ML20211J919
| ML20211J919 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 01/12/1984 |
| From: | Wright B BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| Shared Package | |
| ML20211J491 | List:
|
| References | |
| FOIA-85-59 CP-CPM-6.9D, NUDOCS 8606270095 | |
| Download: ML20211J919 (84) | |
Text
., T,e PROCEDURE EFFECT1yE BROWN OT, INC.
J.,
NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 6.9D 6
1 of 58 ~,,
TITLE:
ORIGINATOR:
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CATE REVIEWEDBY:k*m CP-CPM 6.9D M
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(APPENDIX D) inf B&R E -'
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WELDING AND
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RELATED REVIEWED BY:
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PROCESSES grN TUGC0 QUALITY ASSURANCE DATE REVIEWED BY:
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'4 -W SR. PROJECT WELOUtG ENGINEER DATE APPROVED BY:
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/- I '" ' d CONSTRUCTION PROJLui MANAGER DATE 0.1 TABLE OF CONTENTS
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1.0 INTRODUCTION
ENGINEERING 081 DNLY i.
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2.1 APPROVAL AUTHORITY 2.2 RESPONSIBILITY 2.3 SPECIAL REQUIREMENTS 2.4 PREFABRICATION / INSTALLATION VERIFICATION 2.5 DOCUMENTING WELD INSPECTIONS 2.6 WELD PARAMETER CUIDE 2.7 BALANCE OF PLANT PIPING AND STRUCTURAL STEEL INSPECTION AND DOCUMENTATION 2.8 CONTROL OF WELDING PROCEDURE SPECIFICATIONS AND RELATED DOCUMENTS 3.0 WELDING 3.1 LIMITED ACCESS WELDS (FIELD WELDS) 3.2 CLEANING OF WELD PREPS AND BASE METAL 3.3 PREHEAT /INTERPASS TEMPERATURE 3.4 INERT CAS 3.5 PURGE DAMS AND CONTROL OF PURGE DAMS 3.6 CONSUMABLE INSERTS 3.7 BACKING STRIPS AND/OR RINGS 3.8 PEENING 3.9 IMPACT TESTING 3.10 WELD JOINT DESIGN AND FIT-UP r0WB~
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i JOB 35-1195 COMANCHE PEAK STEAM ELECTRIC STATION f
Construction Procedure 00CUMEPT CHANGE NOTICE NUMBER 3
Notice applicable to Construction Procedure No. 35-1193-CP-CPM 6.9D Rev.
6.
This change will be incorporated in the next revision of the procedure.
Change the procedure as follows:
Please replace the following pages with the attached:
Page 41 of 58 42 of 58 43 of 58 and 44 of 58 Reviewed by:
/4 l*2 *'Y
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+
y Date Brown & Root Quality Assurance Date Originatof Y )l ?.',L / r i f 1kb Date Approved by:
TUGC0' Quality M'surance J'
hh,b gwdM/FI-2-5V' 08/03/84 tConstruction Project Manager Date Effective Date e
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'J03-35-1195 COMANCHE PEAK STEEL ELECTRIC STATION Constructica Procedure DOCUMENT CHAf!GEJ'OTICE NUMBER 2
Notice applicable to Construction Procedure No. 35-1195-CP-CPM 6'.9D I.n*/.
6 4
This change will be incorporated in the next revision of the procedura.
Change the procedure as follows:
Please replace the following page with the attached:
Page 2 of 2 Figure 6.9D-11
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Reviewed by:
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J 4 -ff *-ftl Project Welding Engineer
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!'v' Gr'iginator Dr.t3 Brown & Root Quality Assurcr,m G.'.t 2
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a t3 Approved by:
TUGC0 Quality Ass'Jrance
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%8-h 07/03/84
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Construction Project Managdr Dr.t 3 Eft'Ective Date
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i JOB 35-1195 COMANCHE PEAK STEAM ELECTRIC STATION Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 1
Notice applicable to Construction Procedure No. 35-1195-CP-CPM 6.90 Rev.
6 This change will be incorporated in the next revision of the procedure.
Change the procedure as follows:
Please replace the followino page with the attached:
PAGE 41 of 58 PAGE 42 of 58 REVIEWED BY:
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2-4-24
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Sr. Project Welding Engineer
/4 2/.3AS-;l fS.it 2 3 -E V a
Originato Q Oate spl Brown & Root Qualit Assurance Date 3hN
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Date Approved by:
TUGC0 Quality A nce h k/d n.
AY 7-f-VS/
02/09/84 Construction Project Manager Date '
Effective Date
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PROCEDURE EFFECTIVE s
BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 U.E 12 G34 2 of 58 l
CP-CPM 6.9D 6
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3.11 TACK WELDS 3.12 INTERPASS CLEANING 3.13 WORKMANSHIP 3.14 PIPE ATTACHMENT WELDS 3.15 WELDING TECHNIQUES 3.16 WELDMENT SURFACES 3.17 FINAL NONDESTRUCTIVE EXAMINATION 3.13 FERRITE CONTROL 3.19 WELD AND BASE METAL REPAIRS 3.20 WELDER QUALIFICATION 3.21 POST-WELD HEAT TREATMENT 3.22 BRAZING OF COPPER PIPE OR TUBE 3.23 SOLDERING OF COPPER PIPE OR TUBE 0.11 TABLES 6.9D-1 PWHT MR ASME SECTION III, PIPING SYSTEMS 6.9D-2 PWHT FOR ANSI B31.1, PIPING SYSTEMS 0.111 FIGURES 6.9D-1 WELD PARAMETER dUIDE
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6.9D-2 WELD DATA SHEET 6.9D-3 REPAIR PROCESS SHEET 6.9D-4 FIELD INSPECTION REPORT 6.9D-5 PURGE DAMS 6.9D-6 PURGE DAM LOG 6.9D-7 CONSUMABLE INSERT DESIGN 6.9D-8 JOINT DETAILS FOR CONSUMABLE INSERTS 6.9D-9 BUIT JOINTS WITH BACKING 6.9D-10 BUTTWELD ALIGNMENT TOLERANCES 6.9D-11 SOCKET WELD FITUP 6.9D-12 DELTA FERRITE LOG 6.9D-13 REQUEST FOR WELDER TRAINING AND/0R TESTING 6.9D-14 WELDING PERFORMANCE QUALIFICATION WORKSHEET 6.9D-13 BRAZING PERFORMANCE QUALIFICATION WORKSHEET 6.9D-16 PWHT CONTROL FORM 6.9D-17 THERMOCOUPLE PLACEMENT FOR PWHT 6.9D-18 Q PIPE WELDING FLOW CHART 6.9D-19 TYPICAL FITTING TO FITTING SOCKET WELDED CONNECTION 6.9D-20 HEATING ALIGNMENT FORM 6.9D-21 JOINT PREPARATION FOR INSERVICE INSPECTION 6.9D-22 POST WELD HEAT TREATMENT CHECKLIST e
PROCEDURE EFFECTIVE l
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BROWN & ROOT, INC.
NUMBER REVISION DATE l
PAGE CPSES I
JOB 35-1195 CP-CPM 6.9D 6
JAN 101984 3 of 58 1.0 I"f"0 DUCTION This appendix to procedure CPM 6.9 has been prepared to delineate and control welding and related processes for piping at the Comanche Peak Steam Electric Station (CPSES).
Postweld heat treatment of component supports shall be performed in accordance with this appendix.
2.0 CENERAL 2.1 APPROVAL AUTHORITY The, requirements for origination, review and approval of this appendix shall be in accordance with procedure CPM 6.1.
In addition, this appendix and its' DCN's shall be approved by the Project Welding Engineer.
2.2 RESPONSIBILITY compliance with this appendix shall ba the responsibility of the Project Welding Engineer (PWE) and the General Mechanical Superintendent (GMS).
2.3 SPECIAL REQUIREMENTS This section shall define and control all aspects of welding and welding related controls for ASME component supports and BOP and AsME piping.
In order to differentiate code applicability of welding variables only, a notation has been made in the left-hand margin as follows:
ASME piping and instrumentation "Q"
tubing related requirements.
Balance of Plant piping related "B.O.P."
j requirements, Indicates that the section is No notation applicable both "Q" and "B0P" applications.
QCI Indicates QC Inspection.
mers.
