ML20132B783

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Slide Presentation Re Cadweld Splices Insp & Addl Testing
ML20132B783
Person / Time
Site: 05000000, Marble Hill
Issue date: 02/09/1981
From:
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20132B505 List:
References
FOIA-84-293 NUDOCS 8103180349
Download: ML20132B783 (47)
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Text

- - _ - _ _ _ - _ _ - _ _ _. -

PRESENTATION O

1.

INTRODUCTION W. PETR0

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SPP-6 PROGRAM

- D. INGMIRE N oQ qg 3.

EFFECT OF STRAIN A. M0RCOS O

4 14.

SUMMARY

W. PETR0 4

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CHRONOLOGICAL SEQUENCE OF EVENTS RELATING TO CADHELD PDFSFMTATION 1

AuG. '79 PSI HALTS ALL CATEGORY I !!ORK, AUG. 7.

i NRC CONFIRMS CESSITATION OF CATEGORY I WORK, AUGUST 15.

NRC ISSUES NINE-POINT CONFIRMING ORDER.

FEB. '80 PSI SUBMITS STEPWISE PROCESS TO RESUME CATEGORY I WORK, FEBRUARY 28.

a MAY '80 NRC APPROVES PSI " BROWN BOOK," STEPWISE PROCESS TO RESUME CATEGORY I WORK, INCLUD-ING CONSTRUCTION VERIFICATION PROGRAM, MAY 15.

JUNE '80 NRC CONCURS WITH PSI CONSTRUCTION VERIFI-CATION PROCEDURE SPP-6, REVISION 3, JUNE 4.

JULY '80 NRC CONCURRENCE WITH TESTING PROGRAM.

AuG. '30 PSI SUBMITS CONSTRUCTION VERIFICATION FINAL REPORT (" INCLUDING TESTING PROGRAM") TO REGION III, AUGUST 27.

OCT. '80 NRC MEETS WITH PSI AT MARBLE MILL SITE ON OcT. 31 TO PRESENT NRC DRAFT PROPOSAL FOR ADDITIONAL TESTING OF ACCESSIBLE CADWELDS.

N0v. '80 PSI-NRC HOLDS MEETINO

'.N CHICAGO, TO MAKE PRE'SENTATION ON CADWELD INSPECTION AND TESTING PROGRAM, AFTER 2 MONTHS OF INFORMAL MEETINGS AND CONFERENCE CALLS WITH REGION III, NOVEMBER 10.

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SUtilBRY 4

PROGRAM MET ACCEPTANCE CRITERIA SAMPLE SIZE EXCEEDED THAT REQUIRED FOR A 95/95 CONFIDENCE / RELIABILITY STRAIN EFFECT IS INSIGNIFICANT CONCLUSION N0 FURTHER TESTING IS REQUIRED b

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AGENDA FOR MEETING ON "CADWELDS - MARBLE HILL" 1/08/81 AGENDA A.

BACKGROUND OF CADWELD DATA SPP-6 VISUAL INS. RESULTS - PURPOSE & SCOPE 1.'

(CONSTRUCTION VERIFICATION PROGRAM AT MARBLE HILL) 2.

RADIOGRAPHY RESULTS 3.

IENSILE IEST RESULTS B.

PSI EVALUATION OF ADEQUACY OF EMBEDDED AND ACCESSIBLE CADWELDS 1.

PROGRAM - OvERAL' COMMITMENTS AND RESULTS 2.

ADEQUACY OF EMBEDDED CADWELDS 3.

GAGE MARFS NOT TRuE VISUAL REJECTIONS 4.

STRAIN EFFECT 5.

CONCLUDING STATEMENT C.

NRC CONCERNS /0UESTIONS HAnnouT INFORMATION PRODUCTION AND SISTER SPLICE IEST RESuLTS SIMILARITIES AND DIFFERENCES BETWEEN ACCESSIBLE AND INACCESSIBLE CADWELDS

SUMMARY

OF LOCATIONS FOR CADWELD SPLICES - UNITS 1 & 2 1

DEFINITIONS STANDARD SPLICE:

A SPLICE WHICH MEETS ALL ACCEPT / REJECT CRITERIA (BOTH THE G MARK AND CENTERING CRITERIA AND THE PHYSICAL CRITERIA FOR VOIDS, i

RECESS, SLAG, POROSITY, ETC.)

SEE FLIMSY ON ACCEPT / REJECT CRITERIA.

4 VISUALLY REJECTED SPLICE:

A SPL, ICE THAT FAILS ONE OR MORE OF THE ACCEPT / REJECT CRITERIA.

SUBSTANDARD SPLICE:

A SPLICE THAT FAILS TENSILE TESTING (TEST LESS THAN 75,000 PSI).

PHYSICAL VISUAL REJECT:

EXCESSIVE VOIDS,' EXCESSIVE FILLER RECESS POROSITY, SLAG, LACK OF FILLER METAL, TWO TAP HOLES, TAP HOLE BURNOUT.

GAGEMARK VISUAL REJECT:

No GAGEMARKS, GAGEMARKS NOT CENTERED WITH TAP HOLE, GAGEMARKS EX-CEED TOLERANCE OR LESS THAN TOLERANCE.

,s TYPE "T" SPLICE (T-VERTICAL, TV OR T-HORIZONTAL TH):

i DEVEL0P FULL POSITIVE ULTIMATE STRENGTH MECHANICAL CONNECTIONS B TWEEN TWO REINFORCING BARS WITH A COMMON SLEEVE IN TENSION AND PRESSION.

TRANSITION SPLICES ARE USED WHEN BARS OF DIFFERENT SIZE I

ARE TO BE SPLICED.

