W3-NY-4 R-4 52 During in-weld process, inspectors will be responsible for monitorins 207. or more of field welds. Inspeccors will:
5.2.1 Check that correct joint configuration and cleanliness is mainteined.
5.2.2 Check that correct size and type electrode i,g, used. .
5.2.3 Check that correct welding current, voltage and polarity is
- e maintained. -
QL 5 2.4 Check that correct preheat and interpass temperatures are
, maintained.
5 2.5 Check that slag is removed from each pass and that pass is wire-brushed prior to deposition of additional passes.
5.2.6 Check correct root treatment is performed when required.
5.2.7 Check essential variables of welding process.
53 Post-weld visual inspection:
5 3.1 .Welds shall be visually inspected upon completion.
532 A weld shall be deemed acceptable by visual Inspection if the following. criteria are met.
5.3.2.1 The weld has no cracks.
R-3 5 .3 2. 2; There extse no undercut.
l I
5.3 2.3 All Craters are filled to the full cross section of the welds.
5.3 2.4 Weld profiles are in accordance with the following
%- figure.
,j ' , .
j ,
l ..
(
V: . - (
PAGE 4 0F 10
- - .J. A. JONES CONSTR.UCTION COMPANY PROCNDURENO.
SITE INSPECTION AND TEST PROCEDURC: U-SITP-14 REV. NO. 4 DATE: 2-20-80 TITLE: WELDING INSPECTION PROJECT TITLE: WATERFORD SES UNIT No. 3 CONTRACT NO. W3-NY-4 Coa *.may ase a.:
.ne.e o. ."c" e e. o a in -
.j e ;n; ,K em.
, ; 'p
.. : \ r .
. : .. s :
- I'. N,, ~
h.**.'.....
,_.}l, _}..f..'.~
s .__
s . . ...
s Y, s. - ? ,
h
- s. s. _ ,
Aseeptable Fdlet Wold Peeldes Ostwable Fellet Weld Preides e *
's 's 6
- \ b ;s 's s ,-
1,s
- : s
\
- s\ :
\ ; l'
- s I:: \ I \.
\ l \ N li !
h: -.L,. . . . . . . . \ J _L . .. . .- . . . .
j
]
s s. s.
- s. s. _
- s. -.- -
,a_ a. s . _. . Let Fusen T he.se C.a saw Usesessus h Unseseptseie Fdiet Weed Profiles i
- .. ., , ..i.f.........-..,
. w. .
.- ) / 3 i tn h Acceptable hiest weed profde m _
m
? * % o s t o 's ,
w u Encessive Overlap CaCossive lAsuff4Clont COnv0alty thf001 undercut
@ u a.ousma .
w er
. . . . . - . . ~ . .
f.-
k..'
S.3.2.5 The sum of diameters of piping porosity does not exceed 3/8" in any. linear inch of weld and shall noc exceed 3/4" in any 12" length of weld. The maximum diameter of an Individual pore shall not
.. j ,..
exceed 3/32". - -
4
y- V
. ~
..:n.
i,,; , r 7, ..; **'
I p','
- i; ,
PACC 5 OF to IJ ,1 g, ,
, , _g s' J;eA. JONES C0NSTRUCTION COMPANY t
< , 1 si '
\ ~ q' t 'c S1TC INSPECTION AND TEST PROCEDURE:
PROCF. DURE NO.
k'-SITP-14 t ' REV . NO. 4
' DATC: 2-20-80
- TITLE: WELDING INSPECTION
. . s Le .
CONTRACT NO. W3-NY-4 t i
, P,ROJECT TITLE: WATERFORD SES UNIT NO. 3 l'.
5.3.2.6 Fillet welds in any single continuous weld shall he permitted >to under run the nominal fillet size requi. red by 1/16" without correction provided that\ the undersize weld does not exceed 107. of
-\ the length of. th'e weld.
'L, 1 0
'I t 5.3.2.7 Undercut shall be no more than 0.01" deep ~when the
'l '
4, direction is transverse to primary tensile stress
.s r in the part that is undercut, nor more than 1/32" for all other situa'tions.