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
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REVISION DATE PAGE s
4 of 58 Special requirements for Safety BT Related plant piping fabricated to ANSI B31.1.
Requirements are in excess of those noted for BOP applications.
2.3.1 Weld Procedure Specifications Welding procedure specifications (WPSs) shall be written and qualified in accordance with ASME Section III and Section IX.
The WPSs shall be used as an integral portion of this procedure. All the applicable requirements of this appendix are a mandatory addition to each WPS.
Each WPS shall be reviewed and approved by Materials Engineering or the Project Welding Engineer and Quality Assurance, by Gibbs & Hill, Inc., and when they are to be used on Westinghouse-supplied components, by Westinghouse.
2.3.2 Subcontractor Specifications When existing subcontractor procedures have more stringent requirements than these given herein, the subcontractor requirements shall govern the installation and fabrication of applicable components, i.e., Westinghouse, Allis-Chalmers, etc.
NOTE 1:
Deviations from subcontractor requirements may be allowed when approved by the subcontractor's representative in writing to the PWE.
NOTE 2:
It is extremely important to protect exposed permanent plant equipment such as cable, cable trays, etc., from damage resulting from welding or flame-cutting activities. The foremen in charge of these activities shall be responsible to assure that adequate steps are taken to physically protect such equipment from sparks, etc.
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I PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE o
s CPSES JOB 35-1195 CP-CPM 6.9D 6
14 U34 5 of tb 2.4 PREFABRICATION / INSTALLATION VERIFICATION The QCI shall verify that the documentation to be used in fabrication or installation corresoonds to the enevane revision of the construction drawings.
If revision referred on documentation is current, or if later drawing revisions do not physically affect the work to be performed, such as changes in weld procedure, welds, or configuration work may proceed.
If the work is physically affected by any drawing changes, applicable documentation shall be reviewed and approved by Welding Engineering, QA/QC, and the ANI, as required.
2.5 DOCUMENTING WELD INSPECTIONS Upon completion of an opers: ion or of an inspection, the QCI shall stamp, initial, or sign and date the applicable documentation in the space provided. Work may not proceed beyond an established QC or ANI holdpoint until it has been verified or where permitted for ANI inspection points, waived.
2.5.1 Welding Inspection and Holdpoints.
Final NDE (VT, PT, MT) as required by the WDC may be performed in any sequence. Determination of such sequence shall be made by the cognizant QCI. Final Radiography where required shall not be performed prior to the completion of surface examinations.
2.5.2 Nondestructive Examination (NDE)
When required by a QC holdpoint, NDE shall be performed and documented at the appropriate stage of fabrication or installation. All required final NDE shall be performed after Post-Weld Heat Treatment (PWHT), unless otherwise permitted by MS-100.
Nondestructive examination shall be documented as required by Appendix 6.9-G.
2.5.3 Material / Parts Verification Before installing or the using of materials for fabrication, the QCI verifies that items or materials to be installed or used in fabrication have been accepted for construction
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES 34 6 of 58 CP-CPM 6.9D 6
activities or otherwise released, as delineated in Appendix 6.9C.
2.5.4 Material Traceability Control Material traceability to accepted documentation or on the
(
item shall be maintained at all times in shop or field
,}{l fabrication activities. Traceability shall be maintained by documentation traceable to material markings or where g
marking is impractical, by documentation traceable to segregated material. The QCI shall verify traceability by
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verifying that a material requisition for the material hasr p\\
been completed, approved and verified by the cognizan1JQQ
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receiving inspector, and may enter the MR number on thL e
applicable WDC and initial and date.
(For field welds only.)
s Alternatively in the Pipe Fabrication shop, traceability may be verified through the use of a heat number card file originated in accordance with QAP 8.1.
The QC Inspector shall verify that material to be used i's acceptable for the material type and grade, Piping Specification Category _and Code Class.
2.5.5 Traceability Marking Transfer During construction activities, prior to cutting bulk materials
__such as pipe or olate. or relocating identification bands, etc.,
the markings shall be transfered to the material being cut or the designation relocated. Verification shall also be made that marking is accomplished within the parameters of the applicable design specification.
NOTE:
Where traceability marking may be lost in cleaning operations as is the case with painted markings, the marking shall be transferred as above, using a more permanent marking method as permitted by Appendix 6.9E prior to any cleaning activities.
2.5.6 Prefabrication Prior to cutting pipe for fabrication 6 the latest issued drawings and any applicable CMCs should be checked.
The_
craftsman shall verify the color code, heat code marking,
PROCEDURE EFFECTIVE l BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE o
CPSES JOB 35-1195 U4N I 2 gy4 CP-CPM 6.9D 6
7 of 58 material markings, etc., when required are legible, and shall visually inspect the pipe surface for base metal defects.
Any deficiencies should be reported to the foreman. Pipe without color code markings and/or legible heat codei markings, when required (for ASME fabrication activiti.es),
shall not be used until its acceptability is verified.
2.6 WELD TECHNIQUE SHEET The Weld Technique Sheet (WTS Figure 6.9D-1) is intended to provide the welder or welding operator with the direction needed to weld in accordance with the applicable code and/or specification.
The WTS shall be issued for all welding done using a Weld Data Card ("Q" or "Non-Q") and for all "Q" safety related welding.
The Welding Engineering Department shall be responsible for providing WTS to the MDSs.
The MDS Attendant shall be responsible for issuing the WTS to craf t welders as filler material is issued and for collecting the Weld Technique Sheet when the welder turns in the WFML and remaining filler material.
When the supply of WTS is low (50) for a given procedure, the MDS shall notify WDCC with an AVO (Avoid Verbal Orders) requesting a new supply for the procedure.
_ NOTE :
When ICNs affect a WPS, the complete ICN shall be attached and issued with the WTS.
2.6.1 Distribution The PWE is responsible for originating and distributing new and/or revised WTS to each MDS.
All revisions will be issued with a unique numerical sequence. A routing sheet will accompany each issued revision, and the numerical sequence will be noted on the routing sheet.
The stamped numbers will only be with blue ink to prevent anyone other than the cognizant personnel from producing copies of the issued WTS.
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. EFFECTIVE
-BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE e
CPSES JOB 35-1195 JAN 13 3d CP-CPM 6.9D 6
8 of 58 l
When a craf t welder presents his WFML to the IDS attendant, the attendant shall process the WFML and issue filler material as described in Appendix 6.9B.
The applicable WTS with any applicable WPS ICNs for the latest WPS listed on the WFML shall be given to the welder with each filler material issuance.
The welder shall use the WTS as a reference to ensure that the proper welding parameters are used. When work is completed, the welder shall return the WTS issued to him to the MDS.
If the WTS is in good condition, it may be reused, otherwise it shall be destroyed.
2.7 BALANCE OF PLANT, PIPING, AND STRUCTURAL STEEL BOP INSPECTION AND DOCUMENTATION 2.7.1 Inspection Responsibilities The Site Engineering Staf f or Craf t Supervision shall be responsible for all inspection activities on Non-Q piping, tubing, and hangers except for welds in the systems noted below:
1).
Feedwater System 2).
Mainsteam System 3).
Steam Blowdown Systen l
- 4). - Class 5 Systems 5).
Piping designated "R" (potentially radioactive)
{
6).
Weldments requiring PWHT and/or NDE (PT,MT,RT,UT) in addition to visual examination per applicable code.
The P.WaE. shall be responsible for the inspection and documentation of all welds in 1 thru 6 above.
The P.W.E. shall be responsible for inspecting and monitorine all repairs to Non-O welds and base metal.
When NDE is required, the CIT or CFS, by using a " Request for NDE" form shall request QC or a WT to perform the examination.
The CIT visual examination shall be requested on an NDE Inspection Request, unless otherwise specified by the PWE.
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NUMBER REVISION DATE PAGE CPSES J4/l y ~o,,34 JOB 35-1195 4
9 of 58 CP-CPM 6.9D 6
Once NDE is performed, QC or the cognizant WT shall submit the NDE Report (if any) to the PWE for review and disposition.
When visual inspection is performed, the area CIT shall submit the Weld Data Sheet to the PWE for review and disposition.
If either of the above two reports indicate that a rejectable defect is located in a given weld joint, the area CIT shall mark the joint " HOLD" with bright colored ink.