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DEFINITIONS, CONT.

TYPE "B" SPLICE (B-VERTICAL OR BV):

PROVIDE A MECHANICAL MEANS OF CONNECTING REINFORCING BARS TO

. STRUCTURAL STEEL PLATES AND SHAPES.

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ACCEPT / REJECT CRITERIA FOR SPP-6 AND SPECIFICATION Y-2722 1.

FILLER METAL MUST BE VISIBLE AT THE ENDS OF THE SPLICE SLEEVE.

2.

FILLER METAL MUST BE VISIBLE AT THE TAP HOLE.

3.

FILLER METAL SHALL NOT BE RECESSED MORE THAN 1/2 INCH AT SLEEVE ENDS.

4.

SPLICEti SHALL NOT CONTAIN SLAG AT TAP HOLE OR i

SLEFVE ENDS.

5.

SPLICES SHALL NOT CONTAIN POROSITY AT TAP HOLE OR

~

SLcEVE ENDS.

6.

VOID AREA SHALL NOT EXCEED 2,65 SQUARE INCHES FOR #18 2.00

  1. 14 1.50 FOR #11 1.58 FOR #10 1.03 FOR #10,9,8, 7,6 0.53 5

0.47 4

7.

DISTANCE BETWEEN GAGE MARK AND STRUCTURAL STEEL PLATE OR -

SHAPE FOR TYPE B SPLICE 12 t 1/2 INCHES I

8.

A.

DISTANCE BETWEEN GAGE MARKS FOR A TYPE I SPLICE SHALL BE 24 1/4 t 1/2 INCHES l

3.

THE CENTERLINE OF THE DISTANCE BETWEEN GAGE MARKS SHALL FALL 4

WITH THE DIAMETER OF THE TAP HOLE.

b 9.

I NO GAGE MARKS VISIBLE - WAS A REJECT CRITERIA EVEN THOUGH A PERMANENT MARKING SYSTEM IS NOT REQUIRED.

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SUMMARY

OF INSPECTION PROGRAM TOTAL NUMBER OF CADWELDS INSPECTED 2431 TOTAL NUMBER OF INSPECTED ITEMS 19448 TOTAL NUMBER OF VISUAL REJECTED ITEMS 576 (CASES OF REJECTION)

TOTAL NUMBER OF CADWELDS WITH VISUAL REJECTIONS 504 l

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J PURPOSE OF TESTING:

1.

TO PROVE THAT THE T/PE OF VISUAL REJECT PRESENT IN THE ACCESSIBLE POPULATION OF CADWELDS AT MARBLE HILL ARE NOT SUBSTANDARD SPLICES.

2.

TO ASSURE THAT VISUALLY REJECTED SPLICES MEET THE STRESS AND AVERAGE STRESS REQUIREMENTS (75 KSI MINIMUM, 90 KSI AVERAGE FOR 15) AT A 95% RELIABILITY WITH A 95%

CONFIDENCE FACTOR.

NOTE:

THE ONLY REASON THE ACCESSIBLE SPLICES WERE TESTED 1

WAS DUE TO THE NECESSITY OF EVALUATING THE TYPES OF REJECTS IN THE ACCESSIBLE POPULATION TO DRAW CONCLUSIONS ON THE ACCEPTABILITY OF BURIED CADWELDS.

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SCOPE"0F TESTING RAND 0M' SAMPLE"T0TAL POPULATION SCOPE OF TESTING:

1.

SELECT 59 RAND 0M NUMBERS FROM ENTIRE POPULATION t

0F ACCESSIBLE CADWELDS AND DETERMINE BY VISUAL INSPECTION, RADIOGRAPHY OR TENSILE TESTING TilAT THE SPLICES MEET THE SPECIFIED VISUAL INSPECTION CRITERIA: THE RADIOGRAPH CRITERIA FOR GAGE MARK REJECTION OR THE SPLICE MUST BE CUT OUT AND TESTED ACCORDING TO STRESS RE-QUIREMENTS.

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SCOPE OF TESTING

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RANDOM SAMPLE TOTAL POPULATION 2.

FOR CONSERVATISM, GROUP ALL VISUAL GAGE MARK REJECTS AND RADI0GRAPil SPLICES TO OBTAIN A 95% CONFIDENCE FACTOR TilAT Tile REBARS ARE INSTALLED / EMBEDDED CORRECTLY WITilIN THE SLEEVE-OR IF RADIOGRAPilED OUTSIDE OF TOLERANCE TilEN TENSILE TEST RT REJECTS.

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ADDITIONAL' WORST" CASES PilYSICAL REJECTS 9

3.

FOR CONSERVATISM DETERMINE WORST CASES OF ALL VISUAL PHYSICAL REJECTS AND TENSILE TEST TO SHOW ACCEPTANCE OF MINIMUM AND AVERAGE STRESS.

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SUMMARY

OF PilYSICAL TESTS VISUAL REJECTS METilOD TENSILE TEST RESULTS (PSI)*

INSPECTED TOTAL NUMBER NUMBER OF ITEM NUMBER TESTED PASSED TEST liighest Lowest Average Excessive Void 103 13 13 T

105,000 84,445 98,206 Area Excessive Recess 7

2 2

T 102,205 100,787 101,496 Of The Filler Metal Slag Penetration 26 8

8 T

100,641 89,333 96,203 Beyond The Sleeve At The Tap liole Tap IIole Burnout 3

3 3

T 97,500 92,564 95,188 Porosity In The 14 4

4 T

105,000 89 333 96,277 g*

Sleeve Ends No Filler Metal 1

1 1

T 109,764 Visible At The Sleeve' Ends 1

2 Tap I! oles 2

1 1

T 97,000 (MU)

TOTALS 15 6* **

32 30(T) 109,764 84,445 97,710 1 (MU)

T = Tensile Test (MU) = Mockup

  • = Acceptance Criteria;

< 75,000 psi for individual splice and average of any 15 test results had to meet or exceed 90,00 psi..

