ML20203M936
| ML20203M936 | |
| Person / Time | |
|---|---|
| Site: | Sequoyah  |
| Issue date: | 09/03/1986 |
| From: | Bateman R, Lynskey R, Rose J TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML20203M897 | List: |
| References | |
| WP-13-SQN, WP-13-SQN-R, WP-13-SQN-R00, NUDOCS 8609050190 | |
| Download: ML20203M936 (7) | |
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- WELDING PROJECT
- GENERIC EMPLOYEE CONCERN EVALUATION REPORT REPORT NUMBER: WP-13-SON, R0 DATE 04-08-86 -
SUBJECT:
SUITABILITY OF WELDING EQUIPMENT FOR CONSTRUCTION AND MODIFICATIONS WELDING ACTIVITIES CONCERNS CONSIDERED: IN-85-247-002 IN-85-303-001 PREPARED BY Original Signed By J. E. Rose 4/3/86 , OC, WP REVIEWED BY Original Signed by R. Bateman 4/3/86 , 00, WP j
f REVIEWED BY Original Signed by R. P. Lynskey 4/3/86 , QA, WP I
REVIEWED BY/ ,9 [ -
,/ ,
/ , CEG-H, WELDING 19 APPROVED BY V ~ '
hkh ~
- , PROGRAM MANAGER
\ ,
t .
c 00320
1
. GENERIC EMPLOYEE CONCERN
SUMMARY
SHEET c.
Report Number: WP-13-SON, R0 Report
Title:
SUITABILITY OF WELDING EQUIPMENT FOR CONSTRUCTION AND MODIFICATIONS WELDING ACTIVITIES I. CONCERNS CONSIDERED: IN-85-247-002 IN-85-303-001 II. ISSUES INVOLVED
- 1. Welding machines (grid packs) do not have suitable control settings for welding with 3/32-E7018 electrodes.
- 3. All GTAW equipment should have remote (high frequency are starting) switches so that tungsten inclusions can be avoided.
III. STATEMENI 0F CONCERN / ISSUE VALIDITY l..
Validity: Y ,N I , Substantiated: Y ,N X IV. EFFECT ON HARDWARE AND/0R PROGRAM None V. JUSTIFICATION The equipment described in the concerns does have sufficient features to make acceptable quality welds. All safety-related systems receive inspections in accordance with the QA program.
VI. RECOMMENDATION AND/OR CORRECTIVE ACTION NEEDED ,
None t
' VII. REINSPECTION NEEDED: Y ,N I .
VIII. ISSUE CLOSURE By this report. .
II. ATTACHMENT - ;
- 1. Text of Employee Concerns l
Page 1 of 1 00320
1 GENERIC EMPLOYEE CONCERN Report Number: WP-13-SON, RO i
Report
Title:
SUITABILITY OF WELDING EQUIPMENT FOR CONSTRUCTION AND MODIFICATIONS WELDING ACTIVITIES I. SCOPE OF EVALUATION This engineering analysis covers the following WBN concerns determined to have possible generic implications at SQN:
IN-85-247-002 IN-85-303-001 II. ISSUES ADDRESSED BY CONCERNS Each concern was analyzed to determine the issues voiced by the concerned individuals. These issues are as follows:
- 1. Welding machines (grid packs) do not have suitable control settings for welding with 3/32-E7013 electrodes.
e b' 3. All GTAW equipment should have remote (high frequency are starting) switches so that tungsten inclusions can be avoided.
III. CONCERN VALIDITY OR SUBSTANTIATION The construction and modifications standards (AWS, ASME, ANSI B31.1) for welding provide general statements concerning suitability of welding equipment for particular operations. The standards simply state that welding equipment is to be suitable for performing the particular welding operations for which they are used. This general guidance provides the only code and standard reference to suitability of welding equipment for particular operations.
The choice of and assignment of particular types of welding equipment is made based on overall management and engineering judgements relative to the type activity to be accomplished, working conditions, space limitations, equipment availability, and suitability.
Q Page 1 of 3 00320
WP-13-SQN, R0 j .
,a When large sophisticated welding equipment such as full sized GTAW
- equipment is removed from a particular work area and is replaced with a more compact and simple type equipment (grid packs _or multiple operator systems) which will satisfactorily perform the same welding operations, some unnecessary convenience features such as extremely fine current control and high frequency are starting are not available. The lack of these features, which are not necessary for the production of
Welders are accustomed to the convenience and ease of operation of the more sophisticated equipment. They may not be fully aware that
- factors such as space limitations may dictate the use of smaller less i sophisticated equipment which will still perform acceptably but may require more individual skill and attention by the welder to perform operations such as GTAW with multiple operator welding equipment.
Further, the welders may simply not personally agree with such decisions and will complain about alleged inadequacies and unsuitability of particular equipment when such equipment will perform satisfactorily.