The " HOLD" shall remain until the joint is released for repair by the WT.
A " HOLD" may also be placed on items or operations not conforming to project procedures and will remain until released by the PWE.
Upon issuance of RPSs by the FWTC, the CIT shall monitor all repairs and make the required inspections and signof fs.
2.7.2 Documentation Requirements The PWE shall initiate end control the Weld Data Sheet (Figure 6.9D-2) to be used for inspection documentation of all piping and component welds except as noted in Section 2.7.1.
The Repair Process Sheet (Figure 6.9D-3) will be used to document BOP piping, components, and structural repairs to base and weld metal defects in conjunction with the applicable drawing.
EXCEFTION 1:
Documentation of field run BOP and NNS 2 inch and under socket welds and BOP small-bore hanger welds is not required. However, piping shall be installed in accordance with controlled drawings.
EXCEPTION 2:
Inspection performed by Site Engineering or site supervision need not be documented.
Those welds defined as exceptions within the guidelines of Section 2.7.1 shall have WDCs (or WDSs for Class 5) and the appropriate NDE and/or PWHT documentation.
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES I
JOB 35-1195 AN l2 IE?d 10 of 58 CP-CPM 6.9D 6
NOTE:
WDCs and MWDCs used for BOP applications shall be clearly marked BOP and sections not required to be completed marked "N/A".
Weld filler material logs (WFMLs) and RPSs need not be retained for any Non-Q welds other than those exceptions defined in Section 2.7.1 and all documentation involved with major defect repairs.
For any required NDE for welds documented on the WDS, the NDE Report forms shall be filed in the weld data package.
For rejectable defects, repairs shall be documented as noted ab,ove.
The Field Inspection Report (Figure 6.9D-4) shall document inspection of Non-Q structural steel welds, in conjunction with documentation noted on the applicable drawings (s).
Welds to miscellaneous steel considered temporary nonplant items and welds performed in accordance with Gibbs & Hill specifications AS-5,6,7,17,18,20,SS-16A, and SS-17 do not require inspection documentation. Copies of approved BOP documentation shall be transmitted to the Permanent Plant Records Vault for storage.
NOTE:
The organization responsible for the final completion / review of the documentation is also responsible for ensuring that it is delivered to the Permanent Plant Records Vault.
2.7.3 Documentation Retained by the Piping Superintendent i
One copy of the pipe fabrication / installation drawing vill be maintained by the PS and used as back-up documentation for bo th "Q" and "Non-Q".
1.
Welder's symbol and date completed for each weld made in the PFS.
2.
Craf tsman's initials and date perfor=ed for spool dimensional check.
When fabrication / installation drawings are revised the PS may retain his marked up previous revision and need not mark up the new revision. However, the previous revision shall be stamped " VOID".
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES 1
4 JOB 35-1195 JAN I2 E34 CP-CPM 6.9D 6
11 of 5d 2.7.4 Non-Q Program Monitoring The PWE will sufficiently monitor the Non-Q program defined,
,__herein to assure that all applicable code specificatign_
requirements are met.
Monitor ~ing and documentation of Non-Q stud welding shall be performed in accordance with WES-14.
3.0 WELDING PROCESS AND RELATED REQUIREMENTS 3.1 LIMITED ACCESS WELDS (FIELD WELDS)
Q, BOP QCI When a safety or nonsafety-related weld is located in a limited access area where a mirror or other visual aids are required to make the weld, a limited accessibility test or mock-up that duplicates the production weld shall be required for the welder.
Q Limited access weld considerations are required on ASME III, Class. 1, 2, and 3 and NF Systems and other safety-related welde. This requirement does not apply to welds between carbo 1 steel, wrought or forged products. It does apply to bimetallic welds, welds between cli low-and high-alloy products, and welds involving any cast materials.
Unlimited Accessibility: No physical restriction within 12 inches of the weld joint, or only one physical restriction between 6 inches and 12 inches from the joint that does not obstruct the welder.
Special Access Conditions: If the PWE and/or Owner evaluates a weld as needing a special access performance' test, the welder shall be qualified for limited access conditions per WES-16 or, alternatively, may be given a test simulating existing field conditions.
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NUMBER REVISION DATE PAGE CPSES CP-CPM 6.9D 6
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3.1.1 Determination of Limited Accessibility in the Field Q
1.
Welds with physical restrictions within 12 inches of the weld joint or more than 1 physical restriction between 6 inches and 12 inches is evaluated at time of fit-up inspection by the cognizant QCI.
Q, BOP 2.
If the QCI (CIT for BOP) considers the weld in the limited accessibility category, then he shall contact the PWE and/or the Owner. If the PWE and/or Owner determines that a limited accessibility test is not required, then the PWE with assistance of the piping superintendent shall select a welder best suited to make this weld.
NOTE 1:
The final decision on limited accessibility is made by the PWE and/or Owner. He shall note such on the Weld Data Card or other applicable documentation and initial and date.
NOTE 2:
Qualification for limited access we'iding shall be monitored by QC Inspectors in accordance with WES-16, 3.2 CLEANING OF WELD PREPS AND BASE METAL Materials shall be clean to the extent that no contamination is visible to a person with normal visual acuity. Under no circumstances shall cleaning result in the loss of material traceability.
Q, BOP Final surfaces of all end preps shall be free of sharp surface irregularities, paint, oil, grease, mois ture, galvanization, slag, rust, scale, and burrs before proceeding with fit-up.
Slight irregularities in bevel areas are acceptable providing they are filled during weld out.
An isopropyl alcohol wash and demineralized water rinse shall be used as the cleaning agents for all Westinghouse-supplied items.
Q, BOP Deoxaluminate compound, used to coat weld preps, need not be removed before welding.
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E34 13 of 58 Q, BOP Prior to welding, a minimum of 12 inches on each side of the weld joint shall be free of moisture, dirt, grease and oil. The cleaning agent shall be either Varsol 1 or Stoddard Solvent or other approved solvents.
Isopropyl alcohol and demineralized water shall be used as the cleaning agent fo r all Westinghouse-supplied items.
QCI A minimum of 2 inches on each side of the weld joint shall be degreased prior to welding. Mechanict.1 preparation shall result in a clean surface 1/2 inch to 1 inch each side of the joint.
Q
' Welded attachments such as code plates within cleaned areas-do not have to be removed to satisfy the above cleaning requirements.
Power driven wire brushes shall not be used if the surface
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is to be subsequently Liquid Penetrant Examined.
3.2.1 Stainless Steel - Wire Brushing and/or Filing Q, BOP Wire brushing shall be performed with clean stainless steel wire brushes which have been designated for use on stainless steel only as specified in Appendix E.
Carbon steel files may be used on stainless steel but shall not be used interchangeable on carbon steel and stainless steel. Files used for stainless steel shall be color coded orange.
Q, BOP Shot or grit blasting may be used, providing the grit or shot composition is one of the following:
1.
Iron-free alumina grit.
2.
Iron-free silica grit.
3.
Iron-free silicon carbide grit.
Shot, grit, or stadblasting may be used only when surfaces do not contain, egevices or inaccessible areas or which will not be subsequently subjected to liquid penetrant inspection.
After fit-up, but before preheating, tack welding, or welding, the weld joint shall be cleaned with one of the applicable cleaning agents specified in Appendix 6.9H of this procedure.
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NUMBER REVISION DATE i
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CPSES JOB 35-1195 JAN 12 gg, CP-CPM 6.90 6
14 of 58 3.2.2 Carbon Steel - Mechanical preparation of carbon steel shall Q, BOP be by one of the following methods:
1.
Grinding.
2.
Wire brushing.
1 3.
Shot, grit, or sand blasting (providing surfaces do not contain crevices or inaccessible areas).
3.3 PREHEAT /INTERPASS TDiPERATURE Q, BOP The preheating and interpass temperature to be used for welding shall be in accordance with the applicable WPS.
Where the temperature of the surface of material to be welded falls below 60*F and a higher preheat is not required by the WPS, the weld area shall be preheated to a hand warm condition.
The preheat specified on the WPS shall be established before any welding.
Preheating may be performed by electric induction, electric resistance, or suitable gas burners.
Preheat and interpass temperatures shall be measured by the use of approved temperature indicating crayons, attached thermocouples, pyrometers or any other method approved by the Owner.
