ML20211A453
| ML20211A453 | |
| Person / Time | |
|---|---|
| Site: | Vogtle  |
| Issue date: | 02/09/1987 |
| From: | GEORGIA POWER CO., SOUTHERN COMPANY SERVICES, INC. |
| To: | |
| Shared Package | |
| ML20211A387 | List: |
| References | |
| NUDOCS 8702190173 | |
| Download: ML20211A453 (155) | |
Text
.'5 N 0 T E S THIS @ALITY CONCERN HAS BEEN REMOVED FROM THE PACKAGE IN THAT IT RELATES TO PERSONNEL ACTION AND IT DOES NOT AFFECT THE TECHNICAL CONTENT OF THIS REPORT. SHOULD ANY @ESTION ARISE ON THIS SUBJECT PLEASE CONTACT:
LEE GLENN
@ ALITY CONCERNS MANAGER (3
NJ V0GTLE PROJECT TELEPHONE NUMBER: 1-800-225-2055 THE FRACTURE MECHANICS ANALYSIS, IDENTIFIED UNDER TAB D OF THE ORIGINAL REPORT, WAS MADE A PART OF EACH DEVIATION REPORT AS AN ATTACHMENT.
IN ORDER TO PREVENT SUCH DUPLICATION IN THIS MODIFIED VERSION OF THE REPORT, THERE WILL BE ONLY ONE COPY OF THE ANALYSIS INCLUDED - UNDER j
TAB D AS BEFORE.
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T A'S L E 0F C0NTENTS
( t RESPONSE TO QUALITY CONCERN NO. 86V0515
~ TAB A CONSULTANT'S REPORT TAB B PULLMAN POWE,R PRODUCTS' DEVIATION REPORTS TAB C ROGER REEDY AND ASSOCIATES REPORT TAB D FRACTURE MECHANICAL ANALYSIS TAB E TENSILE TESTS TAB F OVERALL ACTION PLAN TAB G MECHANICAL DISCIPLINE CHRONOLOGY OF EVENTS TAB H CORRESPONDENCE TO PULLMAN POWER PRODUCTS TAB I STOP WORK ORDER TAB J PHOTOGRAPHS OF THE INDICATION TAB K COMPILATION OF AFFECTED PIPE - QTS TAB L DEFINITIONS TAB M GPC DEVIATION REPORTS TAB N WELDING PROCEDURE SPECIFICATION AND PROCEDURE QUALIFICATION RECORD O
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Georgia Powet Ccemetay PduClear CoeltruCf'On Decartmoet Poet Offree 80s 282 Wernescoro Georg,e 3:33o
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CONFIDENTIAL August 15, 1986 Mr. Lee Glenn o
SUBJECT:
Vogtle Electric Generating Plant - Units I and II Quality concern No. 86V0515 Response
Dear Mr. Glenn:
Subject Quality Concern addresses potentially defective welds identified in NSCW piping located in the 28 NSCW Tunnel. Specifically, the submitter states the weld was'made without complete consumption of the "K" insert. .
Subsequent to the initial Concern, the submitter identified inadequate purge as an additional problem.
I have met with the submitter to better understand his concern.
In addition to the specific items identified in his written Concern, he indicated excessive pressure from the superintendent and/or foreman probably contributed to the condition of the weld. Further, he indicated the individual who identified the problem was advised to not report it.
Finally, he has alleged that the questionable weld was ground on the inside diameter in order to hide the problem from investigation. He offered conjecture as to who would have been responsible for this grinding.
The submitter also provided the names of additional people who would possibly have knowledge of this problem.
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9 Mr. Lee Glenn .
Quality Concern No. 86V0515 Response i
O' Page 2 August 15, 1986 This Concern has been broken into two parts. The first part addresses the technical / hardware issues and whether or not a hardware deficiency
<,u.s os e.me.uea ss exists and if =ffMkr,4 require / rework or programatic corrective action. This part of th Conlern is being addressed by the Georgia Power Company Mechanical Discipline. Attached to this letter is a report from the Georgia Power Company Mechanical Discipline on the technical aspects of the Concern. As shown in the report, the Concern was substantiated in that oxidation and lack of complete "K" insert consumption were found. -
The evaluation indicates no detrimental hardware problem exists in that the pipe, as installed and welded, meets or exceeds design parameters.
Additionally, no programatic corrections are required since the inspection I .'
and documentation of the as-welded condition met or exceeded code, specification, and procedural requirements.
Part two of the Concern addresses specific management / supervisor L
action that could be detrimental to the quality of workmanship and installed components at Plant Vogtle. Based on the interview with the submitter, additional names have been identified and interviews are being conducted by Dick Janecke of your organization to obtain additional information for resolution of this part of the concern. Mr. Janecke has indicated that by Tuesday August 19, 1986, I will have the results of his interviews as well as his recommendations for further evaluation and action.
Since the hardware aspects of the concern were reported to the NRC l' as a potential 50.55e, Bechtel PFE is perfoming a detailed 50.55e analysis which will further support our response to this concern. Upon receipt of the recomendations from Mr. Janecke, we will advise you as to a plan
[ of action and timetable for corrective action, if appropriate.
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} To better understand our response, I offer the following
( The problem: A specific 24" weld in the unit !! NSCW piping was identified as having oxidation from loss of purge gas. unconsumed insert, mismatch, and The investigations
, An initial inspection was done of an 18" and a 24" weld / and tentatively substantiated the concern in that unconsumed established as follows:insert was verified., An action plan was All accessible ciasss3 stainless steel schedule 10 pip-ing over 12" in diametSr in the NSCW system was ins-pected.
Justification Tab A, Consultant's for these limits is provided in Report.
All inspection results requiring evaluation were doc-umented on PPP OR's. See Tab B.
Code experts from Bechtel
! and Pullman Power Products were askedplans and action to review code implications, requirements, as well as to review the specific indications as to their effect on the weld quality.
These experts also assisted us in determining the broadness of the problem or, stated differently, they verified the limits stated above. See Tab A.
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Further, for testing.
they assisted us in establishing parameters Roger Reedy and Associates were asked to co a similar
, and review independently, action plans. and to assist in developing tests See Tab C, Roger Reedy and Assoc-iates Report.
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Bechtel performed a fracture mechanics analysis based on a conservative worst case assumption. This was done with assistance from the consultants in establishing the assumptions. See Tab D.
Aintest was designed to test coupons. toTheseinduce the worst case assumption were subjected to tensile testing to confirm the assumptions. It should be noted that, in addition to testing for l ack of compl e te ins-ert consumption, coupons were also tested for oxi-dation. See Tab E.
Mismatch was eliminated as a concern since it i sfora af i t- uf requirement and is not an acceptance criterion finished weld.
be affected, butThe notcontour of the weld on the ID would the quality. See Tab A.
Oxidation was eliminated as a concern since in the con-
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-' l dition found, i,t was only a cosmetic defect and was not l r~T de tr imen tal to weld quality. See Tab A.
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Records reviews were done to determine if similar cone-eens had been voiced via our Quality Concerns Program, or by the NRC, our QA, or INPO. No previous concerns of this nature were discovered.
Records reviews were done to determine it the GPC surveillance program had picked up similar occurences.
No findings were identified.
Records reviews.were.done to determine if these spec-ific attributes (ox'ide, tion, incomplete consumption of the insert, and mismatch) contributed to rejectable x-ray welds. Only one case, unconsumed inser t, was found to have relevance. However, it was responsible for less than 2% of the overall reject rate for x-ray welds. This indicates that the process used is a sound process.
Records reviews were done to determine if any of the welders who worked on the subject pipe had had partic-ular di f ficul ty wi th respec t to the attributes of conc-ern. No evidence could be found to provide a link between welders' prior history and the current problem.
In fact, some of the welders who worked on the NSCW pipe had very low (less than 5% and some 0%) x-ray
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(')N weld reject rates.
This tends to indicate the welders were both qualified and competent for the process used.
Records reviews were done to determine the extent of QC inspections done on these welds and on the welds in
- unit I. In unit I, over 30% of the welds had recieved ,
a root inspection. In unit II, 10% of the welds rec-l eived this inspection. All welds were checked for fit-up and all welds received a liquid penetrant examina-tion of the final pass.
These record reviews showed the Pullman QC inspectors had performed their jobs properly in that they met or exceeded code and procedure requirements in performing their inspections. No welds were accepted and subseq-uen tl y found to be rejectable.
r Welding processes and procedures as well as welder L
qualifications were reviewed to determine if the proc-
[ esses and qualifications met code and spec. require-ments. No deficiencies were found.
l In addition to and parallel to these actions, a stop work l- was issued, an overall ac t i on pl an' was prepared (see Tab l '.
!' f), and the NRC was i n f orme d-th a t this was a potentially reportable item.
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Conclusions:
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( 1. Based on the fracture mechanics analysis and the tensile testing that was done, a hardware problem does not exist. The welds reviewed, and simil ar welds, mee t or exceed their required design parame ters.
- 2. There were no code violations in making these welds.
In fact, the inspections done in resolving this concern exceed code requirements in that these welds are considered inaccessible from a code standpoint and do not require internal inspection og volumetric examination.
. 3. The welders and the w47 ding processes were eliminated as major contributers of this problem. The problem was caused by the very thin wall, larger diameter stainless steel physically moving when heat was applied. As diameters ar6 oe reduced or as wa11 thicknesses increase the potential for this movement i$ reduced. Carbon steel is a much better heat transfer medium and poses even less potential for this type of occurrence.
- 4. Since no hardware problem was found and f ailure on the part of QC was not discovered, and since the welders and the processes were found to meet all requirements, no additional inspections and no rework / corrective action is required. .
- 5. There exists no requirement for internal inspection of the unit I pipe. The analysis performed assumed a worst
' case condition beyond what could reasonably be expected and test results substantiated the assumptions. Hydrostatic testing and preoperational testing of unit I give further assurance of the quality of the welds in question. For this reason we will not do additional inspections in unit I.
Additional information is provided to support our conclusions. The attached package includes a chronology of events from the Mechanical Discipline Tab G), Correspondence to Pullman Power Products (Tab H), a copy of the stop work order (Tab !), photographs of the indications (Tab J), and u.
compilation of the affected pipe (Tab K), e. . C . f ; .. . ; c-rw i
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As stated the submitters concern was substantiated. However no corrective action is required as stated above. The balance of this concern, as regards superintendent involvement in causing or hiding the problem will be addressed under separate cover upon receipt of the interview results and recommendations from your investigator.
M. H. Googe Project Construction Mgr.
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8/8/86 REVISION 4
- g. ASME CODE CONSIDERATIONS The field welds under consideration are classified ASME Section III, I Class 3 piping. The inspection requirements for a Class 3 piping weld is a surface examination by either liquid penetrant or magnetic particle methods. Radiographic inspection of Class 3 piping welds is a permitted alternative inspection method by Section III; however, Project specifica-tion requirements state that liquid penetrant examination is required for eastenitic stainless steel welds. The NSCW System welds were examined by liquid penetrant methods from the outside surface of the weld and docu-mented. In addition, fit-up inspections were performed with satisfactory results documented. These Section III required examinations will not and are not intended to ' determine the condition of the inside surface of
. welds. n A visual inspection of the inside surfaces of some of the NSCW System welds was performed and showed some areas of unfused insert, misalignment and slight oxidation. Having determined that unconsumed inserts exist, regardless of how detected, a detailed evaluation was required by Georgia Power to satisfy their Quality Concern Program. In this case 3 an engi-neering/ technical approach to evaluation was used.
It was decided that critical flaw size determinations be made using frac-ture mechanics analysis techniques to determine what design margins existed in the as-built condition. Flaw size analysis can be provided using conservative assumptions based on the geometry of the insert and the pipe faces. The results of the flaw size analysis are shown in O Appendix A. The analysis shows that with a 5/64 inch deep unconsumed 1~nsert for a full 360 degrees circumference around the weld, that the strength of the weld joint is sufficient to maintain ASME Code allowable stresses.
Other loading conditions have also been reviewed. Specifically, high
, cycle fatigue and seismic conditions have been addressed and have been determined to be acceptable. This conclusion is based on detailed eva-luation of the results of the fracture mechanics analysis as well as the low operating conditions (95'F and 145 psi) of the NSCW System and the extremely ductile nature of the materials specified.
For Class 3 components, including piping, the extent of nondestructive examination is left to the option of the designer. For longitudinal' welds in piping, if the designer chooses to use surface examination (liquid penetrant) on the outside of the piping instead of a volumetric examination (radiography). A joint efficiency (stress reduction factor) of 0.80 is applied in the formulas for design to account for the lower quality of the weld. It is accepted that the quality of the weld will be less than when the radiographic acceptance criteria are met and this fact is accounted for by reduction in the allowable stress used for design.
As far as the final design is concerned, the adequacy of both design options is equivalent and both meet the final quality requirements of the ASME Code. ,
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REVISION 4
!. A$1E CODE COR$10 ERA, TION (Continued)
For circumferential welds in Class 3 piping, the designer is not required to choose between nondestructive examination methods. The minimum requirements of the ASME Code, Section !!!, are that a surface examina-tion (liquid penetrant) is required, but as an option, radiography may be substituted. There is no jojnt efficiency (stress reduction factor) involved because the actual stress in the circumferential welds of piping due to pressure is only one half the pressure stress in the longitudinal welds. Also, there is no change in stress intensification factors for piping design to account for the difference in examination methods.
l In reviewing Section III.. piping, the examiner must be aware of the para-meters allowed to the designer, and judge the adequacy of welds in accor-dance with the acceptance criteria specified by Section III. If the designer feels that con.ditions warrant more restrictive acceptance cri-teria, the ASME Code provides options for him to utilize. When the piping installer meets the ASME Code and project specifications, both Federal and State requirements have been met. Other criteria, not spe-cified by Code or regulations are not part of the Federal regulations j regarding the design, construction and installation of piping.
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- II. LIMITS OF CONCERN The concern regarding unconsumed inserts is limited to Class 3 piping since Classes 1 and 2 require RT (volumetric inspection) which would detect unconsumed inserts for subsequent repair. A review of 1579 radiographs for Class 1 and 2 welds indicate a 1.25 rejection rate (19 welds) for unconsumed insert. These were limited to a relatively small portio *n of the I.D. The low rejection rate indicates that this problem doesn't occur with great frequency.
The NSCW System welds, however, are proving to have a higher percentage of such indications, even though they were made by the same group of
. welders. The unique feature of this system is that it is constructed of
! large diameter (14-24"0.D.) thin wall (Schedule 10) austenitic stainless steel pipe.