    • = Same splice TV-434; 38,333 TV-541; 105,000
      • = 2 splices which had "indeterminant" conditions:

11 TV-1087 & TV-1101 2 tap holes are not included.

SUMMARY

OF GAUGE MARK TESTS i

VISUAL REJECTS METHOD TENSILE TEST RESULTS (PSI)*

INSPECTED TOTAL NUMBER NUMBER OF ITEM NUMBER TESTED PASSED TEST liighest Lowest Average No Gauge Marks 203 25 25 RT Out of Tolerance 106 29 27 RT 97,750 89,750 93,750 Gauge Marks 2

T

    • Centerline Of '

111 19 15 RT 99,250 76,500 93,500 Gauge Marks Not 4

T Within Diameter Of Tap llole i

TOTAL

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73 66 RT 99,250 76,500 93,583 6

T RT = Radiograph T = Tensile Test

. * = Acceptance Criteria:

< 75,000 psi for individual splice and average of any 15 test results had to meet or exceed 90,000 psi.

    • = Bar ends must be within the outline of the tap hole.

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    • * = Splice had " indeterminate" condition (BV-63, 2 gage marks) not included.

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RELIABILITY OF TEST PROGRAM ACCESSIBLE CADWELDS TOTAL 2431 CONFIDENCE RELIABILITY RAND 0M SAMPLE TOTAL POPULATION 59 95%

95%

(2431)

SAMPLE OF GAGE WORK 58 95%+~

95%+

VISUAL REJECT POPULATION (381)

ADDITIONAL WORST CASES 21-PHYSICAL REJECTS (115)

TOTAL ACCEPTABLE SPLICES 95%

99%

INSPECTED & TESTED (188th 13

STRAIN IN CADWELD SPLICES

  • NRC CONCERN:

SPLICES FAILING VISUAL EXAMINATION COMPROMISE STRUCTURAL INTEGRITY

RESPONSE

CODE REQUIREMENTS ERIC0 TESTS STRESSES AND CRACK CONSIDERATIONS AT MARBLE IIILL t

FIGURE l' T

1

CODE REQUIREMENTS STRENGTH, NOT STRAIN, IS CRITERION IN GOVERNING CODES, REGULATORY GUIDES OR MANUFACTURER'S RECOMMENDATIONS.

1 ACI-349-76 NOT GOVERNING - HOWEVER, MET FOR T-SPLICES IN CONTAINMENT SHELL AND BASEMAT.

I FIGURE 2 2

ERIC0 TESTS g'

REINFORCED CONCRETE BEAM 8" WIDE X 12" DEEP

,p< g 1 BEAM, UNSPLICED BARS SP 2 BEAMS, VERY SOFT UNSTAGGERED SPLICES (1 1/2" PLUG) 1 BEAM STANDARD CADWELD SPLICES

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STEEL PLUG m~im 6

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10 0 200 300 400 500 600 700 800 90:

AVERAGE STRAIN OVER 5" SLEEVE LENGTH STRESS -STRAIN CURVES FOR SPLICE BARS I

FIGURE 11

e RESULTS OF ERICO TESTS BEAMS LOADED TO FAILURE DUCTILE FAILURE SIMIlAR CRACK PATTERN SAME ULTIMATE M0 MENT CAPACITY SAME DEFLECTIONS AT LOAD 50% OF ULTIMATE DEFLECTIONS AT YIELD 15% To 20% HIGHER FOR SOFT SPLICES SAME DEFLECTI0tlS AT POINT OF FAILURE D

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.i MID-SPAN DEFLECTION, INCHES FIGURE 6 LOAD-DEFLECTION (URVES FDR ALL THE BE MS (Reference 1)

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MARBLE HILL LESS SEVERE THAN ERIC0 TESTS BLOW OUT (M0ISTENED) CONDITION'MORE CRITICAL THAN MARBLE HILL.

ERIC0 TESTS HAVE A RIGID PLUG PREVENTING THE SLEEVE FROM GRIPPING THE BAR',

ERIC0'S PLUG WORSE THAN MARBLE HILL'S WORST CASE',

IN ERIC0'S TESTS, 100% REINFORCING IN THE BEAM WAS SPLICED WITH SOFTENED CADWELDS AT SECTION OF MAXIMUN MOMENT; WHILE AT MARBLE HILL A MAXIMUM 0F 8% OF BARS IN ONE WALL HAD PilYSICAL VISUAL REJECTIONS (THE WORST PASSED TENSILE TESTS).

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SUMMARY

OF VISUAL INSPECTION RESULTS OF SPLICES WITH PHYSICAL REJECTIONS (RECESS ~, V0 IDS, SLAG, POROSITY)

PERCENT OF LOCATION TOTAL PRIMARY SHIELD WALL 8.2

()W"'~"'g gp 2 oc.

1 i

SECONDARY SHIELD WALL 6.6 REFUELING P0OL WALLS 3.4 CONT. SHELL a EL.' 378'-0" 1,3 1

CONT. SHELL a EL. 382'-0" 0.7 i

CONT. SHELL a EL, 390'-0" 2.1 CONT. SHELL a EL.'394'-0" 2.1 CONT. SHELL a EL. 397'-0" 0.1 i

CONT. SHELL a EL. 414'-0" 0.3 4

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STRESS AND CRACK ANALYSIS - CONTAINENT INTERtlALS.