For Allis-Chalmers applications, it is reconmended that P4 and P5 materials have the preheat maintained until stress relief equipment can be positioned and temperature of the weld joint can be elevated to the stress relief temperature.
The area to be preheated on any weld joint shall be 3 times the wall thickness on each side of the maximum weld width.
The area shall be uniformly preheated to the required temperature before the start of production welding.
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PROCEDURE EFFECTIVE
, BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 jay 1 o~ E34 {
15 of 58 CP-CPM 6.9D 6
i Temperature indicating crayons, when used for preheat and interpass temperature measurement shall be applied to avoid direct contact with the surface to be welded.
The interpass and preheat temperature shall be measured on the surface of the base material, on the side which the welding is performed, within 1 inch of the weld joint edge, and along the joint 1 inch from the starting point for the next weld pass.
3.4 INERI GAS Q, BOP All shielding and purging gasee that are used shall be either " Welding Grade or Lammercial Grade".
Other gases may be substituted for argon; however, the fabricator shall separately qualify the affected welding procedures with the use of the alternate purge gas or--
mixture and furnish all results and evidence of qualification to the Owner / Engineer for review before using such procedures.
Purging plugs and dams used in conjunction with inert backing shall be removed upon completion of the welding. Necessary inspections shall attest to the above fact.
Purge dans shall be returned to the pipe shop af ter use.
QCI The minimum flow rate for the shielding end purge gas shall be in accordance with the applicable WPS, except that purge may be deleted the last 1 inch of the rootpass when purging through the weld joint.
QCI Prior to the start of welding, the exiting gas from the purged area shall be checked for its oxygen content. Oxygen content of the exiting gas shall be 2 or below before welding can begin.
(1% or below for Allis-Chalmers.)
The purge, when required, shall be maintained for a minimum of the rootpass and one fillpass: (rootpass and two subsequent layers for Westinghouse applications) (min. of
.375 inch thickness for Allis-Chalmers).
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CPSES I
E34 16 of 58 CP-CPM 6.9D 6
Socket welds should not require a back purge even if it is required by the WPS.
All Westinghouse-BMI socket welds shall require a back purge.
The purge dams should be placed a minimum cf 4 inches from the edge of the weld being made.
When purging with argon, the gas exit shall always be higher than the gas entrance unless otherwise approved by the PWE and concurred by the Engineer /0wner.
BOP,Q Purging shall be maintained for welding of attachments to stainless steel pipin; having a wall thickness of 1/4 inch or less for field wel'.c only. This may be waived on a case-by-case basis by the PWE and Site Engineering.
3.5 PURGE DAMS AND CONTROL OF PURGE DAMS The Pipe Department shall be responsible for the construction and maintenance of purge dams.
Purge dams shall be of the following types (see Figure 6.9D-5 for typical purge dams).
1.
Inflatable fabric or rubber bladders.
2.
Retrievable wooden plugs.
3.
Rubber and metal construction.
Purge dams shall be issued from the Pipe Shop by serial number.
When a purge dam is required, the craftsman will state the diameter and schedule required on a signed AVO.
Before issuing and upon returning the Purge Dam, the cognizant MDS personnel will complete the Purge Dam Log (Figure 6.9D-6).
Other materials such as pipe end caps, plastic, wood or cardboard cover plates, tape, or any other material which is suitable for maintaining the purge, may be used on the ends of the pipids, but shall not be inserted into the pipe to the extent thet it could go undetected. These items are not considered pcrge dams and are not subject to the controls described above.
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 "7
9 34 CP-CPM 6.9D 6
17 of 58 Complete logs will be filed by MDS personnel.
All purge dams will either be turned in at the end of each work shif t or the craf tsman supervisor or foreman must submit written notice to the MDS attendant as to when the purge dam will be returned.
If a purge dam is damaged beyond use, it shall be returned to the MDS for repair or scrap and this action shall be documented on the Master Log.
3.6 CONSUMABLE INSERTS Consumable insert material shall have the same nominal chemical composition as that being employed for the a_,plicable filler metal.
On austentric stainless steel base material of type 304 and 316, type 308 and 316 filler material respectively shall be used. Exceptions may be extended for Westinghouse applica-tions by the PWE.
Though not mandatory, consumable inserts are preferred in accomplishing the rootpass of all buttwelds.
Recommended shapes of consumable inserts are illustrated in Figure 6.9D-7.
QCI Consumable inserts shall be cleaned before fit-up.
QCI The maximum permissible gap between the consumable insert and the weld end prep shall not exceed 1/32 inch, but may be on either or both sides of the insert.
Notches as prescribed by the PWE for viewing insert fusion should not exceed k inch in length and approximately one-half the thickness of the insert in depth. Gaps between insert ends should not exceed approximately 3/32 inch.
3.7 BACKING STRIPS AND/0R RINGS Q
No backing strips and/or rings shall be used without the consent of Site Engineering.
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NUMBER REVISION DATE PAGE CPSES CP-CPM 6.9D 6
U24 18 of 58 BOP Machined or split-type backing rings may be used for carbon steel piping up to 24 inches in diameter with the exception of piping associated with Main Steam or Feedwater Systems or where the line is designated "R" (potentially radioactive) on Engineering Composite Drawings. The backing rings are not permitted where the piping will receive a subsequent internal lining.
BOP Backing strips / rings outside the systems in Section 3.7 may be used provided they are removed following the welding operation and the reverse side is. visually examined, cleaned, and repaired to sound metal.
Q, BOP Where machined backing strips / rings are used they shall be machined to the dimensions and to the tolerances given by Pipe Fabrication Institute (PFI).
Q,80P Backing strip / ring material shall be of the same material or similar material-in the same P-groupings as the process pipe.
B0P,Q Backing material shall be exempt from all mechanical property tests.
Backing material shall be cleaned in accordance with the requirements established for the base metal weld prep on which it is to be used.
Permanent backing strips shall be continuous and shall be attached by full penetration welds. Spacer pins shall not be incorporated into the weld.
3.,8 PEENING BOP,Q No peening of welds shall be permitted.
3.9 IMPACT TESTING (WELDING PROCEDURE QUALIFICATION)
Q All pressure-retaining materials, consisting of Class 1 and 2 shall be impact tested in accordance with the requirements of the ASME Section III, Subsection NB, excluding the folicwing:
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NUMBER REVISION DATE PAGE CPSES JOB 35-1195 14N 1 3.,O#
CP-CPM 6.9D 6
19 of 58 1.
Materials with a nominal section thickness of 5/8 inch and less.
2.
Bolting, including studs, nuts and bolts, with a nominal size of 1 inch and less.
3.
Bars with a nominal cross-sectional area of I square inch or less.
4.
All thicknesses of material for pipe, tube, fittings, pumps and valves with a nominal pipe size 6-inch diameter and smaller.
5.
Materials for pumps, valves and fittings with all pipe connections of 5/8-inch nominal wall thickness and less.
6.
Class 2 materials exempted by 'the Owner / Engineer from impact testing.
Only P numbers, not group numbers, are applicable to Class 3 materials and non-Charpy-tested Class 2 materials.
3.10 WELD JOINT DESIGN AND FITUP Q, BOP QCI Pipe weld ends shall be prepared as required by Appendix 6.9E unless otherwise approved by the PWE and Site Engineering..
Before fit-up the ;raf tsman shall verify that the correct markings are on the pipe and/or the correct color code and legible heat code, when required, are on the fittings.
When in-line components, spools, etc., are to be joined, prior to fit-up, the correct item identification shall be verified by comparing markings on the component, spool, etc., to that on the applicable fabrication drawing.
Correct flow direction shall be checked on the fabrication drawing by the craftsman.
Q,B0P NOTE:
A CMC is required to remove a weld once it has progressed to the point of QC/ CIT acceptance of Fit-up.
For BOP applications, this requirement may be waived by the PWE on a case-by-case basis, i
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NUMBER REVISION DATE PAGE CPSES CP-CPM 6.9D 6
7?S4 20 of 58 The fit-up gap for buttvelded joints shall be that specified by the applicable WPS.
The maximum offset of the finished weld shall not be greater than the amount listed in the following table. The final weld surface and adjacent base metal shall blend uniformly.