4 l Some considerations which may have contributed to the increased frequency of unconsumed inserts in this large diameter, thin wall pipe are:
- 1) The 0.D. of A312 (welded without filler metal) for larger sizes is less precise and shows greater variation than smaller sizes. The pipe is also prone to greater out-of roundness problems. Both of these conditions result in greater fitup difficulties i.e. fitup pro-bably varies between the extremes of permitted tolerances more fre-quently than in smaller diameters and heavier walls.
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REVISION 4
!!. LIMITS OF CONCERN (Continued)
- 2) The ASME Code provides parameters to be met for fitup prior to the start of welding. After fitup has been accomplished, prior to the i start of welding, the Code requirements have been met. The purpose
! of these fitup parameters is to assure that the final weld will meet
- the acceptance criteria as evidenced by the nondestructive examina-l tion. After the start of welding, movement will occur between the t
members being joined. This is a natural phenomenon whenever large amounts of heat are introduced to metal. This is a law of physics L
which was known when the Code requirements were formulated.
Therefore, when the final weld pass has been deposited, the original
!~ fitup will no Ibnger-exist. In fact, its existance would be an l , impossibility. For thk reason, the fitup after welding has never L been part of the acceptance criteria for the ASME Code or any welding i
Code. The fact that fitup changes after welding was emphasized by i.' the ASME Code Consnittee when the fitup requirements for socket welds were clarified in Section III about two years ago. The change empha-sized that the fitup clearance would not exist after welding.
- 3) Welding of stainless steel, particularly of the sizes involved requires a delicate balance of heat input for three reasons: *
(a) Stainless steel exhibits poor wettability (low flow character-istics). This results in a greater difficulty for the melted insert to flow and wet the inside of the pipe. Higher heat input is needed. ,
(b) Stainless steel has greater resistivity (Iow L at conductivity).
This means that the heat sink (ability of the base metals to drain off heat from the weld puddle) is low. This can result in an excessive amount of heat and can easily result in a burn thru.
(c) Stainless steel is subject to sensitization (carbide precipita-tion) in the heat affected zone adjacent to the weld. To mini-mize sensitization, contractural requirements limit the heat input. Conservative practice dictates lower voltage and amperage ranges and faster travel speed to minimize sen-sitization.
Concern for melting the insert would dictate higher heat, lower speeds, but burn thru and sensitization would dictate lower heat, greater weld speeds.
Purge windows (1/8" x 1" long sections where the insert was removed) were used to observe the I.D. during welding in order to control heat input. In some instances these windows were used to perform a visual examination after welding, " Root Visual Inspection", (see Part IV).
No I.D. inspection could be performed of the window closure.
Considering the above factors, the problem is limited to the large diameter, thin wall stainless steel.
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REVISION 4
!!I. FURTHER REINSPECTION Further reinspection is not required based on the following information:
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- l. Fracture analysis shows the unconsumed insert condition to be accep-table even with a conservative flaw size. The flaw is postulated to be S/64" (1/2 the insert depth) deep, 360* around the circumference.
It should be recognized,that when the welder melts the insert, the resulting root weld is approximately 1/16" to 3/32" thick. The welder, in preparing for subsequent passes, visually examines for any indications and an indication 5/64" deep would have been apparent.
In any case, the indication would be remelted in depositing the second pass, making the' flaw depth smaller than the postulated 5/64".
It is unlikely that a flaw of this depth would occur for a full 360' around the pipe.
- 2. The use of volumetric (UT or RT) examination methods are not mandated I by the Code for Class 3 construction piping. The Code mandates surface examination (liquid penetrant or magnetic particle) or radio-graphy.
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- 3. Deviation Reports and Inspection Reports refer to mismatch in terms of an acceptance criteria on complete Class 3 piping weld roots.
Mismatch is limited by the Code during fit-up, a prewelding con-dition. Once the root pass is made, the weld, a misaligned con-dition is not subject to any weld accept / reject criteria,for ASME Class 3 piping.
IV. QA/0C PROGRAM ASSESSMENT l As a result of Quality Concern 86-V-0515, Pullman and GPC Quality Control
! Groups have performed additional weld inspections on portions of piping within the Unit 2 NSCW System. These inspections were conducted by going inside the pipe as indicated in Part III above. Concurrent with this activity, a documentation review was performed to determine which welds had " Root Visual Inspection" (I.D. visual inspection thru " windows") as hold points after root pass welding. This was an "in-process" inspection activity.
Of the welds in question, two (2) had been assigned " Hold Points" by the Inspector for Root Visual Inspection (I.D. visual inspection thru " win-dows").
Re-evaluation of these welds revealed the following:
Misalignment Unconsumed Insert (where purge window was sealed)
Oxidation (sugaring)
, Unconsumed inserts have been evaluated by the fracture mechanics analysis
(. as being acceptable. Further, the results of transverse tensile tests performed on simulated welds containing misalignment, unconsunened insert O. and oxidation shows more than satl 'actory breaking loads and stress values to accomodate all of the consiured conditions.
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,. REVISION 4 IV. QA/QC PROGRAM ASSESSENT (Continued)
Sugaring indicates a partial loss of purge gas, possibly due to use of inspection windows. This is not a Code problem and the cleanliness of weld I.D. in this system due to this condition is not detrimental to ser-vice.
Visual inspections were performed as an inprocess inspection, not man-dated by Code and thru purge windows where the visibility of the root is poor and detection of the noted conditions is extremely difficult.
Recognizing the inherent limitations of inspection thru windows, the in-process verification- of the root condition is creditable and within
. the procedural guidelines and the inspectors capabilities.
To determine why there was a difference in the number of " Visual Inspection Hold Points" between Units 1 and 2 on System 1202, a review of
- governing inspection procedures was conducted.
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All process sheets for those welds associated with the DR's have been reviewed. It has been verified that the welding procedures used and all welders involved were properly qualified. This assures that ASME' Code requirements have been met.
l The governing procedures included the Pullman General Welding Standard, Welding Procedure Specifications and Final Weld Inspection Procedure.
O Welding and inspection requirements for in-process and final weld inspec-tion were the same for both units.
Root inspection is not a mandatory " Hold Point", but is an optional point which may be utilized by the QC Inspector based on the conditions relating to the specific weld. A review of Process Sheets indicates dif-ferent Inspectors were involved in the welding of Units 1 and 2. Since the inspection is optional there is no requirement as to the degree of application.
Based on the above evaluation, it has been concluded that a QA/QC progra-matic breakdown has not occurred.
I V. SHOP WELDS VS. FIELD WELDS Both shop and field welds were made with the Gas Tungsten Arc Welding (GTAW) process to Code (ASME Section IX) qualified procedures utilizing a "K" insert for the root pass and with filler metal added for remaining passes. The term shop welds refers to those made at the PPPC Williamsport, Pennsylvania Plant, and the term field weld denotes those
] made in place at the site or in the site fab. shop.
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I REVISION 4 V. SHOPWELDSVS.FIELDWklDS(Continued)
( During the internal inspection of field welds conducted by crawling inside the pipe as outlined in Part III above, approximately twenty-five shop welds were checked. Some had been ground on the 10. Of the twenty-five shop welds inspected internally only one (1) had a condition of Accordingly, shop welds can be elimi-misalignment (1/8" by 6" long).
nated from this consideration.
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ATT ACHMENT #/(,
C.W. Rau Georgia Power Company Vogtle Nuclear Site -
Subject:
Pullman's Position Relative to the Term " Accessibility" for Inspection Purposes ,
Dear Mr. Rau,
It is Pullman Power Product's position that the internal surfaces of the ASME Class 3 welds on the below listed DR's were inaccessible for final visual inspection: ,
Oeviation Reports 15627 15635 15628 15636 O 15629 15630 15631 15637 15638 15639 15633 15634 15640 3?'o @k4 i~-#'
Accessibility in ASME Section III terms means no special techniques on proce-dural steps need be taken to accomplish the particular ~NDE method to be used.
The use of auxiliary lighting, provisions for breathable air and the use of safety lines as employed in the visual inspection utilized in the identification of these conditions are hardly usual or normal in technique or procedural terms.
Recognizing that visual inspection is not a required NDE activity for Class 3 welds, Pullman has taken the ASME's interpretation relative to accessibility for application to our procedural requirements.
Should additional information be required, please notify innediately.
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Pullman Power Products QA Manager XC: B. Edwards 'N R. Davis JEM/ terry
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DISPOSITICHi USE - AS - IS
. ACTICH TO RESOLVE /INSPECTICH REQUIREMENTS: NONE JUSTIFICATICH: ACCORDING TO PPP POSITION LETTER DATED AUGUST 13, 1986, J.E, N!LLER TO C.W. RAU, THESE WELDS WERE CONSIDERED IMCCESSIBLE FOR INTERML VISUAL MD NDE EXAM!mTIm. .
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ensovessocims ENGINEERING MANAGEMENT CONSULTANTB August 8 1986 SPC-02-061 , Mr. Michael Googe . Project Construction Manager ' Plant Vogtle Storgia Power Company - Post Office Box 4545 - Atlanta, GA 30302
Reference:
Georgia Power Response and Corrective Action for Quality. Concern Item No. 86-V-0340 0 0 sr ar. . . Welding Concern item No. 86-V-0340 has been detennined to be limited to ASPI Section III, Class 3 Stainless Steel, thin wall, large diameter piping for the NSCW $ystem. A document review of inspection records, field inspections of the NC$W system, and sampling evaluations of other types and sires of, piping, supports the conclusions that the NSCW System meets A$ME Section III Code requirements. Quality Concern Item No. 86-V-0340 was identified to Secrgia Power through it's Quality Concern Program. This Quality Concern Item identifies the existence of a partially unconsumed welding insert on the inside diameter cf the pipe. This Quality Concern item was not identified by the inspections performed in accordance with the requirements of the ASME Section Ill Code, because the inside surf aces of welds in this tne of piping (ASME Class 3) do not require inspection after welding. The requirements of ASME 5ection !!! Code for Class 3 piping of this tne address fit-up prior to welding, and requires a liquid penetrant examination on the outside diameter of stainless steel pipe af ter the completion of the welding. Af ter the initial Quality Concern item was identified, additional fleid inspec-tions found similar conditions in other large diameter thin wall piping in the NSCW system. Georgia Power then reviewed other piping of similar materials, diameter and wall thicknesses for both units of the Vogtle plant to determine if any relationship to this Quality concern 3 tem existed, but none were found. Georgia Pcwer's and Pullman Power Products Corporation's Quality Pecgrams confirm-records ing that the were reviewed original acceptanceand it was wasfound that all welds in accordance were acceptable,irements. with ASME Code requ Other related QC and QA docmentation, such as weld precedures, material speci-fications, and qualifications were also checked and found to be acceptable.
-. . -. -.- . .^::.-
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(...- .. I Mr. Michael Scoge August 8, 1986 - Page Two 5 cme of the B31.1 piping were also reviewed -and determined to be acceptable. An evaluation of the piping, material, welTmetal, welding equipment, welders and procedures, their qualifications and control of application was conducted. All items were found to .be.petisf actory and within the requirements of the A5ME Code. n . In addition to the documentation review inspections, and QA/QC assessment, a fracture mechanics analysis was performed,by Bechtel National Incorporated (Y. Chung). $ ample weld specimens were produced by Pullman Power Products Corpora- o tion to represent a worse case condition as described in the fracture mechan- e
' les analysis report. The specimens documented in the report represented three welding conditions representing mismatch, sugaring or loss of purge, and incem.
plete consumption of the consumable insert. Three specimens from each type of weld condition described were prepared and tested. The details and results of ' these tests are included in a report prepared by teorgia Power Company address-ing Quality Concern Item No. 86-V-0340. We have reviewed the results of the analysis and tests and agree that the results confirm the adequacy of the welds.
+ O Que review of the calculations and test results confirm that Georgia Power's approach and the results presented in their report leave no cause for this, or similar weld conditions in other piping, to be of concern.
i The review of the details of Georgia Power's action plan in response to Qual-l tty Concern item No. 86-V-0340 led to the following conclusions:
- 1. Appropriate Georgia Power managenent personnel participated in the prepa-ration of the Project Plan and the final report.
- 2. The Georgia Power Quality Concern Program is appropriately organized with management being responsive to both the concern of the individual and the condition being reported. Georgia Power management was quick to respond to this item and assigned the appropriate department personnel and qualified engineers to determine the scope of the concern and resolve the condition. .
- 3. Georgia Power's Quality Assurance /Ouality control Prortm is designad to meet ASME requirements and to assure appropriate levels of product qual-ity. We are convinced that these Programs are staffed with qualif ted personnel. There has been no evidence in Quality Concern Item No.
86-y-0340 of a Quality Assurance Program breakdown or any neglect by l Georgia Power's rnanagement. It is evident that the manner in which Eeorgia Power's Programs are designed and implemented in conjunction with their Quality Ccncern Program, offer an extra step to assure a high quality product. i i
g_ .. io Mr. Michael Googe Au6ust 8,1986 Page Three
- 4. Georgia Power's willingness to respond to the concerns initiated through the Quality Ccncern Program by using top managonient and delegating compe.
tent individuals, to evaluate these concerns is evidence of a goed over-all program for resolving issues raised by individuals.
- 5. . Based on a review of the actions taken regarding Quality Concern Item' No. 86-V-0340 we have detemined that Georgis Power s QA/QC Programs are being properly implemented to resolve issues of concern. The QA/QC Pro-grams have the capability and are being applied, to control procedures, -
materials, welder qualifications and their application at the Vogtle site by both Georgio Power Company and their contractors, such as Pull-man Power Products Corporation.
- 6. It is evident that safety and quality are of a prime concern to Georgia Power based on their response to Quality Concern Item No. 86-V-0340.
On the basis of our involvement in this review we are prepared to support the conclusions of this effort in whichever manner you may deem oppropriate. \O Ver{,trulyyour, R ger . e
--De -
Francis C. Berry Pre dent Associate
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-4 be-PF a m AmewnW3 Bechtel National, Inc.
O . So8,n . - c .i,utto,e Fifty Seale Street
- SanFrencisco.Cahtornea - ._.
- Aded Aesroes 8 0 see Mt SeaFransince CAediie To: D. L. Einasch File. No.' YC-086-41 (Rev.1)
Subject:
Evaluation of Nonfused,. Dates August 1, 1986 Consumable Inserts in ,, TF 304L SS Piping Systema From: Y. Oiung
- Vogtle Project
- Bechtel Job No. 9510-008 Of: R&D/ Materials and Quality Services Ddpartment .. ,
Copies : F. C. Breisasister/R. A. Minley At: 30/15/527 Ext. 768-1489 N. M. Evana
- 3. D. Eschney .