, Multiple operator welding systems have been used in the nuclear
, construction industry for both GTAW and SMAW welding operations and have a history of satisfactory service. They are not, however, as convenient to use as GTAW equipment which has additional features such as high frequency are starting and remote roostat current control; and, as such, they do not have the welder appeal that large GTAW equipment does which g can be used for either GTAW or SMAW welding.
Multiple operator units have a minimum five ampere welding current adjustment feature. Many units have a two and a half ampere minimum current adjustment. This current adjustment is not as sophisticated as the vernier current adjustments on GTAW equipment but is suitable for optimum current settings for both SMAW and GTAW welding operations.
i
! A review of commonly used Detail Welding Procedure specifications used )
l for Construction and Modification Work lists a current range of 75 to l 115 amps for 3/32-E7018, 100-145 emps for 1/8 E7018, and 130-205 amps I
for 5/32-E7018 for SMAW welding. The current range for GTAW procedures
- is35-130 amps. The current settings on multiple operator units are well within the acceptable range for both GIAW and SMAW welding.
Most of the welder performance qualification testing at Sequoyah, during both the construction and operations phases, have been conducted using multiple operator-type welding equipment systems without high
! frequency starting. This same type of equipment is utilized at the Browns Ferry Test Shop and in TVA's Mobile Test Shop. The satisfactory l use of this equipment for welder testing demonstrates its ability to i produce acceptable welds. Further, its use demonstrates the sbility of l TVA's welders to perform acceptable welds using multiple operator welding machines without high frequency starting. Test welds made using i this equipment do not demonstrate an extraordinary high amount of tungsten inclusions as would be evidenced if the premise of the concern
, @ held true.
l l
Page 2 of 3 00320
WP-13-SQN, R0 The issue of pinholes and porosity is a symptom of poor welding technique. Correct are starting techniques for low hydrogen electrodes will eliminate starting porosity. Correct welding technique (holding a short are length) and weld prep cleanliness, will eliminate pinholes in the deposited weld bead if correct welding current settings are used.
The issues of remote current and high frequency are starting controls are basically convenience features which welders prefer to have on their equipment. - -
1 Theso features are not necessary for the production of acceptable quality GTAW welds. Strike plates can be utilized for GTAW arc initiation and will effectively eliminate tungsten inclusions from GTAW welds.
An independent verification of welding equipment suitability can be made through inspections of completed welds. The WP reinspection at SQN did not reveal a large amount of problems mentioned in the concerns.
Based on the foregoing analysis, the issues considered in the subject concerns are to be closed based on the following factors:
- 1. There is no industry standard which mandates the use of specific welding equipment for specific jobs.
- 2. Equipment in use has sufficient control features to produce welds.
within the required criteria.
- 3. A; ternate techniques can be used to compensate for the lack of sophisticated features on multiple operator-type equipment and still produce acceptable quality welds.
- 4. The WP reinspection did not discover any indications of a generic problem with welding equipment.
- 5. .There is no effect on hardware due to these issues.
These issues are closed based on this report.
k Page 3 of 3 00320
Attschmtnt 1 03/24/ES CEMPLOYEE COfJCERNS) PAGE 1 of 1
,11r23:CB LOC STATUS RESP -OTC- PPP CFR 'INSP TC ------CCflCERN---- PROELEM ID 4
EGSG NO SR IN-SS-ES7-CO2 - SCMWE_
L . WORDS : EQUIPMENT WELD MACHINE MCKAY & HOSART X: W Y: C Z: N WELDING MACHINES (MCKAY & HOEART) USED IN FIELD SY STEAM FITTERS HAVE 2 SETTI5GS SO & 100 AMPS BOTH OF WHICH ARE UNSUITAELE FOR WELDING WITH 3/32" ROD. THIS CONTRISUTES TO POROSITY AND PINHOLES TECHNICAL COMMENTARY: 1 ISSUES CONSIDERED:1. WELDING MACHINES CGP.ID ?ACKS?DO NOT HAVE SUITABLE C0!!TEOL SETTINGS FOR WELDING WITH 3/32 E7012 ELECTRODES. E.THIS UNSUITASILITY LEACS TO PORCSITY AND PINHOLES IN COMPLETED WELDS.
LOC STATUS RESP -0TC- PP? CFR INSP TC ------CONCERN------- PROSLEM ID EGSG NO SR IN-SS-303-001 WCMUE KEYWORDS: EQUIPMENT UELD MACHINE REMOTE SWITCR X: W Y: C 2: N ALL THE WELDING MACHINES SHOULD HAVE REMOTE SWITCHES S0 THAT THE TUNGSTEN TIP DOESN'T HAVE TO TOUCH THE EASE METAL TO START THE WELD. PRESENTLY THE NOfJ-HOSART WELDERS, WHEN USED, MAY CAUSE TUNGSTEN TO SE LEFT IN THE WELD
.. TECHNICAL COMMENTARY:
'JES CONSIDERED:
C_(-l iLL GTAW EQUIPf1ENT SHOULD HAVE REMOTECHIGH FREQUENCY ARC STARTING) SWITCHES IMAT TUNGSTEN INCLUSIONS CAN BE AUDIDED.
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