ASSllMING Ali SPLICES VISUAlIY_ ACCEPTABLE

/e A.

WALL IS IN COMPRESSION FOR NORMAL, NON-SEISMIC LOADING gf B.

118.6 KSI STEEL STRESS FOR THE HOST SEVERE LOADING 4

l ASSUMING VISUALLLEEJECIED_SELICES_HDH-EXISTENT

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WALL IS IN COMPRESSION FOR NORMAL NON-SEISMIC LOAD i

B.

52 KSI STEEL STRESS FOR THE MOST SEVERE LOADING i

Al10WABLE STRESS _PER ACI 318-_7_1 IS 511 KSI CRACK INSIGNIFICANI COVERED BY 3' CONCRETE SLAB

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OCCURS ONLY UNDER SEISMIC CONDITION, FOR A SHORT TIME

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STRESS AND CRACK ANALYSIS - CONTAINMENT SHEl1 i

ASSUMING VISUALLY REJECTED SPLICES ARE NONEXISTENT, STRESSES ARE WITHIN DESIGN ALLOWABLES FOR ALL LOADING CONDITIONS.

4 N0 SIGNIFICANT CRACKS EXIST UNDER NONSEISMIC SERVICE LOADS (DUE TO POST TEN 510NING).

ANY CRACKS UNDER SEISMIC LOADS ARE. CLOSED BY COMPRESSION LOADS FROM THE POST. TENSIONING SYSTEN.

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CONCLUSION i

1 STRAIN CONSIDERATION RELATING TO PHYSICAL VISUAL REJECTIONS SHOWS N0 IMPAIRMENT OF THE STRUCTURAL INTEGRITY AND SERVICEABILITY AT MARBLE. HILL.

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FIGURE 13 13

i HANDOUT INFORMATION TABLE OF CONTENTS TOTAL CADWELD POPULATION - GENERAL RESULTS 1 PAGE 59 RANDOM NUMBERS OF A TOTAL 2,434 SPLICE POPULATION 2 PAGES TEST GROUP 2 - GAGE MARK VISUAL REJECTS 1 PAGE TEST GROUP 3 - WORST CASES OF PHYSICAL REJECTS 1 PAGE

SUMMARY

TENSILE TESTING 2 PAGES PRODUCTION AND SISTER TEST RESULTS 1 PAGE CADWELD IN-PROCESS TENSILE TESTS RESULTS 1 PAGE SIMILARITIES BETWEEN 5MBEDDED & ACCESSIBLE CADWELDS 1 PAGE SIMILARITIES AMONG OPERATORS REJECT DISTRIBUTION BY CATEGORY l PAGE OPERATOR DISTRIBUTION 1 PAGE INSPECTOR DISTRIBUTION - UNITS 1 AND 2 1 PAGE CADWELD SPLICE DISTRIBUTION 1 PAGE SPLICES WITH MULTIPLE DEFECTS 1 PAGE DISTRIBUTION OF REJECTS BY TYPE / SIZE AND VISUAL REJECT CATEGORY l PAGE CADWELD SAMPLING & TESTING FREQUENCIES 1 PAGE RADIOGRAPHIC EXAMINATION ACCEPTANCE CRITERIA FOR OFF CENTERED BAR ENDS 1 PAGE DISTRIBUTION OF VISUAL REJECTS 1 PAGE

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TOTAL CADWELD POPULATION - GENERAL RESULTS l

2434 TOTAL SPLICES AVAILAELE i

FOR INSPECTION 3 void (NOT INSTALLED) - V i!

1794 VISUALLY ACCEPTABLE

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499 VISUALLY REJECTABLE

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133 INACCESSIBLE

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5 REJECT / INACCESSIBLE

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2434 TOTAL

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OF THE 2431 IN-PLACE' SPLICES INSPECTED THERE WERE 502 SPLICES

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WHICH DID NOT MEET THE VISUAL INSPECTION CRITERIA.

IN ADDITION TWO SPLICES EV-1007 AND BV-1101 WERE IDENTIFIED DURING THE

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INSPECTION AS HAVING TWO TAP HOLES.

BV-1087 AND BV-1101 HAVE I!

BEEN INCLUDED IN THE 504 SPLICE TOTAL.

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j 504 INDIVIDUAL SPLICES WITH ONE OR MORE CASE j

OF REJECTION

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INCLUDING (2 INDETERMANENT CASES BV-1083 AND BV-1101 l!

(2 TAP HOLES)

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{l 60 INDIVIDUAL SPLICES WITH TWO CASES OF REJECTION

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7 INoiv! DUAL SPLICES WITH THREE CASES OF REJECTION

_12-1 TOTAL CASES OF REJECTION 576

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l 59 RANDOM NUMBERS OF A TOTAL 2,434 SPLICE POPULATION l

1) 2047 BV-908 (A)
21) 1317 BV-186 (A)
41) 2161 BV-1022 (A)
2) 2145 BV-1006 (A)
22) 0543 TV-912 (R)
42) 0628 Tv-870 (A)
3) 0178 Tv-179 (A)
23) 1979 BV-840 (A)
43) 0552 Tv-921 (A)
4) 0579 TV-948 (A)
24) 1406 BV-275 (A)
44) 0819 TV-845 (R)
5) 1039 TV-560 (R)
25) 1180 BV-49 (A)
45) 0783 TV-732 (A)

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6) 1646 BV-515 (A)
  • ) 2295 BV-1164 (I)
46) 0433 TV-1121 (R)
7) 0484 Tv-1070 (A)
26) 1138 BV-7 (A)
47) 0089 TV-90 (A) l
8) 1428 BV-297 (A)
27) 1894 BV-763 (A)
48) 1765 BV-634 (A)