R. A. Kaidel
- 1. L. Rogers R. W. Straiton R. A. White (2)
DCC 1428157 (Norwalk 430173) O Re fe rences : (1) Facsimile Request for Evaluation of Flaws, from R. A. Kaidel to T. Chung, July 28, 1986 D. A. Rale, et al.: The Crowth and Stability i (2) of Stress Corrosion Cracks in Larte-Diameter BWR Pipina, Volume 1: S amary, NP-2472-ST, Final Report, July 1982 Electric Power Research Institute (3) D. M. Norris, T. U. Marston, S. W. TaSart, Jr.: - Acceptance Criteria for Circumferential F1sws in Stainless Steel Piping ASME FVP-Vol. 58 Aspect of Fracture Mechanics in Pressure Vessels and Pipina, pp. 185-200 ASME, 1982 (4) Mr. C. Cernan, Y. E mar: Elastic-Plastic Analysis of Crack: OP +aieg. Seeble Gecarth and Instability Behavior in Flawed 304 SS Piping. ASM FVP-Vol. 58 Aspect of Fracture Mechanics in Pressure Vessels and Pipina, pp. 109-141, ASME, 1982 (5) M. F. Kanninen, C. M. Popolar: Advanced Fracture Mechanics, Oxford University Press, 1985 (6) M. D. E mar, et al.: Advances in Elastic-Plastic O Fracture Analysis NP-3607, Electric Power Research Institute, Auguac 1944 l I
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( D. L. Einnash page 2 August 1. 1986 . We have been requested to determine whether or not assumed flaws in TF 304L stainless steel piping systems are acceptable,on the basis of fitness-for-service. Based on limited enamination, some of the rectangular inserts in girth welds in TF 3ML stainless steel piping systems (14- to 24-inch i diameter, schedule 10) may not have been comple'tely fused. The nonfusion I condition any exist only on one side or both sides of the insert. It was i postulate; that the portion of the insert toward the inside surface of the pipe rey have been unfused up to one-half the insert height. Thus, the height l (or the depth) of nonfusion may range from 3/64 to 5/64 inch. The design data for these TF 3ML stainless steel systems and a typical joint design with a - rectangular , consumable insert are provided in the Appendia. . We have used fracture mechanics methodologies in evaluating these postulated, flaws. These methodologies have been recognised and widely accepted by engineers and regulatory agencies. Based on the results of the following fracture analysis using these methodologies, it is our opinion that the flaw condition 1'(naasty nonfusion up to 5/64 inch on one or both sides of rectangular inserts) will be acceptable with the required margin of safety. Based on this. conclusion, we recommend that the piping systems with nonfused O flaws up to half the insert height for the full circumference of the pipe be accepted as-is. A considerably deeper flaw (e.g., up to the entire height of the insert or 5/32 inch) any be acceptable depending on the length of nonfusion. Because of the nonpropagating nature of these flaws under the operating and design conditions, no monitoring will be necessary during the 40 years of plant operation. The details of our analysis are provided below. Fracture Evaluation of Assumes Flaws The results of a number of investigations suggest that material with weld flaws (and material flaws) in size and amounts exceeding the current workmanship acceptance criteria in design and construction codes may still be - fit for intendsd services. ASM Codes recognise this. So do the US NRC and the Department of Transportation (e.g., Alyeska Pipeline). Flaw evaluation methodologies, based principally on fracture mechanics, provide a quantitative techical basis that aids in the decision-making process for accepting or rejecting flaw indications. 'ASM has adopted a linear elastic fracture aschanics (LEFM) method in Sections III and II in evaluating flaws against - - brittle fractures. Specifically, Appendix A* in ASME Section XI provides a methodology for calculating stress intensity factors (Eg) for analysis of flaws in ferritic steels with acceptance criteria provided in IW5-3612 for ! Class 1 systems. For stainless steel piping, however, ASME has adopt'ed a e limit load evaluation approach, as indicated in Appendix C* of Section XI. This is because stainless steels such as TF 304/304L are so ductile and tough that LEFM is not really applicable. (The results of using LEFM on TF 304L will be too conservative.) Whereas brittle fracture is the primary ,
- Neassadatory appendices in A33E gection II
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Amwwer*r D. L. Kinasch fO-Page 3 August 1, 1986 l l concern in evaluating flaws in ferritic steels, the dominant mode of failure l in stainless steels is by plastic instability and collapse. This approach assumes that failure will occur when the remaining ligament' at the flaw location reaches the plastic collapse condition. This has been proven by both tests and field enperience'which have shown that 'TF 304 stainless steel pipe will fait due to plastic collapoeirior to tearing or other instability. The effects of f1 e on the structural integrity and fluid leak of TF 304/304L stainless steel piping systems have been extensively investigated since the advent of intergranular stress corrosion cracking (ICSCC) in boiling water . .. reactor piping systems in 1974-1975. These investigations have culminated in-failure assessment diagrama. One example applicable to the present case is shown in Figure 1. The details of this diagram say be found in References 2, and 3*. The use of this diagran has been justified by experimental data and field experience. It has been shown that the use of this diagram, based on a limit load analysis, is an accurate and simple way to predict failure of stainless steel pipes containing circunferential flaws. Using the acceptance criteria in ASE Section II as a guide, components with known flaw indications may be found to be suitable for service and acceptable O as-is, if it can be demonstrated that the presence of such flaws does not decrease the margin of safety. The margin of safety required in IVB-3642 for Class 1 austenitic stainless steel piping is as follows: 1 ! Fdr normal operating (including upset and test) conditions = 3** l For emergency and faulted conditions = 1.5** i The above criteria apply to Class 1 piping. For Class 3 piping, the acceptance criteria are still under preparation. For the sake of censervatism, we applied the safety margin required for Class 1 to Class 3. Figure 1 shows that any combination of flaw depth and length below Curve (3) will be acceptable with a safety factor of 2.8***. Since this diagram is
, based on flaw size rather than load, as indicated in IWB-3642, there is some y discrepancy between the margin of safety factors. It is considered that a
, safety factor of 2.8 in Figure 1 is equivalent to 3 based on load. For e
simplicity, the shaded men bounded by straight 1ines has been suggested for
.' evaluating f1p acc4 g.Tility. It can be seen that for full circumferential, part-throughl flaws, a fi.aw depth corresponding to 40 percent of the well thickness will be accogable with the required margin of safety .(3 based on lo.id) . For ' flaws encompassing less than half the circumference (i.e.,3hr=
0.3), the 45-degree straight line is suggested for evaluating flaw l
- This diagram or the approach is being considered for inclusion into -
! ASMg Section II.
** Based on load.
*** 2.773 is fictitiously accurate. It should be rounded off to 2.8.
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D. L. Kinasch - O Fase 4 August 1, 1986 acceptability. An upper limit for d/t has been set at O'.75 to prevent fluid leaks rather than to prevent structural failures. It can be seen that for flaws extend (as over three quadrants (or 270.d.egrees), the d/,t ratio can be as high as 41.5 percent according to Curve (3). This happens to be the same ratio that half the insert height will have in a 0.183-inch pipe well thickness for pipe eises 14,167'and 18 inches.' If a 1/32-inch allowance is made in fitting an insert to the girth weld joint (as shown in a typical joint design in the Appendiz), half the insert height will be only 25 percent of the wall thickness. Thereforo, the flaw depth / wall thickness ratio will more likely than not be lower than 40 percent. It can also be seen from the dotted I lines with arrows in Figure 1 that a flaw with a 75-percent wall thickness l ratio encompassing 80 degrees of the circumference (or more than 10 inches in i a continuous length in 14-inch diameter pipe) is still acceptable from a structural integrity point of view. It will be shown later that this will ,
- also be acceptable from a leak integrity point of view. For larger. diameter pipes (20, 22, and 24 inches), the d/t ratios are much lower. gee the table at the top of Figure 1. Thus, they present even a lesser probles.
For emergency and faulted conditions, the required safety factors are lower l (1.5 vs 3) than for normal conditions. As indicated by Curve (2) in Figure 1 O much larger flaws than allowed for normal conditions are acceptable for emergency and faulted conditions. This is consistent with the acceptance criteria (IWB-3612) for ferritic steels. For P. + pb = go, which is the sua of the. primary membrane (P ) and ! primary bending (ph) stresses equal to the design stress intensity value (S.), Curve (1) in Figure 1 predicts that the maximum depth for a, full l circumferential part-through crack is 75 percent of the wall thickness. Under l the same condition, the pipe can sustain a 147-degree through-wall crack. l With a safety factor of 1.5 for emergency and faulted conditions, for example, Curve (2) predicts that a full circianferential, part-through crack with a depth equal to 66 percent of the wall thickness or a through-wall crack -
- encompassing 133 degrees can be sustained. With a safety factor of 3 (based on load), Curve (3) predicts that a full circumferential, part-through crack with a depth equal to 40 percent of the wall thickness or a through wall crack encompassing 65 degrees of the circumference can be allowed.
An insert may be unfused on one side or on both sides, se stated beforts 6 Monfusion on both sides of an insert is analogous to two cracks in a close proximity, separated only by the insert thickness of 1/8 inch. Double cracks in a close proximity will actually act like a blunt flaw, resulting in a lower stress intensity factor (Eg) rather than increasing it. The re fore , the acceptance limit for one-sided nonfusion is equally applicable to two-sided nonfusion, though more conservative. O Figure 2 provides a comparison between the load corresponding to crack initiation from a flaw based on a plastic fracture mechanics (J-integral)'~ analysis for TF 304 stainless steel pipe and the not section stress c rite rion. The plastic collapse line indicates that a full circumferential i I :
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!O D. L. Einasch page 5 August 1, 1986 flav with a depth half the well thickness (d/t = 0.5) will sustain about 30 kai stress before a failure will occur by plastic collapse. The data points along the line verify that the limit iced analysis based on the not section criterion is conservative. - -
Table 1 presents the results of calculations for the internal pressure (limit
' load) that may be sustained by the pir containing a full ciremferential part-through flaw, using the equation shown in the lower half of Table 1. The results are plotted in Figure 3. It can be seen that when a flow stress
- of 48 kei is used, the limit load P. is higher than 260 poi for all pipe sizes, .
as shown in Figure 3. This is the lower bound value for 14-inch pipe with a 5/64-ir.ch deerp full ciremferential flaw. Therefore, it may be concluded that either single- or double-sided nonfusion of consumable inserts up to one-half the insert be!ght (5/64 inch) in pipe-to-pipe sisth welds is acceptable with
- the required margin of safety.
Now let ue ' consider the other aspect, namely a flaw growth analysis as required by IW5-3641. A flaw may. grow during service due to fatigue or stress corrosion cracking in stainless steels. Recent investigations on fatigue crack initiation and propagation using fracture mechanics have shown two O significant findings: (1) A threshold stress intensity factor range (AKthreshold) exists below which a crack is nonpropagating regardless of the number of stress cycles imposed. (2) The rate of fatigue crack growth (da/dN) can be expressed in terms of a stress intensity factor range (AK)**. l ASME Section XI, Appendix A, includes " reference fatigue crack growth curves" ! for carbon an t low alloy ferritic steels. For example, Tigure A-4300-1 - provides the following fatigue crack growth rate for a surface flaw in a reactor water environment. da/dN = (1.02 x 10-0) 61595 microinch/ cycle *** The stress inteceity factor range AK may be calculated using 1.ETM, since the stres: :ycis: in olved in fatigue cracking are assumed to occur in the elastic re gion. 1.EFM provides the following equation for a stress intensity factor range, corresponding to a strese amplitude or stress range. -
- The flow stress is usually assumed to lie between the yield strength (about 30 kai) and the tensile strength (about 70 kai). The value of 48 kai for a flow stress was assumed based on experimental data O (Reference 2).
** da/dN = C(AK)", where C and a are geometry and material constants, respectively.
*** For E = Emin/Imax = 0 in Figure A-4300-1 in AstE Section II, Appendia A.
L._.:.= := m . _.. r . :._ 2 - - . ~ __ _;------ : - _. _ ,, . . . b2-ff- /S&2-7 ; Airmair* 8 D. L. Einasch ! (O Page 6 August 1, 1986 l l
. .. . . _ _ )
AKg = ac/FI F(d/t, Eg/R,) whette Kg = stress intensity factor.tange ac = stress range , d = flaw. depth .
- t = pipe well" thickness Rt /R, = ratio of pipe inside and outside diameters F = shape factor The shape factor F for a full circumferential, part-through flaw is estimated at 1.5 (Reference 6). aKg is then given as follows: -
Kg = ac/0.078w (1.5) = 0.742ac Substituting the above into the da/dN equation on the previous page, da/dN = (1.02 x 10-0)(0.742 ac)5.95
= 1.73 x 10-7 (Ac)5.95 microinch/ cycle Assuming a maximum stress range is equal tc one-third the design stress intensity value S. (16.7 kai for TF 304L) in ASME Section III, da/dN = (1/3+16.7)S.95(1,73 x to-7)
= 4.72 x 10-3 microinch/ cycle or
= 4.72 x 10-9 inch / cycle .
Tor a maximum of 1000 cycles, the calculated fatigue growth from a 5/64-inch flaw would be 4.72 x 10-6 inch, which is a meaninglessly small quantity. For all practical purposes, it aey be ignored. Seismic events will have no effect on the above fatigue crack growth. Vibrational stress ranges mayle shown to be below the threshold value (AKthreshold), which is about 6 kai/in. Therefore, it may be concluded that there will be no fatigue crack growth from ~ the postulated flaws due to nonfusion of inserts. IGSCC is strongly dependent upon the environment and material properties, particularly the chloride content in the water and the carbon content of the pipe material. IGSCC in nuclear power plants has not been a problem with low carbon grade stainless steels such as TF 304L. This is true with vacar as the fluid containing only 6 ppa chloride at relatively low service temperatures (i.e., 95'F). It is our opinion, based on experience and published literature, that IGSCC will not occur in these TF 304L piping systems under the design and operating conditions. Therefore, it may be concluded that the initial flaws will not grow during the life of the plant. Thus, once accepted, no monitoring will be required on
' ~
t I l . i l l ..
h = - . - ... ._ : ; : :: L.: -...; _...----- , . . _. -. . . . :. u z.:. z;.::: ar- - - - . _ _ ~^
-fh'/OhA]
Awaster 9
, D. L. Einasch Page 7 August 1, 1986 these fisws. This is also the reason the use of an upper limit of 0.75 for 4/t will provide an assurance for no leaks as well .as structural integrity with the required margin of safety. -
. Chung
. d
.u.n. ..