5.'4 Stud Welding
.i
"~
5.4.1 Prior to welding' /
5.4.1.1 Check that studs are free from rust, rust pits, scale, oil or other deleterious matter that would adversely affect the welding operation.
c .-
- 5.4.1.2' Check that the stud base is free of paint,
'?Ld t i .
galvanizing and cadmium p1.ti::g.
g
'r 5.4.1.3 Check that areas on members to which studs are
- to be welded are~ free of scale, rust or other
-i injurious material. ,
5.4.1.4 No welding is to be done when base metal te=perature
, l is below zero F or when the surface is wet or
[
- exposed to fallingirain or snow. i
< I.
l' ,
When,the temperature of the base metal is below
- 5.4.1.5 32F, one stud in 'esch 100 studs shall be tested
- ' in accordance with below, in addition to the
,; - first two, tested.
N i 5.4.1.6 If studs are to be fillet welded in place, verify
' that the following requirements are mat:
I a) only low-hydrogen electrodes, 5/32 or 3/16 inch
+
in diamster may.be used. s i ,. ,
b) stud base must be prepared so that the outside circumference of the s,tud fits tightly against r' '
' the base metal. - .
l 4 s v
t J. A. JONES CONSTRUCTION COMPANY PACE 6 0F 10 PROCEDUltE NO.
SITE INSPECTION AND TEST PROCEDURE:
- W-SITP-14
- REV. NO. 4 TITLE: DATE: 2-20-80 WELDING INSFECTION i
PROJECT TITLE:' WATERFORD SES UNIT No. 3 CONTRACT NO. W3-NY-4 8
c) all rust and mill scale shall be removed from the base. metal and the end of the stud shall be cleaned.
d) base metal shall be preheated in accordance with the requirements of the applicable welding procedure.
.-.s 5.4.2 After welding (Shear Connectors) 5.4.2.1 Fillet welding, wh'ere performed, shall be a minimum of 5/16 inch in size.
5.4.2.2 All visual inspection requirements shall apply to
.- 3 at a minimum 20% of studs welded with the exception of . post-weld inspection i
' which requires 100% inspection.
5.4.2.3 The first two studs welded by each welder for each day's welding shall be allowed to cool and bent -
to an angle of 30 degrees from its original axis by striking the stud with a hammer. If failure occurs in the weld zone of eithei stud, the procedure shall be corrected and the process re-
- peated until two consecutive studs have been tested and found to be satisfactory ,before*any production j
~
welding is allowed..
i
- 5.4.2.4 If failure occures in the stud shank, an investi-gation shall be made t'o ascertain and correct the l
cause before more studs are welded.
5.4.2.5 The foregoing testing'shall be performed af ter i
any change in the welding procedure.
l 5.4.2.6 Studs on which a full 360. dag weld fillet is not l obtained may be repaired by adding a 5/16 inch i
l'- .
minimum fillet veld in place of the missing weld
.l , fillet, using the shielded metal arc process with
'I' .
Iow hydrogen electrodes, 5/32 or 3/16 inch in d iame ter'. The repair weld shall extend 3/8 inch
,I minimum beyond each end of defect being repaired.
I .
. w.
- ;~
. . , . . . - ~
. . . _ ....,-.m,-,m,, , - . . me, ___mm,, _.,,_,_.-,m,,__.m_. ..--y.. . . ___~.,,_..._--_._..___.---_-e. -, -,-
( - .-
PAGE 7 0F 10 J. A. JONES CONS.TR.U_CTI_O. N. COM_P_ANY PROCEDURE 50.
SITE INSPECTION AND TEST' PROCEDURE: W-SITP-14
'"REV. NO. 4 DATE: ' 2-20-80 TITLE: WELDING INSPECTION PROJECT TITLE: WATERFOR3 SES UNIT NO. 3 CONTRACT NO. W3-NY-4 ,
5.4.2.7 If the reduction in the length of studs as they are welded becomes less,than normal, i.e., the length of stud is more than 1/16 inch greater A than specified, welding shall be stopped ,
immediataly and not resumed until the cause has been corrected. ;',
5.4.2.8 If visual inspection reveals any stud shear connector that does'not show a full 360 degree weld fillet, any stud that has been repaired by welding, or any stud in which the reduction in
, length due to welding is less than normal, such stud shall be struck with a hammer and bent to an angle of 15 deg from its original axis. For studs
- showing less than 360 degree weld fillet, the f
direqtion of bending shall be opposite to the missing weld fillet. Studs tha,t crack either in the weld, the base metal, or the shank under '
inspection shall be replaced.
.- 5.4.2.9 Veri fy location of studs in accordance with drawings. Studs may vary a maximum of I inch .
.f rom the location shown, provided that adfacent studs are not closer than 2-1/2 inch center to ,
l center and are at least one stud diameter plus
(
1/8 inch from the edge of a member.