3.10.1 Maximum Allowable Offset In Final Buttwelded Joints Section Thickness (inches)
Max. Allowable Offset Up to 3/4" 1/4 t Over 3/4" 3/16" The fit-up gap for "T" fillet joints shall be as small as practical; however, it should not exceed 1/16 inch.
If gap is in excess of 1/16 inch but not exceeding 5/32 inch, this condition will be considered acceptable provided the leg of the fillet veld is increased by the amount of separation'in excess of 1/16 inch. (The increase in fillet size applies only when the excess separation exceeds 10% of the joint length.)
The fit-up gap for " lap" fillet veld joints shall not exceed 1/8 inch at any location along the length of the joint.
BOP,Q Fit-up for consumable insert pipe welds shall be in accordance with Figure 6.9D-8.
BOP Fit-up for welds incorporating backing strips shall be in accordance with Figure 6.9D-9.
3.10.1.1 Inside Surface Accessible.
Q,QCI Q
The inside diameter mismatch for pipe joints shall not exceed the following:
Alignment of sections shall be such that the maximum of fset of the finished weld will not be greater than the applicable amount listed in the Table below where "t" is the nominal thickness of the thinner section at the joint.
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BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 g43 CP-CPM 6.9D 6
594 21 of 58 MAXIMUM ALLOWABLE OFFSET IN FINAL WELDED JOINTS Section Thickness Direction of Joints in Inches Longitudinal Circumferential Up to 1/2, inc.
1/4 t 1/4 t over 1/2 to 3/4, inc.
1/8 in.
1/4 t Over 3/4 to 11/2, inc.
1/8 in.
3/16 in.
Over 1-1/2 to 2, inc.
1/8 in.
1/8 t Over 2 Lesser,of 1/16 t Lesser of or 3/8 in.
1/8 t or 3/4 in.
For components of different diameter, larger offsets are acceptable providing at least a 3:1 taper of the width of the finished weld is maintained and the requirements of NB3200 are met as applicable.
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3.10.1.2 Inside Surface Inaccessible (See Figure 6.9D-10).
Q,QCI 1.
The inside diameters shall match each other within 1/16 inch.
2.
When the components are aligned concentrically, a uniform mismatch of 1/32 inch around the joint can result.
NOTE:
Other variables not associated with the diameter of the component often result in offset rather than concentric alignment. Therefore, when the components are aligned offset rather than concentric, the maximum misalignment at any one point around the joint shall not exceed 3/32 inch.
3.10.1.3 QCI The fit-up for socket welds shall be in accordance with Figure 6.9D-11.
BOP The inside diameter mismatch for pipe joints shall not exceed the following:
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NUMP.ER REVISION DATE PAGE CPSES JOB 35-1195 gar; y ~n EFd 22 of 58 CP-CPM 6.9D 6
1.
A continuous radial mismatch of 1/32 inch.
2.
A radial' mismatch of 1/16 inch at any one position of the inside diameter.
3.11 TACK WELDS 3.11.1 General BOP,Q All tack welds shall be made in accordance with an approved Q, BOP welding procedure by a qualified welder and deposited with an electrode or wire that is the same composition as the electrode used for rootpass.
Tack welds incorporated into the weld shall be visually examined and meet the following requirements:
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1.
The start and stop of the tack weld shall be ground to a feather edge for ease of integration into the weld.
2.
All slag and surface defects (e.g., porosity and cracks) shall be removed from the cack.
3.11.2 Weld Penetration Requirements BOP,Q When using the GTAW process on a full panetration stainless steel weld that will incorporate the tack, an inert gas back purge shall be used during the tacking process.
Tack welds performed by the GTAW process employing a consumable insert shall be tack welded without the addition of other filler metal.
Partial penetration tacks that crack during the welding of the consumable insert may be removed by re-fusing, providing the weld joint does not physically separate.
The tack welds used at the root opening of open butt joints shall be full penetration. Tacks which crack during welding shall be removed and. replaced.
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23 of 58 3.11.3 Clampt Used for Fit-up BOP,Q In addition to the above requirements, the following guidelines should be considered.
The use of jigs, alignment fixtures, or clamps may be used
-for ease of assembly of parts requiring tack welds.
All tack welds should be kept to a minimum number and size.
BOP,Q For consumable insert weld joints, the tack welds should be placed a maximum distance of either 3 inches or 90* apart, whichever is less. The tack welds should be approximately 3/8 inch in length or a length approved by the PUE.
BOP,Q For open buttweld joints, the tack welds should be placed a maximum distance of either 6 inches or 90* apart, whichever is less. The tack welds shc'ald bc approximately 3/8 inch in length or a length approved by the PWE.
3.11.4 Inspection After Tack Welding BOP,Q Af ter tack, welding, the QC Inspector / CIT shall verify that the correct configuration is maintained, verify the presence of socket end gap for socket welds as defined in fit-up, above, verify weld marking adjacent to the weld, and that the tack welder's symbol has been recorded on the Weld Filler Material Log.
Tack welds not requiring QCI, WT, or CIT Fit-up inspection, shall be inspected by the cognizant craf tsman.
3.12 INTERFASS CLEANING BOP,Q Interpass cleaning shall consist of the following:
1 1.
All slag and oxides shall be removed by either chipping, wire brushing, or grinding before making the next successive weld bead.
2.
All surface defects, undercutting, and overlapping shall be removed by grinding before making the next successive weld bead.
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NUMBER REVISION DATE PAGE CPSES I
JOB 35-1195 J49, n _,4 7;
24 of 58 CP-CPM 6.9D 6
3' All crater cracks or pits shall be removed by grinding before making the next successive weld bead.
3.13 WORKMANSHIP
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QCI During GTAW, care shall be taken to avoid contact between the tungsten electrode and the weld puddle, the base metal, or the filler metal. However, if this does occur and inclusions are found during NDE which are in excess of the code requirements, the inclusions shall be removed by grinding. When noted during the welding process, such inclusions should be removed when possible.
The weld bead contour shall be maintained as flat as possible. Excessive convexity (i.e., when the height of the weld bead matches or exceeds the weld bead width) shall not be acceptable.
The edges of all weld beads shall blend smoothly into the adjacent metal.
The welding are shall be manipulated to avoid undercutting the side wall of the weld end prep.
Welding should be not interrupted until at least 1/3 (1/4 of weld or 3/8 inch whichever is less for Allis-Chalmers) of the weld joint thickness is welded out (field fabrication only) unless spacer blocks are welded into position and the root and one filler layer is completed. This will not apply-to P3, P4, or P5 materials. On these materials the welding shall not be interrupted until at least approximately 1/3' of the weld groove has been deposited or 3/8 inch whichever is greater.
BOP,Q l.
The requirement defined in the paragraph above shall be invoked af ter the initiation of joint welding and shall not include tacking of the joints. However, the joint should be adequately supported to prev 49t tack cracking. (The requirements for 1/3 weld out will not apply for Westinghouse or Allis Chalmers-supplied
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 N 1 a rea CP-CPM 6.9D 6
25 of 53 piping unless approved in writing by the site repre-sentative.)
2.
All pressure-containing welds (butt and fillet) shall consist of not less than two passes (layers) regardless of wall thickness, unless otherwise approved by Site Engineering in writing.
Q 3.
Section thickness after grinding, machining, or bending shall not be less than that specified.
3.14 PIPE ATTACHMENT WELDS (Permanent and Temporary)
QCI Q
No temporary attachments shall be permitted for shop-fabricated "Q" piping. Use of temporary attachments on all Westinghouse-supplied items requires Westinghouse approval.
NOTE:
This section does not apply to spacer blocks used to maintain groove alignment provided they are (a) removed before completing the weld joint, and (b) the tacks ars in the groove where they become part of the finished weld. WFMLs for filler metal issuance shall be against the Weld No, requiring the spacer blocks. Spacer blocks shall be of a material compatible with the base material.
This section does not apply to temporary spools used for flush purposes.
Q When welds are to be made for piping attachments a WDC shall be used.
BOP,Q The base material used for a temporary attachment shall be QCI the same P number as the base material of the component to which it shall be attached; however, the attachment need not be certified material.
Temporary attachments shall be marked with the material specification and type, grade, or class as applicable. The QCI shall verify that the temporary attachment material is of the same P number as that of the permanent piping to installation as documented by signing the cleanliness verification on the temporary attachment WDC.