Attachments , O e O . I
. ; . - 3 . .r: .- .; ; -. . -
ff~['h- /6 b A]
~
. Amacanzir#/0 APPENDIX O .
DESIGN DATA FOR TF 304L STAINLESS STEEL FIFING 1 (1) , Material: SA312 Welded Grade TF 304L 8'tainless . Steel Pipe (2) Fipe Sise: 14 16,18, 20, and 24.-inch, Schedule 10 (3) Welding Filler Metals: . (a) SFA 5.30 ER 308L Aectangular Insert, 1/8 x 5/32 Inch (b) STA 5.9, ER 308L Wire / Rod .. l (4) Tempe rature s : 150'T Maximum Design, 95'F Operating (5) Pressure: 200 psi Maximum Design,145 psi operating . (6) Fluid: Water (6 ppa Chloride) (7) Number of Pressure cycles in 40 Tears: 1000 Maximum i' (8) Design Code: ASME Section III, Class 3. Winter 1977 1
~
+ i TYFICAL JOINT DESIGN i 4;::- ' ~. .:::.7
!.I $
l ..N f 0 k\ 4 1/14 typical J --* 1/8 '* 5/32 0 1/32 O .. i l
^~... h:: :- h - b - ~ - i:_ - -
^ ^~ ~ ^
. . . . .: ^:i ., . - - -
o#-MM-/5Lt7 k f N Nf f "//
,O ' . .
Table 1 The Results of Limit Load Calculations for Fully Circumferential Part-through Flaws (d = 3/64, 5/64 inch, 360 degrees around) (d = 3/60 (d=5/64') For 7 = 48 ksi 2 R, t Rt "R R C2 R2 -R2 1 Q -R e Poi l P oy e1 14 7 0.188 6.812 6.859 6.89 1.93 1.53 m pst psi l 16 8 0.188 7.812 7.86 7.89 2.22 1.75 386 305 18 9 8.86 8.89 2.5 1.97 436 344 0.188 l8.812 20 10 0.218 i 9.782 9.83 9.86 3.37 2.78 588 , 484 22 11 0.218 10.782 10.83 10.86 3.71 ! 3.06 647
- 534 24 12 0.250 11.750 !11.79 !11.83 5.0 4.05 872 705 O
Limit load (Reference 5) Po = (2//3)0w(R, -R2) where Po = limit load (internal pressure) psi c = flow stress, ksi ~ Ro = pipe outside diameter, inch Re=R4*d Rt = pipe inside diameter, inch t = pipe wall thickness, inch l d = flaw depth (di = 3/64, d2 = 5/64 inch) k 4 k .
.= .- ._ .-
b A-/ W- / Ra2 ") t 41 Flaw
- Ratio 41/t d2 Flaw d2 /s Ratio gggg[/g pipe Wall Thickneso Depth Death j Sise 24 0.133 3/ 64 0.25 5/64 0.415 0.148 3/64 0.25 5/64 0.415 16 0.415 la 0.1ss 3/64 0.25 5/64 0.21s 3/64 0.216 5/64 0.358 0 e 20 "
0.214 3/64 0.216 5/64 0.35s- jlll ol0 22 24 0.250 3/64 . 0.lsa 5/64 ' 0.312 # WN 'e R e, y %, . l. V NJ/ ' _
.d. s j' h m uo
== 8 . c 650 133' 1473 3600 (=23) 1.0 g \
\ \ f11 P* + Po= Sm
\ \ N (collapse line)
\ N 0 .8 N y
0.75 _. \ %'% - -- 0.75
-- i Mes y ; iisk i (2) Pm + P, = 1.5 Sm N[ ' * - -~_ 0.66 E .........
0.6 WM 1'f s si .. i5siiisi!!# isis!!!i. . (3)Pm + Pe = 2.773 S,,,
':S$hW8!$i!!:, [(safety factor = 2.773) 3 .: f ..Si3i8sii!5itiiA5MSi8MElis
*i(4) Unearus ? 0.4c 6 0.4 Wi! !! approximation .3 -
for allowable f*.: 5I?
;;2
"^
58 flaw size fjj;.;y.:.,l)!;.. ]s . . . 4*M g ?95!5;gjagig : lii.ssiigjiig!.s ys c :Ms ss@gggk!!! " Faisissus ^*
#~1 " -'x 0.2 Mt i
- II :sd@e!!gigg; sissus . . . . .
65!L s> P .
= Sm/2ji.gg.
5;! fg
- i.j!!
O - -- -- - O 0.2 0.4 0.6 0.8 1.0 Fraction of Circumference (a/r) Figure 1 A flaw assessment diagram for TP 304/304L stainless steel pipe . with circumferential flaws. Curve (3) corresponds to normal operating conditions and Curve (2) to emergency and faulted l conditions. (From Figures 3 and 4 in Reference 3) j 4 L
...- --.. . 7- - - --- . . . __ ; _ - - - - - - - _ 3;:= ; ;;;;;; ,, __
- 3R- PP- /.su .2 7 AtracHar* /.3 rO
~
l -
.I i i e*
oto, n go I e= _ iR. Jm= 4 IN. KIPAN.8 l I O 4 INCH DIA. PIPE . I A st INCH DIA. PIPE "6o 'el o so - a ~ Je= 3 IN. KIP /IN.8 . O e 4 INCH DIA. PIPE a e a 20 INCt riL PIPE y# - a o - _ dL O E
?@ -
A . 0 ~ V8 _ _ . _ _ PLASTIC COLLAPSE o w i<m - l t 8 8 i
; I l
0 t i 1 0 0.25 0.50 0.75 1.0 CRACK DEPTH, dA . i 1 I Figure 2 Comparison of the load corresponding to crack initiation against the net.section stress criterion (From Figure 7 in Reference 3) . 4 D l.
. - _ _ + . - . . - - _ - _ _ . _ - _ . . - . . . . . . _ - _ . - - . . - - - . _ . _ . _ . _ _ _ _
L.- ..= .._:..==..__... =: i _. .
. =.1 . .. . z . r;- - - . :: x .
bR-PP- MS 2 7 A? M HMtW7'" M d=3/64
. 800. ' .
7 . . . .
" 700 h
- d=5/64 7w l* 600 -
me b ' o 500 2
=
8 400 a b - 300 < 200 - ::
~
100 14 16 18 20 22 24 inch Pipe Size (ou'tside diameters) Figure 3 Limit load (internal pressure) versus pipe diameters for the two assumed flaws (fully circumferential, 3/64 and 5/64 inch deep). l 0 O
- . . . . . . .. .- - -..-.--...--:- - =-- ..-. = = ~ - -~~
~~~~ ...- T 22 ----
August 11, 1986
,m
( WELD SPECIMEN TEST PROGRAM I. INTE0 DUCTION A Weld Specimen Test Program has been condycted in which misalignment, unconsumed insert and oxidation have been simulated to produce conditions at least as severe as those observed in the NSCW System of , Unit 2. Three transverse ' veld tensile specimens have been removed from cach of the three simulated' conditions and subjected to a tensile test. Minimum breaking load and tensile strength criteria were established and the results compared against the criteria. All results were satisfactory. c II. TEST CONDITIONS < Materials Base Material - SA-312, Type 304L welded without filler metal Filler Metal / Insert - 308L Size of Pipe inch diameter / schedule 10 All of the above materials shall be in accordance with Pullman Power Produces (PPP) Welding Procedure and Materials Specifications. The (\-')' 16-inch diameter schedule 10 pipe size was selected because of availability considerations. Welding Fit-up weld joint in accordance with PPP Welding Procedure Specification (WPS) with one location offset at 3/32 inch. Weld in accordance with PPP WPS 38-111/I-8-KI'-1 in the horizontal fixed (5C) position using PPP velder(s). Produce Unconsumed insert similar to NSCW condition Misalignment similar to NSCW condition
., Oxidation similar to NSCW condition III. SPECIMEN SFLECTION AND PPJPAR ATIOM From the finished weld coupon, select representative areas of unconsumed insert, misalignment and oxidation. Take three specimens' from each area sufficient to prepare transverse tensile specimens. Prepare transverse tensile specimens in accordance with ASME Section IX, QW-462.1(b). Do not grind, machine or otherwise work inside or outside, veld surfaces of specimens.
O) (m-
~
Page 1 of 6 (
- $~~E= . =_ = .=-.L..
.-.: _ 2 . ....:~.... . :: .: :~=.2: . , ; .. T :..- "
- August 11, 1986 O IV. TEST SEQUENCE Testing of the specimens was conducted in the following sequence:
- 1. Photograph inside and outside surfaces of each 's'et of' three specimens.
- 2. Measure and document depth of unfus'ed insert on e'ach side of tensile bar on both sides of three specimens. ,
- 3. Metsure and document width of each tensile specimen. Measure and document base metal thickness for each specimen.
- 4. Tensile test each specimen in accordance with SA-370. Record breaking load (ib) only. .
.5. Photograph fracture face of each tensile specimen. On unconsumed insert specimens, measure and document depth of unconsumed insert if fracture occurs at that face.
V. ACCEPTANCE CRITERIA Breaking load (1b) shall meet or exceed the value determined by lb = UtA Where Ib = Required minimum breaking load, lbs. Ut = Ultimate tensile strength, psi 70 Kei for 304L material A = Wd Where W = Width of machined specimen, inches d = Thickness of base material, inches For unconsumed insert specimens A = W (d - di) - Where W = Width of machined specimen, inches d = Thickness of base material, inches dl = Assumed depth of unconsumed insert (5/64 inch) i k t =f ' s g Page 2 of 6
E _._-. ....._-_... _ . -- --
~
---- Z TCI Z~ - -- - - 1 Z'
, August 11, 1986 VI. TEST RESULTS The results of the transverse weld tensile tests are susunarized below.
The pre-test measurements of the specimen are given in Table I. Specimen Material Ares, Specimen Simulated Width, , Thicknes s , Square Number Condition Inches - Inches Inches UC-1 Unconsumed 0.756 0.168 0.127* ~ Insert , 0.246 0.185** UC-2 Unconsumed 0.749 0.167 0.125* Insert 0.245 0.184**
- UC-3 Unconsumed 0.757 0.166 0.126*
Insert 0.244 " 185** MA-1 Misalignment 0.748 0.246 0.184 MA-2 Misalignment 0.757 0.245 0.187 MA-3 Misalignment 0.748 0.245 0.184 0-1 0xidation 0.763 0.247 0.188 O-2 Oxidation 0.768 0.2465 0.189 0-3 0xidation 0.745 0.2475 0.184 Specimen Required Actual Required Actual Number load. Ibs load, lbs Ut, Kai Ut , Kg UC-1 8890 16,200*** 70.0 129.6* 87.5** UC-2 8750 16,000*** 70.0 128.0* 86.9** UC-3 8820 15,800 70.0 125.4* 85.4** - MA-1 12,880 16,200*** 70.0 88.0 MA-2 13,090 16,200*** 70.0 88.0
; MA-3 12,880 16,100*** 70.0 87.5 0-1 13,160 16,300*** 70.0 86.7 0-2 13,230 17,000*** 70.0
- 89.9 0-3 12,880 16,800*** 70.0 91.3
*Value (area or actual ultimate tensile strength) based on reduction due to assumed 5/64 inch unconsumed insert.
O **Value (area or actual ultimate tensile strength) based on assumed full-section specimen.
. *** Failed in base material.
Page 3 of 6 e
. ;--. 7
- August 11, 1986 O Measurements of Unconsumed Insert Depth The results of the measurements of the unconsumed insert depth both before and after transverse tensile testing are shown in Table II.
Examination of Table II indicates that no depth of unconsu~med insert was visible prior to testing. Upon completion of testing, three areas showing a depth of unconsumed insert of less. than 1/64 inch, 3/64 inch and 1/16 inch were noted with slight to negligible tears observed on the remaining faces. The accuracy of the measurement of unconsumed insert suffers due to yielding and distortion of specimen faces and the dif ficulty in . determining where the depth of unconsumed insert ends and the onset of tearing begins. The measurement of the depth of unconsumed insert is, no doubt, somewhat exaggerated and conservative. It is also important ., to note that two of the three unconsumed insert specimens broke in the unaffected base material. VII. RESULTS AND CONCLUSIONS The following results and conclusions can be drawn from the tensile testing of transverse weld specimens taken from a simulated weld representing conditions at least as severe as these in the NSCW System.
- 1. All tensile specimens fractured at values substantially in excess of O~ the required minimum breaking load.
- 2. The tensile test results for all specimens exhibited an actual ultimate tensile strength substantially greater than that required for unwelded base material.
- 3. Eight out of nine tensile specimens fractured in unaffected base material. Only one (UC-3) out of three unconsumed insert specimens broke in the weld area.
- 4. Measurements of the exposed faces of the tensile specimens both -
before and after testing show that the assumption of a 5/16-inch deep unconsumed insert is conservative and greater than what will occur. Based on the results of transverse weld tensile testing, it can be
- concluded that NSCW system welds have more.than sufficient inad entrying
- capacity and stress carrying capability compared to unaffected base material.
p . i .e f
- O .-
Page 4 of 6
..-m- -- ---.--e,--.- _ _ _ _ _ . , - . , -
..,m. . . . . . - - . ,
- TAM I Pullman Poww Products capwar.on INTEROFFICE CORRESPONDENCE l
DATE: . August 6, 1986 _, TO: T.M. Wilkie
*~
FROM: R.G. Davis
SUBJECT:
Post Machining Measurements ALL MEASUREMENTS TO BE TAKEN USING CALIBRAT D TOOLS. a- _ ] c I .p. e t
! 1 L e
@ (*---., wpr l'._ . r "C" AND "D" ARE WALL THICKNESS MEASUREMENTS A 8- C D UC-1 .1tXo 1.25 .24 6 . 'l%
UC-2 .149 t . t3 t , ,14(. .244 UC-3 .151 8.144 .245 .243 . ) MA-1 .14 6 1.149 ,746 . 24 (, MA-2 75'l t IAS . ZAG . 24~1 I MA-3 .M6 1.l40
.247 J24(,- -
i 0-1 .7M i.14 7 .14"i .241 -
,, 0-2 .168 n.245 .247 .14G 0-3 145 1.1 % .248 .'24 7 s
A, C, AND D MEASUREMENTS WERE TAKEN UTILIZING MICROMETER B-88-62
- l. CALIBRATED 6-3-86, CALIBRATION DUE 9-3-86.