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28) 0280 TV-357 (A)
49) 0939 TV-712 (R)
9) 1279 BV-148 A

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10) 0573 TV-942 (A)
29) 1854 BV-723 (A)
50) 1472 BV-341 (A)
11) 1443 BV-312 (A)
30) 0489 TV-1065 (A)
  • ) 1567 BV-436 (I) i
12) 2157 BV-1018 (A)
31) 1178 BV-47 (A)
51) 2064 BV-925 (A) i
13) 2413 TH-38 (A)
32) 1989 BV-850 (A)
52) 2135 BV-996 (A)
14) 0990 TV-511 (A)
33) 0322 TV-279 (A)
53) 0287 TV-244 (A) i
15) 0972 TV-594 (A)
34) 0932 TV-705 (A)
54) 0254 TV-331 (A)

I

16) 0985 TV-506 (R)
35) 2269 BV-ll30 (A)
55) 0070 TV-70 (R)
17) 0222 TV-223.(A)
36) 1999 BV-860 (A)
  • ) 2389 TH-14 (I)
18) 0127 TV-128 (A)
  • ) 2356 BV-1225 (I)
56) 0643 TV-885 (A) i
19) 0212 TV-213 (R)
37) 1929 BV-798 (A)
57) 1224 BV-93 (A)
20) 1193 BV-62 (R)
38) 1140 BV-9 (A)
58) 0881 TV-654 (R) 1
39) 0634 TV-876 (A)
59) 0154 TV-155 (R)
40) 0045 TV-45 (A) 1 i

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  • Splice was exposed but inaccessible to any inspections or tests.

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Note 1:

48 splices inspected as acceptable 3 splices rejected due to physical visual defects 4

(TV-70; TV-155; TV-560) 8 splices rejected due to gage mark visual defects 4

(BV-62; TV-506; TV-654; TV-712; TV-845;.TV-912; TV-213; TV-1121) 59 Total randem numbers Note 2:

Three gage mark visual rejects did not pass the radiography procedure and were tensile tested.

These were TV-506, TV-654 and TV-845.

Note 3:

Tensile Test Results:

Splice I.D.

Tensile Strength

, Type of Failure TV-70 95,276 Bar Failure TV-155 103,937 Bar Failure TV-560 97,500 Bar Failure TV-506 99,250 Sleeve Failure TV-654 99,250 Pullout Tv-845 99,000 Bar Failure G

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l TEST GROUP 2 - GAGE MARK VISUAL REJECTS LIST OF SPLICES RADIOGRAPHED FRCM G.M. VISUAL REJECT POPULATION 1.

BV-63 21.

BV-828 39.

TV-171 i

2.

BV-13 3 22.

BV-837 40.

TV-235 i

3.

BV-236 23.

BV-911 41.

TV-339 4.

BV-350 24.

BV-920 42.

Tv-341 25.

BV-ll22 43.

Tv-343 5.

BV-356 6.

BV-377 44.

TV-358 7.

BV-485 26.

TH-23 45.

TV-360 8.

BV-488 27.

TH-26 46.

TV-366 1

9.

BV-539 28.

TH-28 47.

TV-370 s

10.

BV-605 29.

TH-43 48.

TV-440 11.

BV-665 49.

TV-454 12.

BV-670 30.

TV-41 50.

TV-729 4

13.

BV-755 31.

TV-51 51.

TV-777 14.

BV-757 32.

TV-55 52.

TV-959 1

15.

BV-759 33.

TV-73 53.

Tv-1017 16.

BV-768 34.

TV-75 54.

TV-1029 i

17.

BV-816 3 5 ~.

TV-77 55.

TV-1052 18.

BV-820 36.

TV-79 56.

TV-ll31 19.

BV-823 37.

TV-82 57.

TV-1133 20.

BV-827 38.

TV-85 58.

TV-ll34 i

Note:

1.

58 splices radiographed for 95% reliability with 954 confidence factor.

Only 54 required for population of 390.

i

~

Note:

2.

Three gage mark visual rejects did not pass the radiography procedure and were tensile tested with results as follows :

Splice I.D.

Tensile Strength Type of Failure TV-777 76,500 Pullout TV-ll31 89,750 Pullout TV-ll33 97,750 Bar Failure k

f 1

s e

h l

l t

\\

1 TEST GROUP 3 - WORST CASES OF PHYSICAL RIJECTS The following splices were tensile tested based on the worse cases in Appendices B, C, D, E, F & G in Car PC 0602.

i Splice I.D.

Tensile Strength Type of Failure i

1.

BV-68 99,750 Bar Failure 2.

BV-242 100,641 Bar Failure 3.

BV-541 105,000 Bar Failure 4.

BV-626 101,000 Bar Failure i

5.

BV-635 100,000 Sleeve Failure 6.

BV-742 92,564 Pullout 7.

BV-757 94,872 Weld Broke 8.

BV-796 102,308 Pullout 9.

BV-ll39 97,500 Pullout 3

10.

TV.6 8 99,591 Bar Failure 11.

TV-80 102,205 Bar Failure 12.

TV-87 109,764 Bar Failure 13.

Tv-91 102,835 Bar Failure

~

14.

TV-153 100,787 Bar Failure 15.

TV-174 87,402 Pullout 16.

TV-285 84,445 Pullout 17.

TV-408 92,444 Pullout 18.

TV-433 99,556 Pullout 19.

TV-434 89,333 Pullout 20.

TV-729 95,500 Bar Failure 21.

TV-890 97,500 Bar Failure e

22.

MU-2 97,000 Bar Failure I

4 e.