5.4.3 After Welding (Applications Other Than Shear Connectors) l l'
5.4.3.1 Fillet welding, where performed, shall be a minimum of 5/16 inch in size.
5.4.3 2 All vi,sual inspection requirements shall also apply to stud welding.
l l @
- p. .
e T
- - - - . ~ - _ _ _ . ___ _ _ _..
PAGE 8 0F 10
.. . .J. A. JONES CONSTRUCTION COMPANY PROCEDURE NO.
SITE INSPECTION AND TEST PROCEDURE: W-SITP-14 REY: NO. 4 DATE:2-20-30 TITLE: WELDING INSPECTION N PROJECT TITLE:
WATERFORD SES_ UNIT NO. 3 Contract No. W3-NY-4 5.4.3 3 Before starting the welding opera ions, or at the request of the Engineer, two stue connectors shall be welded to separate material in the same general position (flat, vertical, overhea , sloping) and of similar thickness sad material as the member.
After being allowed to cool, eact stud shall be tested by striking the stud with i hammer and bend-Ing it to an angle of 30 degrees fr'om its original axis. If failure occurs in the s sid zone of either stud, the procedure'shall be cor seted and two successive studs successfully we ded and tested before any studs are welded to t e member.
The foregoing testing shall be p eformed after any 5.4.3.4 change in the welding procedure.
5.4.3.5 If failure occures in the stud s ank, an investiga-h tion' shall be made to ascertain ind correct t e cause before more studs are welcid.
Studs on which a full 360 deg we id fillet is not 5.4.3.6 obtained may, be repaired by adt ing a 5/16 inch
.- minimum fillet weld in place of the missing weld
- fillet, using the shielded meta -are process with
' low hydrogen electrodes, 5/32 o ?/16 inch in requir6mentr, of diameter, in accordance with th W-SP-4. The repair weld shall xtend 3/8 incht minimum beyond each en6 of defe t being repaired.
If the reduction in the length if studs as they 5.4.3.7 are welded becomes less than nc mal, i .e., the ~
length of stud is more than 1/li inch greater than specified, welding shall be stcaped.immediately has been corrected.
and not resumed until the cause
( :. .
S b * .
P*
l l
l
(
(
. . j, ,
' PAGE 9 0F. 10 J. A. JONES CONSTRUCTION COMPANY.
i PROCEOURE NO.
SITE INSPECTION AND TEST PROCEDURE: V-SITP-14 REV. NO. 4 DATE: 2-20-80 TITLE: WELDING ltJSPECTION .
PROJECT TITLE: WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4 5.4.3.8 The areas of all components subjected to tensile stresses where a defective stud has been removed shall be made smooth an'd flush. Where, in such areas, base metal has been pulled out in the course of stud removal, a shlejded metal-arc welding process with low-hydrogen electrodes in accordance with the requirements of W-SP-4, sh'all be used to fill the pockets and the weld surface ground flush.
In compression areas of members where stud ~ failures are confined to shanks of studs or fusion zones '
of studs, a new stud may be welded adjacent to the defective area in lieu of repair and replacement on existing weld' area, if metal is pulled from the base metal of such areas, the repair provisions shall be the'same as far tensile areas except that, when the depth of defect is not more than the lesser of .1/8 inch or 7% of the base metal thickness, the def'ect may be faired by grinding in lieu of filling .
the defective area with weld metal . Where a re-placement stud is to be placed in the defective area, the above repair shall be made prior to welding the replacement stud. Replacement shear connector studs shall be tested by bending to an .
. . angle of 15 deg from thei r original axes. The
- areas of components exposed to view in completed structures shall be made smooth and flush where a stud has been removed.
5.4.3 9 If visual inspection reveals any stud shear' connector that does not show a full 360 degree weld fillet, any stud that has been repaired by welding, or any stud in which the reduction in length due to welding is less than normal, such stud shall be struck with a hammer and bent to an aagle of 15 deg from it original axis. For studs showing less than 360 degree weld fillet, the
, direction of bending shall. be opposite to the
(.~ missing weld fillet. Studs that crack either in
.. the weld, t_h_e base metal, or the shank under in-spection or subse'quent straightening shall be replaced.
t n -
= . -
,o 9
PAGE 10 0F 10 J. A. JONES CONSTRUCTION COMPANY PROCEDURE 50.