Temporary attachments shall not be welded directly to austenitic stainless steel piping materials.
BOP,Q All temporary attachments shall be marked with some means of QCI identification (i.e., painted or marked) so that removal of the attachment will be ensured.
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NUMBER REVISION DATE PAGE CPSES l
JOB 35-1195
""N I2 E?4 26 of 58 CP-CPM 6.9D 6
Attachment fit-up, alignment, orientation, and location shall be in accordance with this section.
For permanent attachments, the design location is defined by the isometric drawing and this procedure.
3.14.1 Removal of Temporary Attachments The removal of temporary attachments shall be in accordance with the following procedure:
1.
. Temporary attachments shall be removed using either oxy-fuel cutting, air-carbon are cutting or grinding.
2.
If the attachment is removed by one of the thermal cutting processes, at least 1/8 inch (1/16 inch for NF) of the attachment shall remain above the component surface. This remaining portion of the attachment shall be removed by grinding. When using air-carbon-arc cutting, stainless steel piping shall be protected from contamication.
QCI 3.
The area of component from which the attachment was removed shall be ground emooth and blended into the surrounding surface.
Q, 4.
Af ter grindit.g the area from which the attachment was QCI removed, it shall be liquid-penetrant or magnetic-particle examined.
3.14.2 PWHT Af ter Removal Q, BOP If the WPS that was used to weld the temporary attachment requires PWHT, the PWHT shall be accomplished after the attachment has been removed.
If the PRHT is required, the area shall be reinspected visually after PWHT.
3.14.3 Welding Attachments on Lines Which Contain Non-Volatile Fluids Attachment welds may be made to systems containing water provided the conditions of paragraph 3.14.3.1 or 3.14.3.2 are met (reference i
DCA 12,204). When such welds are to be made, the weld data cards shall be returned to Welding Engineering for the addition of hold points and approval.
3.14.3.1 Stainless Steel a.
Attachments and pipe are of compatible material;
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NUMBER REVISION DATE PAGE CPSES I
JOB 35-1195 J4fg y
, 34 27 of 58 CP-CPM 6.9D 6
c b.
The throat thickness of the attachment fillet weld shall not exceed the pipe wall thickness; c.
The maximum heat input shall be the maximum allowed for a 5/32" electrode; d.
All welds and adjacent pipe base metal up to " from the toe of the weld shall be liquid penetrant examined.
3.14.3.2 Carbon Steel a.
Attachments and pipe are of compatible material; b.
The throat thickness of the attachment fillet weld shall not exceed the pipe wall thickness; c.
The base metal shall be 0.30% carbon or less; d.
The maximum input shall be the maximum allowed for a 5/32" electrode; e.
The base metal shall be pre-heated to 200*F; f.
'All the welds and adjacent pipe base metal up to from the toe of the weld shall be liquid penetrant or magnetic particle examined; g.
If the SMAN processes is used, the minimum electrode diameter shall be 5/32".
3.15 WELDING TECHNIQUES Q, BOP If possible, all welds shall be accomplished using stringer beads. The following are guidelines for the allowable bead widths in accordance with process and material. However, the maximum allowable bead width shall be established by the WPS.
Austenitic Process Ferritic Steel Stainless Steel Q, BOP GTAW 3/8" 3/8" Q, BOP SMAW 4 core wire diameters 4 core wire diameters GMAW 3/8" 3/8" FCAW 3/8" (5/8" BOP Shop) 3/8" (5/8" B0P Shop)
Tungsten _ electrodes manufactured in accordance with AWS AS.12 (Class EWTH1 or EWTH2) shall be used with the GTAW process.
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NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 6.9D 6
I2 534 28 of 58 3.15.1 When welding the pipe girth in the SG or 6G position, the Q, BOP following bead placements should be followed. Other placements may be used when approved <by the Project Welding Engineer.
1.
None of the weld beads, including the root passes of the welds, shall be stopped or. started at the 6 o'glock position of the pipe.
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2.
The starts and stops of^all we'l beads betweeti adjacent weld layers shall be staggered a minimum of approximately 1 inch.
The minimum thickness of a bimetallic overlay after i
machining or grinding to the appropriate configuration shall be 1/16 inch.
3.16 WELDMENT SURFACES n
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q,qCI 3.16.1 POST-WELDING SURFACES Q, BOP The final surfaces of all welds shall be free of sharp surface irregularities, blowholes, cracks, laps, slag, are strikes, spatter, mishandling marks.' intermittent hollows and bumps.
In r.o case shall the surface conditionjinterfere with the interpretation of liquid ' penetrant, magnscic particle, radiographic or ultrasonic examinations Nhe'n 'these are required.
The weld's reverse side shall be clean, smooth, and free of icicles, lumps, slag accumulations, incomplete penetration, lack of fusion, burn-through or severe oxidations.
3.16.2 Weld Contours and Surfaces ASME Class 1 and 2 welds which are subject to in-service inpsection shall have their surfac.s prepared as required,by MS 100 and shall meet the following requirements:
The weld crown shall be prepared as described iu-
a.
Figure 6.9D-21.
[
b.
The adjacent base material shall be left in its "as-manufactured" condition unless nicks, gouges, et'c.,
exist. These discontinuities shall be blended into the base material to allow a smooth transition of the UT transducer.
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NUMBER REVISION DATE PAGE CPSES CP-CPM 6.9D 6
I ? gga 29 of 53 3.16.3 vald Reinforcement and Configuration QCI The maximum weld reinforcement on the pipe's outside diameter shall conform to the requirements of this section.,
The minimum weld reinforcement shall not be less than the outside diameter of the pipe.
When the weld joint is to be filled to the outside surface of the component having the larger diameter, a gradual transition, not exceeding a slope of 30' in the weld between the two surfaces -shall be attained.
However, to remove unnecessary weld deposit, the outside surface of the component having the larger diameter should be mechanically tapered at an angle not to exceed 30* with the pipe axis.
Q The surface of the reinforcement of all buttwelded joints to vessels, pumps, valves, and hangers may be flush with the base material or may have uniform crowns. The reinforcement height on each face of the weld shall not exceed the thickness in the following table.
NOMINAL THICKNESS, INCHES MAXIMUM REINFORCEMENT, INCHES Up to 1, Inc.
3/32 Over 1 to 2, Inc.
1/8 Over 2 to 3, Inc.
5/32 Over 3 to 4, Inc.
7/32 NOTE:
Butt joints are those between two members aligned approximately in the same plane. Reinforcement for other joint configurations shall be as defined by the PWE.
Q For double-welded butt joints, the limitation on the reinforcement given in Column 1 of the following tabulation shall apply separately to both inside and outside surfaces of the joint. For single-welded butt joints, the reinforce-ment given in Column 2 shall apply to the inside surface and the reinforcement given in Column 1 shall apply to the outside surface. The reinforcement shall be determined from the higher of the abutting surfaces involved.
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BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES CP-CPM 6.9D 6
2 G34 30 of 58 Material Nominal Maximum Reinforcement Thickness, Inches Thickness, Inches Column 1 Column 2 Up to 1/8, inc.
3/32 3/32 Over 1/8 to 3/16, inc.
1/8 3/32 Over 3/16 to 1/2, inc.
5/32 1/8 Over 1/2 to 1, inc.
3/16 5/32 Over 1 1/4 5/32 BOP The OD surface of pipe welds shall be prepared so that surface imperfections will not interfere with the NDE method that is used for the acceptance of the welds.
'he maximum weld reinforcement on the OD of a pipe weld shall not exceed 3/32' inch for material thicknesses up to and including 3/16 inch,1/8 inch for thicknesses from 3/16 inch through 1/2 inch, and 5/32 inch for all other material thicknesses. The minimum weld reinforcement shall not-reduce the thickness of the weld below the minimum wall thickness of the pipe.
The weld edges of buttwelds shall be free of overlap which forms a re-entrant angle of less than 90*.
Welding of Weldolets, Sockolets, and machined half-couplings shall conform to the weld reinforcement and configuration shown in Figure 6.9D-23.
Weld metal in excess of that shown shall not be cause for rejection.
3.16.4 Fillet Weld Size QCI Socket welds shall have a minimum fillet leg size of 1.1 times the nominal thickness of the pipe wall, but not less than 1/8 inch.