S l ---.-

~,,,_--,-,.--,,-.,.r,.,.,----,.-y-r-u,-,,.-,-.-,

.-,-,.-.m.y.--.

,--------,-m

.w-r

,m

,,-.,4

SUMMARY

TE24SILE TESTING Splice Tensile Type of t

Identifica tion Strength Failure Remarks 1.

BV-68 99,750 Bar Failure 2.

BV-242 100,641 Bar Failure j

3.

BV-541 105,000 Bar Failure 4.

BV-626 101,000 Bar Failure 5.

BV-635 100,000 Sleeve Failure 6.

BV-742 92,564 Pullout 7.

BV-757 94,872 Weld Broke Wald of " Butted sleeves 8.

BV-796 102,308 Pullout 9.

BV-1139 97,500 Pullout 10.

TV-68 99,591 Bar Failure 11.

TV-70 95,276 Bar Failure 12.

TV-80 102,205 Bar Failure 13.

TV-87 109,764 Bar Failure 14.

TV-91 102,835 Bar Failure 15.

Tv-153 100,787 Bar Failure 16.

TV-155**

103,937 Bar Failure 4

17.

TV-174 87,402 Pullout Wald metal did not fail sheared deformations ef f bar corner of bar fractured 18.

TV-285 84,445 Pullout 19.

TV-408 92,444 Pullout 20.

TV-433 99,556 Pullout 21.

TV-434 89,333 Pullout Sheared deformations off bar 22.

TV-506*

99,250 Sleeve Failure 23.

TV-560 97,500 Bar Failure 24.

TV-654*

99,250 Pullout i

1 25.

TV-729 95,500 Bar Failure 26.

TV-777*

76,500 Pullout Sheared deformations off bar 27.

TV-845*

99,000 Bar Failure 2 8."

TV-890 97,500 Bar Failure 29.

TV-1131*

89,750 Pullout Sheared deformations off bar j

30.

TV-1133*

97,750 Bar Failure 31.

MW-2 97,000 Bar Failure

  • Worst cases gage mark failure
    • TV-155 from random 59 numbers Page 1 of 2 G

t

. ~. _ _ _.. _ _ _.. _

'Of the 30 production splices pulled out and tested:

The types of failures broke down as follows:

2 sleeve Failures 16 Bar Failures 11 Pullouts (Bar pulled out of sleeve) 1 Butt Weld Failure 30 Total Of the 11 pullouts:

6 Pulled out at above 90,000 psi 5 Pulled out due to deformations shearing off bar 0 Pulled out due to lack of or failure of filler metal 11 Total 9*

Page 2 of 2 e

b O

e a

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=. -..... -

i..

6(A)

PRODUCTI0ft AND SISTER SPLICE TEST RESULTS CONTAINMENT #1 6 PRODUCTION 185 SISTER CONTAINMENT #2

{ PRODUCTION 166 SISTER TOTALS 10 PRODUCTION

  • 351' SISTER 4
  • NOTE 1.

ALL PRODUCTION AND SISTER SPLICES PASSED THE i

t MINIMUM AND AVERAGE STRESS CRITERIA.

NOTE 2.

SEE ATTACHMENT PAGE 6(3) FOR PRODUCTION, SISTER AND QUALIFICATION TEST RESULT DISTRIBUTION.

O o

9 g

l

  • I t

I 6

CADWELD IW-PROCESS TENSILE TESTS RESULTS i

Cadweld Splices TV-10 TH-11 BV-11 TV-10 BV-18 TV10-18 TV14-18 TV11-10 TH-8 TM-9 Cumber of Testa 407 201 26 84 8

24 40 11 9

2 2

ge;a ;,,

,,,1, 102.93 100.9.

103.52 107. x 100.47

9. 50 106. n 100.93 104.i.

106.56 99.60 ga ;na g

5.99 4.45 5.23 1.i2 2.59 4.34 5.14 4.4.

6.64 i

,,,1,

(.

I '"

5.82 4.40 5.05 6.63 2.57 4.40 4.84 4.44 6.30 t

F.inge (kst) 29.94 18.25 24.35 27.05 7.71 12.25 15.59 16.44 19.10 4.55 0

hn.Strcnoth (ksi) 87.11 91.25 92.43 90.00 96.53 92.74 93.38 87.11 95.64 104.30 99.60 Jr.J roIc of railure P

BF Dr er Br Dr P

P D f' DF P

F.a s. Strength (ksi) 117.05 109.50 116.79 117.05 104.25 105.00 108.97 103.55 114.74 108.86 99.60 and W e of raiture Br Dr Dr nr SF Br Br Dr br Dr P

P IS 4

7 0

1 O

1 3

0 0

2 Sr 8

4 2

0 2

0 0

0 0

0 0

)

tir 3s1 193 17 84 5

24 39 8

9 2

C 23 C

jg Visu.nlly 1

0 0

1 0

0 0

0 0

0 0

RejectcJ l

i TOTAL 40s 201 26 85 a

24 40 11 9

2 2

{

Probability of l

ab ab ab Strength exceed-

.9842

.9931

.9951

.9925

.9975

.9748

.9991

.9825

.9750 ing 90 ksi I' rob. of average b

b b

b ab b

b ab a

I t

d

.9999997

.9999997

.9999997

.9999997.9999997

.9999997

.9999997

.9999997.999975 I

50 kst notes:

Notation :

a - t-student distribution b - laresce th.an the ntualier shown Ar - Dar railure c - rc jecte.1 by the lab because of slag at tap hole P = Pult out of the bar Sr a Sleeve rallure

7./

q' ).