B MEASUREMENTS WERE TAKEN UTILIZING MICROMETER B-88-52 CALIBRAT 5-28-86, CALIBRATION DUE 8-28-86. , O MEASUREMENTS TAKEN BY j y/f // bs - DATE f- 7-86 Page 5 of 6
~~
- - : ~ - - + -
~~
=
- TABLE II Pullman Power Products CorporaGon fh v? INTEROFFICE CORRESPONDENCE DATE: August 6, 1986 .
TO: Mike Wilkie - FROM: R.G. Davis
SUBJECT:
Measurement to be Tak'en After Milling ' Operation and Af ter Fracture
' ' -
- S is axvstes I
A FACE. . i ! !k sint 1-+ (u* sio n TEAE, %IC)E
)
W 5 d O Using 6" scale, measure depth of unfused insert on each side of insert on both sides of the specimen and record as follows: . BEFORE l AFTER UTILIZE 6" SCALE PRIOR TO TENSILE; FRACTURE FRACTURE blodst dE6. TEAQ, UC-1A Side 1 = UC-1A Side 2 = Mod E JE4.TEAQ. UC-18 Side 1 = NedE MFA TEAQ - UC-1B Side 2 = blouE ME6. TEAQ. UC-2A Side 1 = deOE suGWt"TEAGL UC-2A Side 2 = Mout SuGuT TEAQ. su6uf TEAQ O
' UC-2B Side 1 =
. blodE
- UC-2B Side 2 = kWE R.t(sHT TEML UC-3A Side 1 = kva N(d UC-3A Side 2 = MW E N/A UC-3B Side 1 = k' ops '%*
UC-3B Side 2 = MME
- N/A i
1 der AopucAcy e
- SDEcmE 1 W AT W M A W G W S E.06r-.
At L.Acx, or PEue.To.1 nod 4 b" O GiBune R.G. avis me soe - s 1,. ee e.4 s - a h A t myg, g 6(,
. Assi ant QA Manager Page 6 of 6 gt
--- - u--- -
r :: . _. . .: . . r: ::::.. . . . . . . . . - - W-D Pullman Poww Preducts Cwpwauon
?'
INTEROFFICE CORRESPONDENCE DATE: , August 6, 1986 .. TO: T.M. Wilkie FROM: R.G. Davis
SUBJECT:
Post Machining' Measurements ALL MEASUREMENTS TO BE TAKEN USING CALIBRATED TOOLS.
' 0 .
j (, o g .,, O t
\ q .
I d V. w-. X {? e e --. .
) "C" AND "D" ARE WALL THICKNESS MEASUREMENTS A B C D UC-1 .1tk 1.1% .24 6 . 'l4(o UC-2 .149 t.t'St ,,246 244 UC-3 .151 i.144 .245 i24 3 MA-1 .14 6 i.149 .146 .74(e MA-2 .751 t 143 ,1% .74'I MA-3 .M6 i .ZAO .1L41 . 2AG .
0-1 . '7M l.147 .147 .14'l 0-2 1(og L245 . 2.fi .14G 0-3 145 1/l % . 14 8 . 24 7 A, C, AND D MEASUREMENTS WERE TAKEN UTILIZING MICROMETER B-88-62 CALIBRATED 6-3-86, CALIBRATION DUE 9-3-86. B MEASUREMENTS WERE TAKEN UTILIZING MICROMETER B-8B-52 CALIB 5-28-86, CALIBRATION DUE 8-28-86. O MEASUREMENTS TAKEN BY j 77 ' /b[L[ih DATE f- 7-86
~
l . . . .
.: : :: . = = :.: .. :: m - : . . . . - . -_ ___ -. .. .
_, _._..a s* Q - 7.- Punman Poww Products Corperst6en
,m
/
's_/ INTEROFFICE CORRESPONDENCE DATE: ' August 6, 1986 TO: Mike Wilkie .-
FROM: R.G. Davis
SUBJECT:
Measurement to be Taken After Milling Operation and After Fracture
'p 6 n a.svsecs l l .A ru.E.
4 1 i l sint I--+ g*sint 1 32, %IDE
- e '
J .
'!) , j
/
u i ,q (.J Using 6" scale, measure depth of unfused insert on each side of insert on both sides of the specimen and record as follows: BEFORE I AFTER UTILIZE 6" SCALE PRIOR TO TENSILE; FRACTURE FRACTURE UC-1A Side 1 = Nede dE6. TEACL. UC-1A Side 2 = Mode 0 % .TEAQ._ UC-1B Side 1 = >Jo4 E MFA TEAG - . UC-1B Side 2 = NoWE ME6. TEAQ._ UC-2A Side 1 = deuE su6af TOGL UC-2A Side 2 = Mout tuGur v.AQ. UC-2B Side 1 = >JWE su6af WM2 R UC-2B Side 2 = WE,, _, TA.tC,HT TEA 9 UC-3A Side 1 = but 1 N/A N64 UC-3A Side 2 = be UC-3B Side 1 = Wous % l MME
- N/A UC-3B Side 2 =
A dot AppucA%E
- SECMnd % E M . w A s e 6 T i H S E.t M t. ,
{ 0F Peut.TQ1 nod 4 %A AA I U.' avis @M 6-7-d3d' Assi ant QA Manager JL
~
~~
_.__. _ ~.~~ < W yn jeggEy WSMA)6 ^ ~ A(MN/A/C S c 75 CM DA R* 4-25 F(// /4.n #6 AUGUST 6, 1986 VI. TEST RESULT 5 The results of the transverse weld tensile tests are sumarized below, Specimen Material Acfg Specimen Simulated Width, Thickness, ga /d. Number Condition Inches Inches
' M' , .. - *M '/2 7 UC-1 Unconsumed .
- Insert ,144 . /6 7 ./25
. UC-2 Unconsumed '
Insert' -
, N,6 ,//
UC-3 , Unconsumed ' , 7.37
- Insert
.NO Md-1 Misalignment - ,246 ,/6 7 M5t2 Misalignment ,1f7 M513 Misalignment ,7# . ff5 ,
, /84-
. 743 ' f4 7 ,/86 0-1 Oxidation .24G5 0-2
- 0xidation .7Gg ./69 0-3 'e Oxidation .746
< 2476 gy C) }.t.-
Specimen Required Actual Required Act'ual Numberi lb, 1bs. 1 b , 1 bs ._ Ut, #51 Ut osi (- 10 0
,UC-1 1.. 8990 l' 200 %
l
- UC-2 . g7So /6000 10 0 UC-3 8620 /5 800 79 o MA-1 ;;. ./2894 f.6 2co 7#- . .
MA-2 t,
/3090 / 6 200 '70 - 5
/ 2B60 / G /oo </g.c MA-3[ ,
s 0-1 ': . , /3/40 /6304 74. . 0-2 s. /3230 /7000 ,y, y 0-3 - ,gggo j p goo G. . i
.s . ,.
s VII. RESut.T5 AND CONCt.USIONS r The following results and conclusions can be drawn from the tensile 1 testing of transverse weld specimens taken from a simulated weld repre-senting conditions at least as severe as these in the NSCW System. PAGE 3 0F 3 A
August 6 b r) n. d l: QUAL.ITY CONCERN NO. 86V-0515 ACTION ITEMS I.
'lj RESPONSIBLE TARGET '!
EM NO. ITEM PARTY COWLETION DATE COMENTS s Identify all Sch. 10 S.S. piping PPP 7/29/86 Action completed 7/29/86 !! greater than 12" dia., installed in Unit #1 & Unit #2 by drwg. no., Field Weld No. & building location '{ l Review all process sheets for field PPP 7/29/86 Action Complete 7/29/86 ,l welds identified in item #1 above to 1 detemine acceptability of weld on ;, I.D. of piping and document. Consult with Bechtel Welding Engineering GPC/8PC 7/29/86 A'ction Complete 7/29/86 to detemine if similar problem with welding Sch. 10. S.S. piping has occured and identify corrective action taken Establish a statistical sampling plan GPC/BPC N/A Not Required , for reinspection of Unit #1 Sche.10. S.S. pipirg welds.(if required) Issue D/R's for deviations identified PPP 7/28/86 Action* Complete 7/28/86 l~ during visual reinspections. ,
.i Perform sample reinspection of known PPP/J. Miller 7/31/86 Action' Complete 8/1/86 j!
welds that have previously had root ,l weld inspected and accepted by Q.C./ANI l Issue Report , Identify entry points in NSCW system PPP 7/30/86 Action Comp.: 7/28/86 , for Unit 1 & 2 reinspectior.. (if required) ,
'l G
4
ew August 6, i l. Qtl4LITY CONCERN NO. 86-V-0515 ACTIM ITDES )!
~
RESPONSIBLE TANGET l} 3 ITEM NO. ITEM PARTY C(BFLETIM DATE CSSENTS j
- l. Work with RMB for U-l access (if req'd) CWR N/A Not Required !'
- p. Justify limits of problem (ie. > 12" DH/E.F. Gerwin 7/31/86 Action Complete 8/1/86 Dia. Sch. 10. S.5.) Eng. Analysis ;
Causes
- 10. Provide on the sgot review of weld- K. Caruso "As required" Action Complete 7/28/86 '
ing deviations re~ ported by Q.C. prior . , to issue of deviation reports.
~
'i LI. Initiate reportability of welding prob. CWH 7/28/86 ActionComp.Reportedaspotent ;
giro'blem. 7/28/86 ;i l2. Add Bechtel M&QS to inspection team CWR 7/28/86 Action Complete 7/28/86 f; l3. Review GPC Q.C. Surveillance records CRB 7/29/86 Action Complete 7/28/86 ! No previous problems identified to identify if this welding problem ; was previously idantified or why it No inpr'ocess inspections performed. l was not identifie1. . ; 14 Review w1dirg an.1 inspection proce- 'PPP/J. Miller 7/30/86 Action Complete 8/1/86 ' dare to determine why methodology of GPC ,. of root pass inspections has changed. Pevies process sheets of ,eeldslassoc. with DR's and verify correct helding - procedure was used and that welder was qualified .
)S. Identify old Q.A., NRC problems re- GAM 7/30/86 Action Complete 7/29/86 lated to the nature of this welding No related prob. identified il problem including INP0 and SIE's. , )6 Provide report on procedures used to PPP/J. Miller 7/30/86 - Action Complete 7/30/86 '
fabricate and weld shop joints versus ~ field weld joints. .
;l
)7. 'ssue written stop work order GPC/QC 7/28/86 ActibnComplete7/ 3 S/W-N-16 ! l 1esued. !
August 6 .
;}
,1 QUALITY CONCEltN N0. 86-V-0515 ACTI(Ni ITEMS
,I RESPONSIBLE TARGET PARTY C(NLETI(Ni DATE C(NOOfT5 ;.
IN N0. ITEM : 7/29/86 Review complete 7/28 Quality Concerns to review their LBG No prior problems identified - records to determine if this weld- i;' ing problem has been brought up !: previously 8/01/86 Action Comp. Definition provided
) Develop clear definition of what CWR on S/W order must be done to lift stop work and -
restart work I: PPP 8/01/86 Action Complete 8/01/86
) Review procedures to determine if ,.
changes are required to implement
.l.l corrective action.
7/30/86 Action Complete 8/01/86 ,l 1 Perform Fracture Analysis Study DLK Issue Final Report DLK 8/07/86 iji 2 8/06/86 Eval. Cosy. 8/04/86 Testing to 3 Evaluate the need for testing worst DLK ' Perform Testing comp. 8/,06/86 case samples of welds. DLK 8/01/86 Action Complete 8/05/86 4 Investigate existence of code cases etc. on insert welds related to problem.
@ Perform 50.55 (e) Analysis DLK 8/ /86 ,
Disposition Pullman and GPC D/R's DLK 8/08/86 b l e i . i ig. -;
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t DRAFT CONFIDENTIAL , s August 15, 1986 Memo To: M. H. Googe ,
Subject:
Vogtle Electric Generat;ing Plant - Units I- and II ! Partial Response to Qualtty Concern No. 86V0515 File No.: X4AZ01 l Correspondence No.: M-6941 1 - f
References:
- 1) D/R - GPC MD-8860 ,
, 2) D/R - GPC - MD-8861 f 3) GPC Correspondence, C. W. Rau to B. Edwards, 7/24/86 .
- l. ,
, 4) List of Sch 10, S.S piping Unit #1 and #2
- 5) Action Plan
- 6) Stop Work Order No. SW-N-16
- 7) 13 Pullman D/Rs
- 8) Bechtel " Final Report" j 9) Definitions: Lack of fusion, X-insert, oxidation, lack j A of penetration i , 10) Photos of welding indications.
i Quality Assuran.ce (GPC) wa's notified 7/16/86 that welding of 24" piping outside NSCW Tower 28, was not being . performed properly. The submitter
- stated that' the "X" insert consumable ring in a field weld joint was not Q.A. infer =ed the Quality Conc ^ erns Organization of completely enne.nmod.
! the submitter's; concern on 7/16/86. Quality Concern investigator C. W.
j Janecke requested G.P.C. Quality Control (QC) to perform field inspections in the area described by the submitter to substantiate the concern. It j should be noted that the submitter did not identify a specific joint in
!A his concern. Q.C. inspected piping in the area identified by the submitter and ' issued D/R MD-8860, on one (1) joint (18"-034-W-01 Dwg. 2'K5-1202-034-01)
~
due to incomplete fusion of the weld root on the inside of the pipe (see Attachment No. 1). Quality Concerns was contacted on 7/17/86 by the submitter, , D
- . . . - _ . . . . . - - . . . . _._4.8.- __ . . . .. . >_ .m. . . _ . _ _ . . _ - . . . . . _ . . . _
t Indicating the weld joint related to his concern as being a 24" - weld 006-W-25 on dwg. 2K5-1202-006-02. Q.C. inspected this joint on 7/17/86 and issued
~ /
D/R MD-8861 due to the weld root on the inside lacking complete fusion Nee Attachment No. 2). Quality Concerns notified Q.A. of the inspection results on 7/18/86 and a plan of action was established t'o reinspect 't'eF(10) additional
~
welds to detennine extent of the welding problem. Field reinspections started 7/21/86 on the additional ten welds. The Mechinical Discipline was infonned of the welding concern, the 'subntitter's concern and the results of the field - reinspections 7/23/86. ' The following action has been taken as a result of the above subject Quality Concern. On July 24, 1986, (Reference 3), assigned action items for Pullman
- Poewr Products (PPP) for innediate implementation. This action item list was issued to enhance the fitup process used on the Sch.10 S.S. weld joints and require root pass weld inspection, until the welding concerns were properly
( evaluated. On July 25, 1986, PPP identified all schedule 10, S/S piping greater than 12" diameter installed in Units 1 and 2 by drawing number, Field Weld , Number and Building Location (see Attachment No. 4). The scoping was limited l to Sch.10, S.S.,12" diameter and greater because of the following: l f Limited to S.S. because: de a) concern was identified)pf S.S. ! b) all review and analysis indicated concern resulted from fitup difficulty, r primarily due to heat transfer characteristics of S.S. l 3 Limited to Sch.10 because: 4 3 a) thinner wall exacerbate, heat transfer induced fitup problems. l Limited to 12" and larger diameter because: . L a) concern was identified in large bore piping. b) Preliminary investigation indicated no problem with small bore g piping.