Fillet welds used for attaching slip-on or socket welded flanges shall have a minimum leg size of the thickness of the hub or 1.4 times (Q) or 1.1 times (BOP) the nominal thickness of the pipe wall, but not less than 1/8 inch.
Fitting-to-fitting socket weld sizes, i.e.,
reducing insert to socket welded T, shall be based on the nominal wall of the larger size pipe or equal to the socket lip dimension, whichever is smaller (See Figure CPM-6.9D-19).
For attachment welds, fillet weld sizes specified on the 4Eay&ggwaI8 }Dinginimum size required along the full length
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I CPSES JOB 35-1195 d4h i s 7334 CP-CPM 6.9D 6
31 of 58 Additional welding is acceptable provided it does not distort the items being joined together. Fillet welds to systems which have been acceptably pressure tested shall not exceed 3/8" throat thickness.
Q, Undercuts shall not exceed 1/32 inch and shall not encroach QCI on the required section thickness.
3.17 FINAL NONDESTRUCTIVE EXAMINATION 3.17.1 RT Flagging PS,QCRT Welds which require radiography should be so designated on the spool, assembly, etc., in the following manner:
1.
All buttwelds, that require radiography should be identified with a blue plastic ribbon and a radiography identification card, with the following information:
the applicable drawing, line, weld number and date.
The Craf t Foreman is responsible for these activities.
2.
After a weld has been radiographed, the blue ribbon will be replaced with a yellow ribbon showing the weld has been radiographed. The r.diography technician may apply the yellow ribbon.
NOTE:
The application of colored ribbons and cards to welds is to assist handling and has no effect on quality; therefore, replacement of lost ribbons, cards, etc., is not mandatory.
3.17.2 Documentation At the conclusion of the weld process, the craft submits a RT request attached to the applicable WDC, for tracking purposes. Both the RT Request and WDC are forwarded to the PWE for informal review. The RT Request and WDC are forwarded to QC radiography for radiographic testing processes.
All NDE shall be performed as required by the fabrication drawings and WDCs.
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i CP-CPM 6.9D 6
32 of 58 If the examination results are acceptable, the QCRT group shall sign the RT holdpoint on the WDC and file the RT report with the WDC, noting the log number, and the procedure and revision to which work was accomplished in the applicable space. The WDC package shall be returned to the FWTC af ter obtaining ANI review of the resulting film.
If examination results are unacceptable, the QCRT group shall return the WDC with the " rejected" RT request to the FWTC for the issuance of repair or removal documentation via a. Repair Process Sheet or CMC.
NOTE 1:
For component supports, the entire component support package shall be routed in the same manner as for WDCs.
All non-co'e required radiographs and those to d
NOTE 2:
ANSI B31.1 and B31.3 may be interpreted by welding engineering personnel.
3.18 FERRITE CONTROL (FIELD WELDS)
Q,BT l
QCI When Delta Ferrite is a QC holdpoint, the-QCI shall make these verifications concurrently with the WT.
3.'18.1 DELTA FERRITE CONTROL The following instruments shall be used to measure the delta ferrite content in welds unless otherwise approved:
1.
Ferrite Indicator (Severn Cage) - manufactured by the Severn Engineering Company.
2.
Ferritescope - manufactured by Twin Cities Testing Laboratories.
3.18.2 Calibration Equipment used for the measurement of delta ferrite shall be calibrated in the manner prescribed in CPM 13.1.
3.18.3 Stainless Steel Butt Welds Austenitic stainless steel field buttwelds shall include examination unless exempted by the PWE using a magnetic measurement device or indicator to ascertain a minimum delta-ferrite content of 5%.
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When an inspected weld does not meet the requirements of this section, the Owner / Engineer shall be notified by the transmittal of a copy of the WDC applicable to that weld.
Removal and/or repair of a weld shall only occur upon the receipt of written direction from the Owner / Engineer and shall be done in accordance with an approved procedure.
3.18.4 Velta-Ferrite Tests of Field Welds Delta-Ferrite testing of field welds shall be performed as outlined below:
NOTE:
Delta ferrite testing may be eliminated by testing other than in production welds.
In the event that a ferrite analysis of a weld deposited pad has excluded the welds completed utilizing particular stainless rod, the PWE.shall note " Ferrite Testing Waived" on the applicable WDC and initial and date.
A listing of filler material heat numbers exempted from ferrite testing shall be supplied to' the QC Department by the Pk'E.
1.
All austenitic SS buttwelds with a thickness exceeding i inch shall be checked to assure compliance is within that prescribed by Section 3.18.3.
2.
The first 100 buttwelds,1 inch or less in thickness within each applicable piping system, shall be checked to assure compliance is within that prescribed in Section 3.18.3 above.
3.
The number of buttwelds not meeting the specifications, as determined by the Owner's Welding Engineer, shall not exceed 5%.
If the failure rate exceeds this amount, an additional 100 welds shall be inspected to assure compliance is within that prescribed in this paragraph.
4.
Where the lot of welds inspected meet the delta ferrite requirements, a total of 10% of the remaining field welds in the system shall be inspected. Any welds rejected from this sample shall require inspection of the following 100 welds to ascertain that the 5%
rejection rate is not exceeded.
5.
Welds not meeting the delta ferrite requirements shall be repaired or removed in accordance with an approved procedure and shall only be performed upon receipt of written direction from the Cwner's Welding Engineer.
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NUMBER REVISION DATE PAGE CPSES JOB 35-1195 J4f;y3 bb4 CP-CPM 6.9D 6
34 of 33 Examination of austenitic stainless steel welds in the SG or 6G position shall be conducted at the approximate centerline of the weld at 12:00, 3:00, 6:00 and 9:00 o' clock.
Other welding positions shall be examined at four locations, located approximately 90' from one another in the center line of the weld.
Each evalu'ation shall be within that prescribed by this paragraph or repaired and removed in accordance with (5) above.
3.18.5 Inspection Procedure Calibrated delta ferrite measurement devices shall be issued as required to WTs by the calibrated tool room. These devices shall be returned to the tool room at the end of each work day.
When a weld requires delta ferrite testing, it shall be noted on the WDC.
The results of the examination shall be documented on the WDC by the WT.
~
Two Delta Ferrite Logs (DFL) shall be maintained by FWTC for each applicable piping system.
1.
One DFL shall list all delta ferrite checks on welds with thickness one (1) inch or less.
2.
The other DFL shall list all delta ferrite checks on welds with thickness over one (1) inch.
The DFL is shown as Figure 6.9 D-12.
A copy of the DFL shall be turned over the Owner / Engineer on a monthly basis.
The original DFL shall become part of the documentation for each system and shall be filed in the Permanent Plant Records vault.
3.19 WELD AND BASE METAL REPAIRS FWTC
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NUMBER REVISION DATE PAGE CPSES JOB 35-1195 JAN 1o.
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3.19.1 In Process Weld Repairs Q
In process repairs shall be defined as those discovered prior to final code required NDE.
All major weld defects discovered before final inspection shall be evaluated by the PWE who may generate an RPS operational sequence at his discretion.
NOTE:
Through wall repairs or those where 1/8 inch or less metal remains shall require an RPS.
The removal of starts and stops and slag, etc. may be routinely ground out during the welding process. No documentation is required.
When wel.d. defects are discovered before final inspection (In process), and operational steps are not defined by the PWE, the following operational steps may be used to affect reworking:
Grind as required to remove defects within the guidelines of this procedure.
Perform information PT or MT Reveld utilizing original welding procedure Grind and fair deposited area into the surrounding metal surface t.
Reinspect utilizing the original NDE method and acceptance criteria for information unless defined otherwise by the PWE.
3.19.2 Weld Metal Repairs 3.19.2.1 Major Defects BOP,Q The following defects discovered during or af ter final code required NDE shall be classified as " Major Repairs":
1.
All cracks and/or linear defects identified during the final inspection of a weld joint.
2.
Cracks, that are repaired and then reappear after the repair.
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PROCEDURE EFFECTIVE l BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 g43 y ~,,,'30',
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36 of 58 3.
Minor repair excavations that result in a repair cavity that reduces the thickness of the weld to approximately 1/8" or less.
4.
Any defect which is identified during final PWHT or hydrostatic testing.
5.