4 SIMILARITIES BETWEEN EMBEDDED & ACCESSIBLE CADWELDS TOTAL TOTAL SPLICE SHOTS j

TYPE REJECT / OPERATORS

  • ALL OPERATORS REJECTS /0PERATORS*

TOTALS

& SIZE UNIT 1 UNIT 2 UNIT 2 F

G L

S X

JJ KK CC

)

l!18-18V 570 532 1104 67 35 16 0

1 32 0

0 151 i

18-14V 127 173 300 15 11 13 0

0 0

0 0

39 18-10V 481 433 914 32 0

0 40 4

73 0

0 149 BV-11 912 862 1774 28 0

50 0

0 18 38 1

134 i

142 46 79 40 5

123 38 1

473**

TOTAL REJECTS 154 46 79 40 5

130 39 1

i i

  • 28 QUALIFIED CADWELD OPERATORS, ONLY EIGHT SHOT REJEC'TS IDENTIFIED UNDER SPP-6 PROGRAM.

(NOTE:

REJECTS HERE'ARE INDIVIDUAL SPLICES) i

  • 473 0F 502 INDIVIDUAL SPLICE REJECTS (94%) SHOT BY 8 OPERATORS ON ONLY 4 TYPES OF SPLICE.

9 4

9 i

Sli.)tARITIES~ AMOM OPERATORS O

REJECT DISTRIEUTION BY CATEGORY OPERATOR BAR GAGE MARK EXC. REC. POROSITY OTHERS CASES SIZE &

REJECT VCIDS 3 SLArg TYPE CASE 9*

CASES' CASES l

F

  1. 18-TV 111 1.0 18 1
  1. 11-BV 18 10 3

0 l

OTHERS 7

0 2

2 G

  1. 18-TV

- 50 1

0 0

  1. 11-BV 0

0 0

0 OTHERS 0

0 0

'O L

  1. 18-TV 32 0

2 0

  1. 11-BV 21 24 4

1 OTHERS 0

0 0

0 S

  1. 18-TV 33 16 0

0

  1. 11-BV 0

0 0

0 OTHERS 0

0 0

0 X

  1. 18-TV 5

1 0

0

  1. 11-BV 0

0 0

0 OTHERS 0

0 0

0-JJ

  1. 18-TV 96 20 9

1

  1. 11-BV 2

15 1

0

~

OTHERS 4

2 0

1 XX

  1. 18-TV 0

0 0

0

  1. 11-BV 29 11 1

0 OTHERS 1

0 0

0 CC

  1. 18-TV 0

0 0

0

  1. 11-BV 1

0 0

0 OTHERS 0

0 0

0 Sus-

  1. 18-TV 327 48 29 2

T TALS

  1. 11-BV 71 60 9

1 oTvE=9 12 2

2~

3 TOTALS 410 110 40 6

= 566"

  • NOTE:

CASES ARE INDIVIDUAL TYPES OF REJECTION.

SOME IflDIVIDUAL SPLICES HAVE MULTIPLE CASES OF REJECTION.

  • THIS NUF3ER EXCLUDES HORIZONTAL SPLICES WHICH DO NOT HAVE GAGE MARKS.

C

1 OPERATOR DISTRIBUTION Statistical Probability For Rejects In Unit 1 Physical Unit 1 Unit 2 Unit 2 All Categories Operator Actual Actual Rejects Categories Only JJ 258 579 130 58 17 F

648 650 154 154 44 S

37 132 40 11 3

G 287 203 46 65 19 X

98 39 5

12 3

L 240 396 79 48 14 KK 178 457 39 15 4

LL 398 16 1

25 7

Totals 2,144 2,472 494**

388*

111

  • Statistical probability of cadweld splice rejects in Unit 1 based on percentage of operator rejects from accessible splices (SPP-6) from Unit 2.
    • Horizontal splices not, included in this total.

.--y,-

y,

q s -

f:

INSPECTOR DISTRIBUTION UNITS 1 AND 2 Statistical Probability For Rejects In Unit 1 Unit 1 Unit 2 Unit 2 Physical Cadwelds Cadwelds Rejects All Categories Ingpector (Actual)

(Actual)

(Actual)

Categories Only

  1. 1 98 1,242 289 23 7
  1. 2 1,880 1,405 117 157 45
  1. 3 48 299 60 10 3
  1. 4 109 92 14 17 5
  1. 5 510 200 12 31 9

66 346 35 6

59 17

  1. 7 880 366 4

10 3

Subtotals 3,871 3,639 502 307 89

  1. 8-11 590 633 0

0 0

s Totals 4,461 4,272 502 307 89 I

CADWELD SPLICE DISTRIllU'rION a

I Nundsor of Rejects umber of Shots g

Operator Spilco Type Cont. 42 Cont. Il cont. 42 Total shots JJ 18/18V 32 7

130 137 JJ 18/10V 73 2

186 188 JJ 11 DV 18 249 174 423 JJ 18 BV 7

0 89 89 P

18/18V 67 197 184 381 P

10/14V 15 18 85 103 F

18/11V 3

0 32 32 F

18/lOV 32 187 99 286 P

18 DV 9

120 72 192 P

11 DV 28 126 178 304 9

S 18/10V 40 37 132 169 G

18/18v 35 222 137 359 i

G.

18/14V 11 65 66 131 X

18/18V 1

18 23 41 X

18/10V 4

80 16 96 L

18/18V 16 126 58 184 L

18/14V 13 36 22 58 L

11 BV 50 78 316 394 KK 18 BV 1

24 101 125 KK 11 BV 38 154 356 510 CC 11 BV 1

398 16 414 Total 494 2,144 2,472 4,616 t

s -

eT Splicas With ! Atiple Defects - 66 X Splices With 1 Physical & 1 G.M. Defect -2 3

  • Splices With 3 Defects 1.