- = .-..- ..- .--. .... - - . - - - . - _ . . - . . . - - . -- ..._
~. _
ydu 0.9. SA. D ( c) Some :r" b=jiping had been X-rayed and found acceptable. On July 26, 1986, PPP reviewed all process sheets, for the piping in, the scope stated above, for level of acce tability of weld on I.D. of piping. A total of 104 process sheets were @::d for Unit. 2 and eleven (11) showed
~
evidence of a visual inspection of the root pa'si I.D. A total of 153 process sheets were reviewed for Unit 1 of which 58 showed evidence of visual inspections being performed on the root pass f.'D. On July 26 and 27, 1986, a visual inspection was perfonned on 25 accessible field welds. These were all the large diameter that were accessible at ] this time. These reinspections were verified by Georgia Power Company Welding Engineers. Of the 25 joints inspected, 20 welds had indications requiring evaluation, 3 were acceptable, and 2 welds were in process. Of the 2 in i l process welds, I was foudn to be unacceptable, no DR was written on this weld. A total of 9 DR's were written by PPP identifying the 20 welds with
- indications requiring evaluation. The main indications were found to be incomplete consumed inserts, lack of fusion mismatch and oxidation. Preliminary copies of these DR's were given to PFE on 7/27/86 for evaluation.
During the walkdown, PPP identified additional welds that can be made accessible the removal of mechanical joints or the disassembly of valves ! in Unit 2. Similar points of entry were reviewed for Unit 1 access. On July 27, 1986, a verbal Stop Work Order was issued against welding activities related to the Unit 2 NSCW System. Actual welding on the system had stopped 7/23/86 when Pullman was made aware of the welding concerns. For purposes of safety and to prevent possible closures of access joints, the verhl ordsr ias issued. G 1. Written Stop Work Order No. SW-N-16 was issued 7/28/86 to follow up verbal issued 7/27/86 (see Attachment No. 6). I i
' 2. Welding concerns were reported to the NRC as a potential 50.55(e). , ,
- 3. Bechtel Material and Quality Services (M&QS) was added to inspection team.
I
,. r - - - . _
u
- 4. PPP completed visual inspection of all NSCW System Large Bore Pipe Welds that could be made accessible in Unit 2 system. As a result of the field inspections 7/26/86 through 7/28/86 a total of thirteen (13) DR's were issued by Pullman against twenty-five (25)~ welds'.
~
Sixty (60) welds were inspected (35 field /25 shop) (see Attachment No. 7). -
- 5. Quality Concerns reviewed thelp records to determine if related welding concerns had been brought up previously. No prior problems were identified.
- 6. A review was performed to identify old Q.A., NRC, INPO, or SIE problems '~
c related to the nature of this welding concern. No related problems were identified. .
- 7. A review of GPC Q.C. surveillance records to identify if this welding concern was previously identified was perfonned. No previous problems ,
f were identified. The following actions were started 7/29/86.
- 1. Bechtel Welding Engineering was consulted to determine if similar problems with welding Sch. 10, S.S. piping has occurred.
- 2. BechtelD.Hackne)andPullmanE.F.Gerwinassignedtoverifylimits (ie. >12" diameter Sch.10, S.S.).
~
of concern. The following actions were started or completed 7/30/86.
- 1. Pullman provided report on proceduree. nsad to fabricate and wcld shop joints versus field weld joints. Shop joints (vendor) are ground on I.D. then visually inspected. The shop welds are readily accessible for inspection, unlike the field welds. Accordingly shop welds were.
eliminated from the welding consideration.
- 2. Bechtel started a fracture analysis study of the NSCW system.
- The following actions were completed 8/1/86.
i
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- 1. Pullman completed a review of welding and inspection procedures to determine
( why methodology of root pass inspections had changed (ie more inspections on Unit #1 versus Unit #2). The procedures had not changed. The inspection of the weld root pass has always (throughuot Unit #1. and #2..insp.).been an option of the individual inspector working each weld and not a mandatory hold point for nspection. Because this in,spection is an option, the variation between the two units exists. ,
- 2. Pullman perfonned a review of he process sheets for all weld joints that had indications requiring evaluation to assure correct welding procedure had been used and that welder was qualified. No problem were identified.
- 3. Pullman performed a review of welding and Q.C. procedures to detennine if changes are required as a re'sult of the reinspection. The procedures were found to be in compliance with Code and Specification Requirements.
- 4. Bechtel completed their fracture analysis study.
- 5. Bechtel/ Pullman verified limiting the scope of the welding problem to large bore Sch. 10 S. S., 12" diameter and greater.
On 8/4/86 Bechtel evaluated the need for tesning worst case samples of welds. Mock-ups of worst case welds were fabricated. On 8/5/86 Bechtel investigated existence of code cases etc. on insert welds related to concern. No related problems were identified. Also on 8/5/86 GPC consulted Reedy Associates, Inc. to provide an independent evaluation of the welding program, code compliance, procedural requirements, etc. related to the welding concern. On 8/7/86 sample weld specimens produced by Pullman to represent the worst case welds as described in Bechtel's fracture analysis report were tested. The tests indicated that the weld joints in the NSCW System are sufficient to maintain ASME Code allowable stresses and maintain required safety factors. - tiL .-._ - _ _ - . - - . - ._ _ _ _ _ - , - . _ - _ .
.1 i 'e s On 8/8/86 Reedy Associates, Inc. stated that their preliminary evaluation
( s- f of Georgia Power's programs related to the welding concern did not identify any discrepancies. Also on 8/8/86 a " Final Report" was issued by Bechtel justifying the limit of concern and acceptance of reported welding deviations (see Attachment
~
No. 8). -
, On 8/86 all deviation reports issued as a result of the weld reinspections have been dispositioned "Use As Is" by Bechtel based on the fracture analysis study and tensile testing.
c On 8/86 Stop Work Order No. SW-N-16 was lifted and work on Unit 2 NSCW System resumed. . It should be noted that Bechtel is performing a 50.55e analysis. The concern reported by the submitter was substantiated and has been properly evaluated under the direction of the Mechanical Discipline. No corrective actions were required as a result of the concern related to hardware problems. However, potential program enhancement resulting from our evaluation are being reviewed to provide additional assurance of welding quality. Based on inspection requirements for this particular code class, fracture analysis of worst case scenarios, and destructive testing to qualify the fracture analysis, additional Unit 2 and Unit 1 inspections / evaluations - are unnecessary. All evidence accumulated indicatos the welding on NSCW piping in both units meets or exceeds required safety factors. The remainder of Quality Concern No. 86V0515 is not hardware related - and will be answered by others. C. W. Rau () Mechanical Discipline Manager RP/JJG/CWR/dd xct File
_ :: . . = - __ _ _ 3 : ::: = -. I Afyfac4 meg r j, , l .- .. ,,- k REV. 1 July 24, Ig86 b ;
. Vogtle Project 14r. B. Edwards Pullman Power Products - ;
P. O. Box 286 ._ l Waynesboro, Georgia 30830
Subject:
Voetle Electric Generating Plant Units 1 & 2 Assignment of Corrective Action
Reference:
Quality Concern flo. 86-V-0515 .
Dear ler. Edwards:
The following Action Items are assigned to Pullman . for immediate isplementation as a result of field inspec-tions mlative to the above referenced Quality Concern.
- 1. Require that consumable inserts used in ,
weld joint fitup of Sch. 10 S.5. pipe, O 12" dia. and larger, be. tack welded to both items being joined (i.e. pipe to pipe).
- 2. Require that tack welds used during fitup of Sch.10 S.S. pipe,12" dia. and larger, be spaced approximately every 2" apart.
- 3. Require welder performing the root pass of Sche. 10 S.5. pipe to check I.D. of pipe periodically to assure complete fusion of items being joined or complete melting of -
consumable inserts. Also have the welder check to assure that the mismatch tolerances have not been exceeded due to the in process - welding.
- 4. Require Q.C. to visually inspect I.D. of
- root pass prior to coupleta installation of the root pass on all Sch. 10. S.S. 12" diam, and larger weld joints.
- 5. Review process sheets of weld joints identi-fied during. field walkdown to detenpine if weld root I. D. was inspected by Q.C. or others. .
50
. 1
_ , , , _ _ 7_ ,_. , .
.. Mr. 8. Edwards -
QualityConcern , July 24. 1906 ( Page 2
- 6. Verify that Q. C. does inspect I.D. of pipe welds when accessable, per procedure ._ _
X-18.
- 7. Identify location of all .5ch.'10. 5.5.. pipe installed in Unit 1 and 2.
- 8. Issue devia' tion reports 1sumediately for non-conforming conditions identified during field walkdown.
A meeting will be scheduled later to discuss and de- ~ " termine further action. t C. W Rau Mechanical Discipline Mananger . O RP/CWR:ef ) xc: File I M. H. Googe J. E. Sanders D. Fiquett
- 8. Harbin L. Glenn - Quality Concern Mgr.
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Vogte Nuc'oer Protect
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V. Pullman Power Products Corporation warnescoro. George 3083o
% eieo u s .rris,rrir August 6, 1986 -
Mr. C.W. Rau ._ Georgia Power Company P.O. Box 282 .. Waynesboro, GA 30830 ,,
SUBJECT:
Quality Concern No. 86-V-0515
REFERENCE:
Memo Dated 8/1/86 C.W. Rau to Richard Davis
Dear Mr. Rau:
In response to the above referenced correspondence we offer . the following information: Item 1- Did the root pass welds accepted by Q.C. require D rework prior to Q.C. acceptance? , Records associated with this work will not indi-cate if any rework was perfonned prior to Q.C. acceptance. In accordance with site approved procedures, root preparation may be accomplished as part of the "in process" activities and not be specifically documented in the weld records. Item 2- What type fitup inspection is perfonned on butt weld joints? A typical fitup inspection of a large diameter pipe weld would consist of the following func- , tions: (1) Utilizing a "hi-lo" gauge, the window area would be measured for internal misalignment. (2) Visual check the remainder of the joint. This is accomplished by a 360" visual inspection using a straight eoge on the ex-terior surface to determine the worst cause of offset. The pipe involved (SA-312 welded without filler metal) is made from plate. Actual thickness measurements taken from the pipe have shown a less than 0.010" variance.
1
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9 Pullman Power Products Corporanon o.' - Mr. C.W. Rau
SUBJECT:
Quality Concern No. 86-V-0515 Page: - 2 . Item 2- (Continued) . . . (2) (Continued) . Accordingik,themismatchontheIDwillbe essentially identical with that found on the OD. The alignment is modified, if necessary, ~' until the mismatch is within tolerance prior to the start of welding the root. . (3) Tack welds are visually inspected to assure ! that they are adequate and properly prepared . i for incorporation into the weldment. l (4) Inspect the spacing between the insert and the i land to assure that the joint is properly fit (face to face) using acceptance criteria shown , l in the appropriate General Welding Standard.
; t," ~t p)
Upon completion of these specific functions, general visual inspections for adequate support of the line, cold spring, and cleanliness are performed to satisfy the requirements of Procedure IX-19. Item 3- What is the status of Pullman Q.C. and Welding
! Procedures as a result of the reinspection? ! Do they require revision?
h (1) QC and welding procedures have been re-viewed and found to be in compliance with ~ Code and Specification requirements. (2) Upon resumption of welding, further ad-ministrative controls in the form of more
- t extensive use of windows for ID root ob-L servation may be employed.
(3) Upon completion of the investigation into ' this concern, a mutual'PPP/GPC analy: is'will ] be performed to determine if additional i specification and procedure controls are necessary. hO .. L
-- -~
T. - . . . - . - - - . . ... ::~ : T T T T : - = r' . Pullman Power Products Corporation b ( i h v Mr. C.W. Rau
SUBJECT:
Quality Concern No. 86-V-0515 - Page: 3 Item 4- DefendquestionsaskedbyThEmasrelativetoweld procedure and welder qualification. How can the welding procedur,e be qualified at one amperage setting and that qualify the procedure for a range of amperage settings, etc? General
- Weld procedure and welder performance qualifica-tions are governed by ASME Section IX. Pullman has prepared and received approval on all weld procedures utilized at Plant Vogtle and has pre- .
pared and received approval on project procedure II-8 titled " Welder Performance Qualification" for all welder performance testing. Specific " (1) Procedure Qualification For gas tungsten are welding (GTAW), amperage v ranges are detemined by experience. Ranges are generally wide to allow for variances in welding conditions and individual welders. A change in amperage ranges is considered a nonessential variable as defined by QW256 of ASME Section IX. This means that amperage ranges may vary (within range) without requal-ification of the procedure as allowed by QW-251.3 of ASME Section IX. (2) Perfomance Qualification Pullman typically qualifies welders utilizing - 2" XXH and/or 6" Schedule 80 test coupons. The root, in this case, would be made utilizing # a consumable insert with one " hot" pass uti-lizing the GTAW process. The remainder of the coupon would be completed utilizing the SMAW process. ' This typical test would qualify a welder up to .250 wall thickness utilizing the GTAW process. Qualification on 2" or 6" diameter piping also qualifies for welding on any lar-ger pipe diameter. This is allowed by ASME Section IX paragraphs QW 452.1 and QW 452.3. v ..
. Pullman Pourer Products Corporation
( -
\ -
Mr. C.W. Rau
SUBJECT:
Quality Concern No. 86-V-0515
' ~ ~ '
Page: 4 ASME Section IX is the, basis ,for both Procedure and Performance . _ Qualification. In no case does Section IX require testing to a " worst case" criteria. Additionally, Yogtle specifications do not contain any requirements over and above those specified by Code. Construction Supervision is responsible for assigning qualified welders to specific applications based on their field evaluation of the welder's experience and capability. .