SITE INSPECTION AND TEST PROCEDURE: W-SITF-14 REV. NO. 4 DATE: 2-20-80 TITLE: WELDING INSPECTION PROJECT TITLE: WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4 5.4.3.10 For studs other than shear connectors, at least one stud in every 100 shall be struck with a hammer and bent to ana'ngle of 15 degrees from its original axis. If the stud fails, the pro-cedure shall be checked in accordance with 5.4.3.3 and two more of the existing studs shall be bent. If either of these two studs fails, all of the studs represented by the tests shall be bend-tested or rejected.
5.5 other nondestructive inspection:
R-4 5.5.1 Any radiography, magnetic particle, ultrasonic or liquid penetrant examination to be performed on J. A. Jones welding shall be performed by duly qualified and certified ihspectors or outside agencies in accordance with SNT-TC-1A. AWS Dl.1-72 latest revision, and the requirements of ASP-IV-26* latest revision.
5.5.2 Such nondestructive testing shall be done in conformance with
.- all applicable codes and standards and will be subject to surveillance by J. A. Jones Quality Verification Personnel.
6.0 DOCUMENTATION l
All welding inspection by J. A. Jones Quality Verification Personnel will
! be documented on the Welding Inspection Report.
l 7.0 ATTACHMENTS l
l l 7.1 Welding Inspection Report.
1 R-4 7.2 Process Control Sheet For Welding.
l l R-4
- ASP-IV-26 will become effective as of the approval of this procedure.
l l
~
~
\. -
- 'a
- e
. l - .e.- e
- . *U . , . ' . , , '
e INSTRUCTIONS FC.' COMPLETING WELDING INSPECTION REPORT
- 1. Print name of Welder, Velder's identification number, inspector's name, date of weld / inspection, and indicate checking of Welder's certification.
- 2. Complete identification of weldment, e.g. embedded plate identification _
number; *(Item (1))
3 Indicate position of item with sufficient accuracy so that it may be located at a later date, (ltem (2)) .
5 Check yes or no * (Item (4))
- 6. Check yes or no (item (5))
7 Item (6) is to be used for connents, if any. Any welds whicN iricluding reasons for non acceptance, are indicated as unacceptable should be fully described in this section, proper construction supervision notified and the deficiency properly documented on a Discrepancy Report in accordance with POP-N-713 or a Nonconformance Report in accordance with POP-N-703, which ever is applicable.
- 8. Inspector signs and dates form in space provided.
e T
- ~ ?e .
\[. '
e .e e= .+e. *
- e e+ ese en eo e *e m.ece e me e esp 4
k/ - Attacnment 71
( .
,-,,., j .j' , ,. . .. ,
-[* '
J. A*. JONES CONSTRUCTION COMPANY
~ WELDING INSPECTION REPORT ,
Inspector Weider's Name Date:_
4 Welder's 10 NO. _ _ .
Welder Certification Checked .
(1) Item or bomponent Welded (2) Final Location of item (3) Weld Procedure Designation Yes No Complies With (4) Weld. Procedure Approved (5) Welding Accomplished lie accordance with Procedure and Requirements of this Procedure Yes No
- 5 (6) Comments Date Inspector's Signature
~
m M4 3
w.+
'. g. --. A.d S CONSTRUCTION COMPANY W-SITP-14 (
At tache.an: 7.2 PROCESS CONTROL SHEET LOG NUM3ER:
WATERFORD UNIT NO. 3 FOR WELDING MATERIAL SPECIFICATION: ASTM A-36 and ASTM-441 and similiar carbon steel not to exceed 0.30". carbon content WELDING PROCESS: .
Manual Shielded Metal Arc (SMAW)
FILLER }ETAL SPECI7ICATION: AWS A-5.1.
CURRENT: D .C .R.P .
FILLER METAL CLASSIFICATION: E 7018 LOT OR HEAT NUM3ER:
ELECTRODE DIAMETER: ;i ACCEPT REJECT N/A FIT-UP INSPECTION
- 1. JOINT FIT >EETS W-SP-4
- 2. JOINT DETAIL MEETS AWS Dl.1-72#
- 3. JOINTS FEET AWS D1.1-72 IN PROCESS INSPECTION
- 1. PREHEAT TEMPERATURE
- 2. ROOT TREAT >ENT
- 3. ROOT PASS
- 4. INTER >EDIATE NDE
- 6. INTERPASS TEMPERATURE
- 7. POSTHEATING FINAL WELD INSPECTION _
- 1. VISUAL INSPECTION per W-SITP-14
- 2. NDE
- 3. JOB COMPLETE I
(
COFD!ENTS:
i 6
?
l I
t l
I
(
- L .
l Q.C. IN5fEGIOR uAls t
i