BV-378 X

23. TV-87 X
45. TV-473 2.

BV-541

24. TV-93
46. TV-533 3.

BV-720 X

25. Tv-97
47. TV-607 4.

BV-724 X

26. TV-110 X
48. TV-632 5.

BV-742

27. TV-153
49. TV-684 X

6.

BV-757 X

28. TV-155 X
50. TV-729 7.

TV-18

29. TV-184
51. TV-773 8.

TV-40

30. TV-192
52. TV-777 9.

TV-46

31. TV-230 X
53. TV-840 10.

TV-50 X

32. TV-339
54. TV-863 X.

11.

TV-55 33..TV-351

55. Tv-869 12.

TV-59

34. TV-354
56. TV-890 X

13.

TV-65 X

35. TV-356 X - 57. TV-914 1

14.

TV-66 X

36. TV-370 i
58. Tv-926 X

l 1

1 15.

TV-68 X

37. TV-401 X
59. TV-940 g

16.

TV-70 1

8

38. TV-403 X
60. TV-959 17.

TV-73 X

39. TV-433
61. TV-967 18.

TV-77

40. TV-434
62. TV-971 19.

TV-78 X

41. TV-437 63..TV-983 X

2"0.

TV-79

42. TV-440 l
64. TV-1025 l

21.

TV-80 X

43. TV-446
65. TV-1064 22.

TV-82

44. TV-459
66. TV-1134 Individual splices 504 2 Cases 66 3 Cases 6

W

..~ - -

= - -...

o 6

~

i f.

k g

/

DISTRIBUTION OF REJECTS BY TYPE / SIZE AND VISUAL REJECT CATEGORY t

CAR PC 0602 Appendix Cadweld Type / Size A

B C

D E

F G

II J

K L

Totals 18-18TV 67 1

0 3

6 1

0 61 7

23 0

169 18-14TV 15 2

0 2

9 0

0 10 0

9 0

47 18-llTV 0

0 0

0 0

0 0

3 0

0 0

3 18-10TV 39 38 7

5 4

0 1

37 3

53 0

187 18-DV 10 2

0 0

2 1

0 0

1 0

3 19 11-BV 61 60 0

4 5

1 0

0 7

3 0

141 ll-Til 8

0 0

0 0

0 0

0 0

0 0

8 9-Tli 2

0 0

0 0

0 0

0 0

0 0

2 l

rotals 202 LO3 7

14 26 3

1 111 18 88 3

576 Key:

Appendix A No Gage Marks H Sleeve Not Centered B

Excessive Voids J Gage Marks Exceed Tolerance C

Excessive Recess K Gage Marks Less Than I

D Porosity at Sleeve Ends or Tap Hole Tolerance E

Slag at Sleeve Ends or Tap liole L Indetermanent - 2TII P

Tap I! ole Burnout and 2CM G

No Piller Metal Visible 1

.t CADWELD SAMPLING & TESTING FREOCINCIES HORIZONTAL VERTICAL DIAGONAL (For Each Grade & Size) 1P From ist 10 r

r lP From Splices 3S11-100 1P From Each or Subsequent 1.S Group of 33 Notes:

1.

Samples from curved bar production shall be straight sister splices 2.

Samples from B-type production shall be sister splices 3.

Selection of samples shall be from recognized methods of random sampling 4.

For back to back sister samples:

1S From 1st 20 s

2S From Splices11-100 1S From Each Subsequent Group of 33 O

9 m

mMW m e ewe m m =

6 y

d

'8 O'- 9"

,/ 6" RECESS j 316 RECESS

.(3 1 D = 2(3 )

/8 TAP HOLET SLEEVE f

n.mf / / smqc

^

ll gg N eC :n ll 9j X

ijco gb' i

i u

v o-l o

,- h-t VM/

//

/M/

"l8 6

  • D=3/ +2(%8)+3/16*9 " (IF THERE IS NO RECESS AND

/8 16 VOIDS WITHIN ALLOWABLE )

  • ENDS OF THE BARS SHALL BE WITHIN THE DIAMETER D.

o RADIOGRAPHIC EXAMINATION ACCEPTANCE CRITERIA FOR OFF CENTERED BAR ENDS 4

l-6 4

_'TRIBUTION OF VISUAL REJEC' s

D SPLICES CASES 328 Individual Splices, only 1 G.M. Defect 328 23 Individual Splices, only 1 G.M. Defect & 1 Phy. Defect 23 29 Individual Splices, only 2 G.M. Defects 58 4

Individual Splices, only 2 G.M. Defects & 1Phy. Defect 8

2 Individual Splices, only 1 G.M. Defect & 2 Phy. Defects 2

1 Individual Splice, with 2 G.M. Defects 1

Subtotal-Individual Splices with at least 387 1 G.M. Defect 420 109 Individual Splices, only 1 Phy. Defect 109 23 Individual Splices, only 1 Phy. Defect & 1 G.M. Defect 23 8

Individual Splices, only 2 Phy. Defects 16 4

Individual Splices, 1 Phy. Defect & 2 G.M. Defects 4

2 Individual Splices, 2 Phy. Defects & 1 G.M. Defect 4

Subtotal-Individual Splices with at least 1 146 Phy. Defect 156 CASES SPLICES 437 Splices with one Defect 437 46 Splices with 1 G.M.

& l'Phy. Defect 23 58 Splices with 2 G.M. Rejects 29 16 Splices with 2 Phy. Defects 8

12 Splices with 1 Phy. & 2 G.M. Defects 4

6 Splices with 2 Phy. & 1 G.M. Defects 2

1 Splice with 2 G. Marks 1

576 504 e

g 9

e

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