)
Sincerely. f
<r John E. Miller
- QA Manager RG0/JEM/dward l
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,- Stop Work Notice e
5
- OTo Project Construction Manager O *
<1,8y).fr), l(p z
'*n L Control Number og (3) A Verbal Stop Work was Civen To Carl Rau At 10:00 ' .on 7-27-86 Name Time Date Pullman Power Products (4) ,
Contractor Involved (5) Work Activltten Stopped _ Work on the NSCW 1202 System Unit 2, Schedule 10 stainless Steel Piping laraer than 12". (6) Area NSCW (7) Building NSCW 2A,2B (8) Elevation All (8A) System 1202 (9) Reason For Stop Work Welding Defects (m) v
>/ r r WWW 7-28-86 ZX'C. W B. C. Harbin 7-28-86 (10) H. W. Swatn (10A) Mech OC (11)
Initiator Date Discipline Manager - Quality Control Date l l (12) Actions Taken To Restart Work ImDiementation of directions to PPP given in letter C W. Rau to B. Edwards dated July 24, 1986.
} F. Coleman GPC weldino enoineer to verify fit-up prior to welding root pass on . the first weld.
l l l (12A) Documentation GPC-D/R-MD-886088861, PPP-D/R-1 27 th 15631 & 15633 thru 15640 (13) M 7.f f-g% (14) h ff C, Profet(g' Section Supervisor Data Project Cdnitrudtion Manager ' Date J (15)Results The action taken (as Described in block 12 above) has been verified as b complete (See attached letter from B. Edwards to C. W. Rau dated August 8,19.86) and is adequate for restart of work activities. All DR's listed in 12A have been closed ( lC Ig , W nn ,, ,
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- c : 9.k'.ql av. t July 24, 1986
'[ '
Vogtle Projec't nr. s. Edmerds - Pullman Power Products P. O. Box 286 Maynesboro. Georgia 30830 ' ~
Subject:
Voetle Electric Generating Plant Units 1 & 2 Assignment of Corrective Action
Reference:
Quality Concern No. 86-V-0515
Dear Mr. Edwards:
The following Action Items are assigned to Pullman for immediate implementation as a result of field inspec- . tions relative to the above referenced Quality Concern. .
- 1. Require that consimable inserts used in weld joint fitup of Sch. 10 S.S. pipe.
12" dia, and larger, be tack welded to , both items being joined (i.e. pipe to pipe). O 2. Require that tack welds used during fitup
' of Sch.10 S.S. pipe,12" dia. and larger, be spaced approximately every 2" apart.
- 3. Require welder performing the root pass of Sche. 10 S.S. pipe to check I.D. of pipe periodically to assure complete fusion of items being joined or complete melting of consumable inserts. Also have the welder check to assure that the mismatch tolerances -
have not been exceeded due to the in process . welding.
- 4. Require Q.C. to visually inspect I.D. of root pass prior to complete installation of the root pass on all Sch. 10. S.S. 12" dias. and impr weid joints.
- 5. Review process sheets of weld joints identi-fied during. field walkdown to deter $1ne if weld root I. D. was inspected by Q.C. or others.
O ..
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I.I, .7 Nr. 5. Edwards 4 Quality Concern . July 24, 1906 ,
.I- Page 2 ,
- 6. Verify that Q. C. does inspect I.D. of ..
. pipe melds when accessable, per procedure X-18. .
i
- 7. Identify location of all Sch; 10. 5:5; pipe installed in,Unft I and 2; l 8. Issue deviation reports insediately for non-confoming conditions identified during field welkdown.
~~
e A meeting will be scheduled later to discuss and de- e termine further action. i C. W Rau '
' a'= ciau a * ' a -
O RP/CWR:sf i
- xc: File M. H. Googe
- J. E. Sanders
' D. Fiquett
- 8. Harbin 4
) L. Glenn - Quality Concern Mgr. i l l lO l i
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. , voges 88mber Propet Poet once een tee
") Pullman Power Products Corporation C # J:.f,'f,,,,
( August 8, 1986 . Mr. Carl Rau - Georgia Power Company . . . Vottle Nuclear Project
Dear Mr. Rau:
Pursuant to the commitments concerning Stop Work Notice, SW-M-16 Pullman is prepared to restart work on the NSCW 1202 system in Unit 2. The following action has been taken as requested: .
- 1. Craft involved in the installation of large diameter, schedule .
10 s/s piping have been instructed to: Tack weld consumable inserts to both items being joined. , a) Tack welds to be spaced approximately every 2". b) c) Welders shall check the I.D. (root) periodically to assure complete fusion and consumption of the insert. d) Craft shall monitor alignment during welding to assure
- continuity of fit-up tolerances.
- 2. QC Inspectors responsible for inspection of subject piping welds have been instructed to:
a) Visually inspect I.D. of root pass prior to comolete installation of root (Hold Point). b) Visually inspect I.D. of completed welds as a part of final visual inspection hold point, when acccssible. The other comitments pertaining to Process Sheet Review (item 5), Identification of Schedule 10 s/s Pipe Installed in Unit 1 & 2 (item 7) and Issuance of Deviation Report (item 8) has been implemented. . In addition, all Deviation Reports concerning Quality Concern 86-V-0515 have been processed to the Designer for final dispositioning. The first field weld to be made upon lifting the Stop Work NoticeNotice - will be 006-W-25B on Iso 2K5-1202-006.
~
GPC WeldinBngineer at time of fit-up inspection of the first joint. - t
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Pullman Power F. ducts Corporation i Of . Should additional information be required, please contact myself or Brian Edwards as soon as possible. g s I L _lbr% ; John ;.. Miller i ' QA Maigger . JEM/ck . CC: B.L. Edwards M.H. Googe J.E. Sanders D. Figuett , B. Harbin O H. Sinclair L. Puzo C. Scannell O . ee
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S P E M I O C C N N I E I C I F E D L A C K C . T O O I AT O P E L N R Y P E P H S I T N T _ O FI T E A _ I T OWRP N _ P T O I N EDI O SN I S ._ R U C MNT F _ S NEA GET TER F E I O D L A A N K L E C SPP I A MRF L OO , W' D EN N O L E E TO F RO- M D T E N T EI T OTH U . E TR C L A S R S E RPL O K AG I E P R N ES U S F E M OE T C T AEO RM O C N I fNS OM l OF U CN U I C D NE LN TE N N ., I P P E O I y U N i D i
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..* Deviction Report '1 3 /Mb - 886C) Desien.to, .M g,,,
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- 1. ContractorNendor . Pages Atten (G -
- 2. Date Reported FGP
- 3. Reported By Tel. Ext.
LE/X
- 6. Unit No. ( f "
3 St., GAmuil CHfEN HrJIMY' W. SU!Alf) '7613 Td)O
- 4. Item / Condition De6Cription FIELD UJElO 034-01-01
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- 10. Specification Rev. 11. Procedure Rev.
X4 AZO) -P3 ',/7 PPP X-I6 Il-15-fM '
- 12. Drawing Rev.
2 K'5 -I202-03A -0I lo
- 13. Deviation Description PPP X-l8 PMA,9.l.Zi GTRS TMP THOGu6H FUSI 0tJ SMll EXIST SP1/EEA/ <
WElb hMD BASE METRL. TNC0fnPIETF FUSION INAS NDIED DA/ 77/E RDDT OF Ael'UE tRlD JolflI' AS MllOf AS Yn X lJt DF AN IMH DF TttE LRA/D [AT SE1/EERL RKf5) HAD NDT BEEAI FU.TED. kEEAllRCHrD PHGTC) '
- 15. Hold Tag Reg'd trutlais % fold Tag A ly!g8 ate /N . 19. Hold Tag Removed By/Date/No.
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- 16. ted By 20. Action To #' g )MA [./4 I' Date l, ) ,
-44)- f**/ /* O Prevent Recurrence CAR No. '! @ :p a 7 l' 6h
[21. Recommended Disposition
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- 24. Action To Resolvelin, tion Requirements /j ,yg g ROC ' K a Yet F+-- RL%w of--W&t a m :1! Accc La ik't --- a'ms(j ^
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- 25. Justahcation g V' S Tce+- '-n 3k M MWpW6H5-- .T % ME A%M'/fb lD'Ma.E atarac mAxwemewas dA.4ma -Anxments ameams. g
- 26. Approv i i j[ge ggg Signature j [1([ g /3 3) Date O /*U* W%4 tl8YL ~{h /}/) ./ W sf. /Q { . I ?v-
- 27. Design Change fequired: PFE ( ~) Yes K)No 4(OE: ( )Yes (Q )No EGS #4/rJ.*mM4-Affected Documents Date [ d' bl f W h-N*b (V) 2f ANI Review ( )N/A Signatu Date E Work Complete (g)N/A ( )Yes Signa
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- Contros No tub-88&o One ,-ts -86 e
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(* DR/00R , Nh8b o ATTACN e /4-DISPOSITIW: USE - AS - I.S ..
. ACTION TO RESOLVE /INSPECTim REQUIREMENTS: NONE JUSTIFICATI m: ACCORDING TO PPP POSITION LETTER DATED AUGUST 13, 1986, J.E.
MILLER TO C.W. RAU, THESE WELDS WERE CONSIDERED ItaCCESSIBLE FOR INTERtML .V!SUAL
#4D NDE EXAMINAT!W.
DATE: /3 b O PFE CODES #@ STANDARDS ENGINEER i I !O .. . I
, - - - - - ,w-,wg--w-e - -
l L . -. : __.-: z..: =-z. NLV y n r-? n:e :- [
. JN lii2'/ 17. Con i No. S. System Startup i' O ~
bf Desicmator G [,0,0, i
- 14. No,,Pages ttch
- 1. ContractorNondor Put \w f%wer3. Reported Pctdudo WM M.w Tel. Ext. C. Uninho.'
B b' N . L. k(-b / MA* h8d DatJ Reponed 2. 7 6 7 it 3 a
- 4. Item / Condition Desenption R e h w o_{ rd OO. Q - ( M B - CO k - W 3 5 7.ASME Class 8. Project Class 9. Item t.ocatbn es C No 3 3t3 - N T T b rn p k u st., brce eF s Rev 11. Procedure Rev.
- 10. Specification y4-A tot-P 3 r7 T- g 8 s sh 5/n
- 12. Drawing Rev.
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Hold Tag Reg' initials 18. Ho Tg pil es 0 No Yb o ~7-\'1-9lo f 1 ,aG
' ' e'- M~ ev tR urrence AR No. b !
- 21. Recommended Disposition $f 8 '7 04
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p j7, fjg k22. ' ~ 21 Approved Disposition
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- 24. Action To Resolveilnspection Requirements gg
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- 25. Justification g,,f ~
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~n f-/V*fb Date j 29' ANI Review ( )N/A Sipaturej _g , ,
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- 30. Work Complete ( X)N!A ( )Yes SignakeN ~~)5=' G 1 Y ~ ' ~
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- 31. OC Acv:eptance ,
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DRioDR e /HD EE&/ AmCm e /S DISPOSIT! ms USE - AS IS .. , ACTim TO RESOLVE /INSPECTim REQUIREMENTS: NONE JUSTIFICATim ACCORDING TO PPP POSIT!CN LETTER DATED AUGUST 13, 1986, J.E. MILLER TO C.W. RAU, THESE WELDS WERE CONSIDERED IMCCESSIBLE FOR INTERML.VIStML MO NDE EXAMimTICN.
- O j
PFE CODES AND STMDARDS ENGINEER 1 li l} c l l P. P lt O L
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V96TLE ELECTRIC 4'08 No.
Ol8TRIEUT105 T0: POR: REVIEW INF0.
- MECMANISAL -
IQUIMIENT TAG N0. YOf"IOd3 HVAC f EQUIPldEJIT PROCESS
- CONTACLSYSTEMS e*
- ELECTRICAL WIRING . ,, ,
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- H AIARDS '
(TARTUP
- CIVIL / STRUCTURAL -
DESIGNATION N0.
- NUCLEAR
- STRESS / PLANT 0E310N ,
y C00E5 AND STANDARDS
# g e ARCHITECTURAL
- UA RETROFITTIES REQUIRED YIs @
e CONITRUCTION *
- NOT REQT 8Y ENGRO
- CLIENT e EQUIP. QUALIFICATION e M & QS
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IDENTIFYING TITLE OF THIS 00CUldillT: bem ( o c. Ort
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184P0RTANT Peresamme a pressed dess met seeseterte asespasses or espresel of desige demas, emessee seer m . .seeei n essertels desdeped er edented W es
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_, - - z ;= _ Pullman Power Products as-rII/I-a.KI-i ; co ~, , permango ev, J.P. Runyan apenovgo sy, K.J. Freed KJF MgE 1/7/30
- PROCEDURE FICATICM "['jje .
h__ 'g,8 1 of 3
~ ' - -
. .... . ... ... ... LATEST REY. DATE
. . . 12/6/85
, QUALIFIED IN THE As -
# WELDED CONDITION ONLY Copyright 1985 .
PULLMAN POWER PRODUCTS 3 I HEADQUARTERS AT WILLIAMSPORT, PENNSYLVANIA O I 1/7/80 J.P. Runyan K.J. Freed KJF Initial Issue 3/31/80 J.P. Runyan K.J. Freed KJF Added SFA 5.9 for Insert Material and ER309(L) for Perf. Qual, only 9/18/80 J.P. Runyan K.J. Freed KJF Corrected Thickness Qualified 12/6/85 C.R. Bowles G.L. Martin Revised to New Forms, Bare Wire, Inc. Jff! PCN #1 N N N N ,
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Pullman Power Products 38.ni/t.s.c.i 00cwtst w PnEPAaEn eY: J.P. Runyan APPROVED BY: K.J. Freed EJF Datti 1/7/80
~
e pagg l, vetelse 70 BE USED
. Pescasess specipicATtse* ONLY ON J0s #
NO. 2 Of 3 TMs3 S MusT GE USED IN CONJUNCTION wiTH suneentins pan c. Tut GENERAL WELO NG ST AND ARD (St. GWS-T T T/I 120, IU l , p no, a sa.no. N/A to e' el R sa.mdi M/A spectrication Twt a enaos N/A
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To spec 1Picatim ret a esos N/A pm0 Cess & Type Manual GTAW
$FA/ AWS SPEC. NO. 5.9 F-NO. / A-NO . F6/A8 Araan ,,,,,, , m i,,,, All )
siinnins eastasi N/A nom.,usins a Taisses None reseswr cuneestram (uixturts) casumets swesar marssian, SFA 5.9 pLos a m 8 CFH Min, n,sestm EscTacos sizt a twe 1/16" . 3/32" or Argon Purge 1/8" EWTh-2 sas sacuime ses anacxims sas muses ount".pe 9 of GS-III/l sininess on esm saae Both vna:Line siistoins oas N/A saava esas tscu 3 X Core Dia. Max. omipics os oas cup sir 4 - 10 ' N/A staats on w tripts ase Single catact was to sosu onstanct Multipass i ase Tuanspun mot N/A sinsLs on u tipass M/ A pass miass w y N0ne putsatins m THICKNESS 00ALIFIED 8ASE METAL GTAw SMAw l wlTwour vwMT 1/16" .560" 0 .560" N/A N/A N/A N/A wiTu wwwT wiglwuu sast uaftnial TwiCEMtst Quatirito ace iv84Cfs N/A PRENEAT & INTERPA55 TDFERATURE REQutRE. VENTS: 0 See Para. 5.0 of GWS-III/I fOr preheat; interpass - 350 F Max. POST #ELO HEAT TREATWENT RECulREMENTS: N0ne Qualified As Welded Only ADDITIONAL INSTRUCTIONS: 0 8 ED OR C0 STRU . i R7+A 261- l95-T 3 - - _ _ _ _
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Pullmar, Power Produc.s as-t r u t-a-r.r-i ,
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- peectoves spactricaties 0:tLY ON Jo0 * *b __
I W E L D i > G VdtT E ft AL ' /' S AS. C ' M E T A L CONT *0L etterani samt sinc rtus l sast uttat Carbon Steel (Perf. Qual.Only) N/A ER309 or ER309L N/A {l ER308 or ER30SL N/A Type 304 to Type 304 N/A ER316, ER316L or ER308. N/A Type 316 to Type 316- N/A ER308 or ER308L N/A ,1 Type 304 to Type 316 N/A .. (Ow.4o2) Jo t N T DESIGNtS) 3HUWN l;E r.r. 1 3 A TYP: CAL I L L U S T R .ii l C N C.h ' 37/2 Io 4 2t Io ig+ Ig __ ! _ i
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.no {
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10-50 3-12 .5 IPM (NOTE 1) OCSP All GTAW As above DC5P 50-100 7-14 1.5 TDM Parameters fur 10-13 2.5 IPM li1G", $32",1/0" OCSP 100-150 or K-Ins;ert must fall thme 0 CSP 150-200 11-16 3.5 IFK h,"r ge
*Ctreet Cur ent - Straight Polarity f, -To be u ld with tubing so :ket weld sonly) ~
' (NOTE 1 i I hX+420/,/95-5' t _ - . _ - - - - - _ - -- _._n------- _ _ _ _ - - _ - -
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- PREa A9ED BY, R. I. 80Ver* APPROVED 9Y ".. L Dichandi 9 Y.._ DATE. A-p_?o -
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PROCEDURE TO BE USED PAGE QUALIFICATION RECORD ONt.Y ON JOB 8 NO- 1 of 3
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121-8-0B 1
. AS WELDED t
PREPARED BY - PULIMAN POWER PRODUCTS DIVISION OF PULLMAN INCORPORATED HEADQUARTERS AT WILLIAMSPORT, PENNSYLVANIA
\
REVIsl0N PREPARED 8Y AP P R O V E D BY INI TI ALS
- DESCRIPTION FJR 9/7/71 R.f Rnvor F 1 Richarde nrininst nnsi f #4 r s f m.
6/14/78 R.I. Bever F.J_Richardu Reviend t au ra r- e IMPORTANT N
- Perrmeison to proceed does not constitute a.:esotance or approval of design details. calculations. a'talyses. test methods or materials gjgAO/'/(y
^--
J 1.ivg.u w, - .W.J ;,, J., . i e. . . .. .J Jc . ; .e ; . ;! .; . ; ; ;;!. . - from full conipliance with contlactual oblig.itions. nate >> s , e sano M.MDEpiggi, ;[ RECElvt0 // " / ~ /O DoctJME NT ST,ATUS s , t W wom u ** Ay p ar>f p s o. 2 QmEVISE A =0 RESU8Mif. WCm K M Av ameCE Eo /[./2,-7p SU6 JECT 'O INComPOR ATICN OF CM ANC E5 iNO'C A f t 3. 3 CaEvisE A o aEsusuir. wcla= uav Nor P4 0CE E 0, 4 UeNFOR M A Fe gps GN LY. y G i 5 F R i B U T i G "4 li k G g. .AO 0498 4/74 O V _ . __. .. ., 3, . A X4 A IO I I
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., O.v+on of Pullman incorporated gP' 00CUMENT NO.
fi * * # ' F. J. Richards f46' OATE, 6/i4/70 v'hPREPAREDBYt - O7 E ) PAGE
.'. PJoctavat 70 BE USED CNLY ON J088 7{5 Q9 ,4 NO. 2 Of 3 C quaLIFICATics RECORD (Pgal Rev. O wPS DATE 5/7/78 .
WPS NO.._29 111-8-08-1 TYPES manna 1 WELOING PROCESS (ES) PTM' Iw ANu AL . Au tou Ar i C . Stui . Av re i Denrint nf f4WK PR OR-F7 GTAV-Q AG Rev. O RASE METAL (CW-403) MATERIAL'$Ptc. d'117 3[*I* "' TYtt oR GRAct CF P No. g TDEM TenP No. R 3 , , .g THICXNES S ( IF P IPE , Ol #4TER ANO e ALL
, Q .o.
i THICKNES$) 6" X .280" POSITION (Cw 405) P051 TION OF GROOVE 40 Uphill stLD PROGRES$loN (WPutLb
- 0 0 * * ** t b ri
' PREHEAT (Ow 406)
PRtHtAT TtwP. 500 F. Min. INTERPASS TEMP. qqnop M3y CTHER (G) v ,..- F* GAS (CW 408) GROOVE DESIGN USED A,on. TYPE OF GAS OR GASt$ '"3" FILLER METALS (CW 404) COMPOSITION CF G AS WlxTURE 04-QCEM Pttro OTHER WELD utTAL FILLERMETg ANALYSIS A NO. O F No. TECHNIQUE PROCEDURES (CW 4101 S.F. A. SPEC. 5.9 A.S CLASS ER10R STRING oR wt Avr. st Ao noch CSCILLATICN 1 t i !"'M tii A of wpld FM WATlPASS OR SINGLE PASS Mul ti O M t M POSTWELO HEAT TREATVENT (Cw 4071 (*ss seco SINGLE OR uutTIPLE ELECTRCOCS $i ngi,0 TEletR ATURE _ None flWE OTHER ELECTRICAL CHARACTERISTICS (CW JO9) cygergy W OC TRAvtL TELO!NO CLCCT"CCC 9.ast rg(t,ge Vol. T S SPtto 4 W*L aif 5 OlA. wlRE otA, g Ave S} PCtARITY PROCESS Tungsten Min. Torch Gas GTAW 3/32 3/32 65-120 9-15 Straight 2.5 IPM Argon 0 20 C.F.it.
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- oros.on of Puuman incorpormd DOCUVENT NO.
[~')( 6/1k/70 U.h PREPARED BY: n I _ ' Dm!e r APPROVED BY': e. _1 o f ch as r c _ M- _ DATE -
; PROCEDURE To BE USED O 7
- Pact 3 of 3
- gpALIFicAfl08 RECORD (PQRI ONL.Y ON JOB 8 V O ek WO.
** TTNSILE TEST (OW-150) -
ULTIMATE ULTIMATE CHARACTER OF ML-71-30 . SPECIMEN TOTAL LOAD UNIT STRESS TAILURE & LOCA-NO. WIDTH THICKNESS AREA LB. PSI TION
.182 Broke in B/M 30-1 .719 .131 11.200 B5.500 30-2 .72,7 .179 .13'd 11.100 25.400 brekoin9/M CUIDED BEND TESTS (QW-160)
TYPE AND TYPE AND FTctinr No. RESULTS FICURE NO. RESULTS 71 an_rn_1 apnt 1Rno Hn indicatinne. f3 (j 75-56-FB 5 Bent 1800 Mn indicationsI 71-30-R8-2 Ront 1Roo No indicatinnd 71-30-RB-1 Bent 1800 No indications: TOUCHNESS TESTS (QW -170)
'***I^N-SPECIMEN NOTCH NOTCH TEST IMPACT NO. LOCATION TYPE TEMP. VALUES AVE % SHEAR MILS l
l i l j . I I Walder's Name R. Webb Clock No. O Stamp No. of Test Conducted by: Pull m n Pnwar Penduc*e Laboratory Test No. % 7 M Per: A T - Rnyar We certify that the statements in this record are correct and that the test velds were prepared, welded and tested in accordance with the requirements of Section IX of the ( C/ ASME Cod _e. , t . l~ , , .I ' ' I l l. Date 6/14/79 ,
-~
By Q eetert I, egyer l
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"l S II Pullman Power Products Paa n0. 120 Divis.ori of Pu!!.74, iricorocrateo 00CLv!NT No.
() b PREPA9ED BY R. I. Bnver "AoPoovto BY: F. J. Ri cha rds .;.V, OATE. f/19/78 _
.'. PROCEDURE TO at usto { O PAGE
=
QUALIFICATION RECORD 'ONL.Y ON JOB 8 Q d 's no. 1 of 3 i ( 120-8-XI-1
, ' , , AS WELDED PREPARED.BY PULIRAN POWER PRODUCTS DIVISION OF PULLMAN INCORPORATED HEADQUARTERS AT WILLIAMSPORT, PENNSYLVANIA '
I V) atvision potranco av arraovco av INiriAts otscairrios l 9/4/62 D. Keller F.J.Richards FJR Oriainal Qualificati6n 6/19/78 R.J.Boyer F.J. Richard - Revised to New Fams M
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\ cudTt . \ l IMPUHTANI g Pertnession to proceed does not constitu :e acceptance or approval ACCIUb !
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g, . .- . . .w .. ....n _ .. PQR NO. 120 Pullman Power Products f o,Y, On 0, ron inc0,x,.i.. 00CtJ4ENT NO. R.I. 80yer APPROVED BY, F. J. Richards _ .44 OATE, c/iarva
- hPREPAREDBY,
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- Pe0Ct00tt TO BE USED k
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[ AGE NO. 2 of 3
- ONLY ON JOB 8
$UALIFICAfl0s SECORD (PQs) 38 111 8 KI.1 Rev. O wPs DATE 9-4-62 WP5 No.
,Typgg u,,n,3
- GTAfJ WELOING PROCESS (ES) Rev. O tuaNuat.aufowaric.stui.auroi DenPfnp nr 7tv Do_vt_rt c_p u_7_77 BASE WETAL (CW-403)
.A MAftRIAL satc. A?do
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- c 4, [.* THICxhtSS (IF PIPt. DI AMETER AhD WALL THicxhtss) 1M*
POSITION (CW-405) P0slTION OF GROOVE 70 6,f N/A stLO PROGRES$10N turmo66 . con =mi6ti g
' PREHEAT ( Ow--406 )
PRtHEAT TCMP. 500 F. Min.
'IEOO p, gu -
I l INTERPASS TEWP. OTHER GAS (0* dO8) GROOVE DESIGN USED TYPE OF GAS OR GA$t$ APnnn i FILLER METALS (CW 404) cowpoSITloN OF G A5 MIXTU E QQ 4fC" OTHER nf f PA
. wCLD utTAL g FlLLER WCTAL g ANALYSIS A NO. F NO. TECHNICUE PROCEDURES (CW 410) 5.9 A.s etAss _ER308 37,,so e, ,c,yc g.a Stringer s.F. A. $PEC.
CSClLLATloN N/4 waTIPAss cR stN u pass Mn1 pp. POSTWELO HEAT TREATVENT (CW 407) - Nnna stNGtt CR wutflPLt (LtcTacets Rinnla TEWPERATURE TlWE OTHER ELECTRICAL CHARACTERISTICS (CW 409)
.I LunN6Mt Ww ThavtL CO*CNTS wtLDING ELtcTROCE BAut P i tt.t n v0LT! peg ag ,k,TY SPtto PROCESS DIA. .lRE DIA. l auP S)
"X"- Insert Torch Gas Tunasten 60-120 9-15 :traight 2,5 IPM GTAW 3/32 1/8 X 5/32 Argon @
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- GTAW Tu ston 3/32 60-110 8-15 straight 2s5 IPM
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Pullman Power Products PQR No. 120
*o r 4 Dev$on of Pullman incorporated 00CUMENT NO.
PREPARED BY, R. J. Boyer AppnovEo BYr F. J. Richards .dE- D ATE. 6/19/78,
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- PROCEDeRE QUALIFICAflos ret 0RO (PQt)
TO BE USED ONLY ON JOB 8 fQ Lg 4 1 PAGE NO. 3 of 3 T1mSILE TEST (0W-150) 62 7 - ULTIMATI ULTIMATE CHARACTER OF SPECIMEN TOTAL LOAD UNIT STRESS FAILURE & LOCA-NO. WIDTH THICKNESS AREA LB. PSI TION 2G-1 1.265 .099 J253 in;44n 41,11n Brnke in 9 ?'
. I 2G-2 1_777 .Ing ,137A 11;n40 RA;100 Rrnko in R/M
. GUIDED BEND TESTS (QW-160)
TYPE AND TYPE AND FTC1tRP Mn. RESULTS FIGURE NO. RESULTS O FB-1 bnt lano Nn i n e4 4 r.wi n n s ! FB-2 Rone inno pg 4-d1 3tjen; RB-1 Rant 1Rno un 4 , a 4 ,. s u ,, ,, ,.
. RB-2 bent 5800 NoindiEAtlNU
. TOUCHNESS TESTS (QW -170)
TA m AT. m SPECIMEN NOTCH NOTCH TEST IMPACT NO. LOCATION TYPE TEMP. VALUES ' AVE % SHEARfMILS
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_ _ . - mv I r= A13 1 MCl lD P I' "3 h :kI l\. lj LI FUT m w "' Welder's NameJ. Carpenter Clock No. 107 Stamp No. ec l Test Conducted by: o u!1 m., o;;- Dreducts Laboratory Test No.=62 7 Per: n, vg11 9 We certify that the statements in this record are correct and that the test welds were - v prepared, welded and tested in accordance with the requirements of Section IX of the ~ ASME Code. Signed M Pullman Power Products 6/19/78 By Rnha *i - ar e ,- l Date. ,}}