All defects which penetrate the root of the weld, such as grind-throughs or burn-throughs.
The resolution shall be by the PWE using a RPS and shall contain as a minimum, the following:
6.
An explanation of the method to be used to locate and excavate the defect (mechanical means or thermal gouging).
7.
Method of inspection to be used to ensure the defect has been removed.
8.
The method such as the Welding Procedure Specification and any special technique that may be required to be used to repair the excavation.
9.
The method to be used to reinspect the repaired area and the acceptance criteria for the reinspection.
10.
The proper approvals of the other groups involved with the repair.
NOTE:
This may include the component manufacturer, QC and/or Construction, and the Owner / Engineer.(Westinghouse as applicable.)
3.19.2.2 Minor Defects Q, BOP The following types of defects discovered during or af ter final code required NDE shall be classified as " Minor Repairs":
1.
All code rejectable defects not included under the Major Repair classification.
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BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 JAN 1~o sea CP-CPM 6.9D 6
37 of 58
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2.
All defects resulting from fitup, cleanliness, and other welding parameters which are violations of the WPS or this appendix.
The applicable operations shall be as follows:
3.
Locate the defect and mark the area to be excavated.
4.
Excavate (remove) the defects by grinding or air-carbon-arc gouging. If air-carbon-are gouging is used, the gouged surface shall be ground back to clean bright metal; SS piping shall be protected from contamination.
5.
When it is felt the defect has been removed, inspect the excavated area with MT or PT.
6.
After rewelding the excavation, the repaired area shall be ground and faired into the surrounding metal surface.
7.
The repaired area shall be reinspected using t!a original NDE method (s) and acceptance criteria.
8.
Westinghouse will evaluate and provide resolution on any minor repair to Westinghouse supplied items.
3.19.2.3 Additional Recuirements Q, BOP When a weld is made utilizing a consumable insert and is rejected af ter NDE, use of the open buttwelding technique to make repairs to the root pass is peimitted when the repair does not exceed 3 inches. Repairs to areas greater than 3 inches will be handled on a case-by-case basis and will require Owner / Engineer approval.
Q, BOP Through the root excavations shall not result in a root opening in excess of 5/16" wide.
In those cases where this dimensica is exceeded, the sides of the joint shall be buttered to achieve an acceptable opening prior to closure of the root.
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 JAN 1p CP-CPM 6.9D 6
38 of SS Q,BT To minimize sensitization of SS material, each defect shall be limited to two repairs. If the defect has not been eliminated in two attempts the procedure shall be submitted to the Owner for approval defining methods for further repair and sensitization control. When a weld is completely removed for any reason, the weld prep configuration may be restored and the weld repla,ced in accoriance with an approved WPS.
If any weld defects are evident in the replacement weld, a procedure shall be submitted to the Owner for repair and sensitization control to remove all such defects.
In no case shall a weld be completely removed and replaced more than twice without specific Owner approval except that uoints where the RAZ has been removed on both sides of the joint and the removal documented the replacement weld may be treated as a virgin weld.
NOTE:
When stainless steel items which have been welded previously are reused, the new weld number shall be 'the next sequential number of the item with the highest alpha numeric weld number.
3.19.3 Cosmetic Repair A cosmetic repair shall be considered the removal of ID or OD surface conditions which interfere with the interpretation of NDE after the final visual examination has been completed.
This provides a secondary signoff for' Visual examination and other NDE.
A pre-established sequence may be used for cosmetic repairs.
If the final visual examination on the WDC or MRS has not been signed an operational sequence to require reinspection is not necessary.
If visual examination has been completed, initiate a RPS operational sequence.
If an item covered by an MRS, " Final Dimension / Surface Condition" holdpoint has not been completed by the ANI, ANI review shall be noted as "N/A".
If signed, ANI, review is required.
NOTE:
For fabrication,ANI review shall be documented on the MRS.
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l PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 I
CP-CPM 6.9D 6
E?4 39 of 58 Require visual examination where accessible. Require UT examination, or where possible, mechanical measurement to verify wall thickness. Where VT is impossible, RT may be substituted.
3.19.4 Base Metal Repairs 3.19.4.1 Major Defects Q, BOP Base metal defects that must be repaired by welding are major repairs ~
3.19.4.2 Minor Defects.
Q, BOP Base metal defects removed by grinding are minor repairs; however, if grinding violates minimum wall thickness, the repair must be completed as a major repair.
3.19.4.3 Reporting and Documenting Surface Defects BOP, Q Welding Engineering shall prepare a RPS for all major repairs.
Surface defects (including laps, seams, are strikes, gouges, etc.) do not require a RPS if they can be corrected without welding. These conditions may be recorded on a Base / Weld Metal Inspection Report (B/WMIR) by QC. The B/WMIR may be presented to the craf t and corrective action taken.
If during the corrective action minimum wall is violated, work shall be suspended. A RPS shall be obtained before work may be resumed.
Minimum wall violations within 1" of piping end preps may be identified on a B/WMIR and forwarded to Welding Engineering for preparation of a RPS.
BOP, Q Surface defects (other than are strikes) no deeper than 1/16 inch need not be repaired if the defect does not encroach on the minimum wall thickness.
Minor base metal repairs do not require an RPS.
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QCI The QC NDE Inspector will mark the repaired area, when b
practical, with a " Nissen Ink Marker" showing a circle around the area and the repair number after the visual examination is complete.
Mafor base metal repairs on the inside surface of an item shall be located and marked on the outside surface to facilitate inspection during the pressure test.
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES CP-CPM 6.9D 6
22 G34 40 of 58 QCI Af ter performing base metal repairs the repaired area shall l
be inspected as requirea oy Appendix 0.9G and as supplemented by the PWE.
QCI Westinghouse will evaluate and provide resolution on any major or minor repairs on Westinghouse supplied items (this shall include all are strike repairs.
Modification of any Westinghouse-supplied items must have
-Westinghouse approval prior to the modification.
All arc strikes shall be removed from base metal surfaces.
NOTE:
Defect repair' cavities shall be-sufficiently wide to permit complete fusion and allow free manipula-tion of the electrodes during repair welding.
t 3.19.5 Documentation and Evaluation of Minimum Wall Violations 3.19.5.1 Minimum Wall Violations at Weld End Preps 1.
QC shall place a hold tag on the item ani note the rejectableNDE report number on the hofd tag.
2.
Submit the NDE report to Welding Engineering.
3.
If the minimum wall violation at weld end preps can be repaired in accordance with the requirements of Speci-fications15-100 or MS-43B or MS-44B, then Welding Engineering will issue a RPS (for completed or par-tially completed welds) or additional operations on the WDC (for joints where welding is not initiated).
4.
If the minimum wall violations at weld end preps cannot be repaired in accordance with the requirements of Specifications MS-100 or MS-43B or MS-44B, then Welding Engineering shall submit the RPS to Mechanical Engineer-ing for evaluation and resolution.
5.
The hold tag will be removed by QC prior to start of work only after the RPS has been issued or the NCR dispositioned "use as is" by engineering.
3.19.5.2 NCR's For Minimum Wall Violations 1.
Welding Engineering shall review the condition stated on the NCR and compare the stated wall thickness against the specified minimum wall for the piping system in accor-dance with the following criteria.
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PROCEDURE EFFECIIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 6.9D 6
01/12/84 41 o f 58 The ministan wall thickness for seamless or welded without filler metal pipe ordered to nominal wall in the Engineer's Piping Specification Sheets shall not be more than 12.5 percent under the specified nominal wall. thickness according to the following formula:
Tn X 0.875 = Tm (Note 1)
Where Tn is the nominal pipe wall thickness Tm is the minimum wall thickness.
NOTE 1: For pipe ordered to minimum wall, Tm is as specified in the Engineer's Piping Specification Sheets. Minimum wall for line 30"-SW-2-001-150-3 shall be de fined as 0.364 in, as dispositioned 'on NCR-M1681 Rev.1.
2.
Where the stated wall thickness is 10% or less under the specified minimum, Welding Engineering shall disposition the NCR to " Rework" _and issue an RPS to build up by welding in accordance with the ASME B&PV Code Section III, Paragraphs NB 2539 and the applicable provisions o f Gibbs & Hill Specification 2323-MS 100, 3.
In those cases where the stated thickness is more than 10%
below the specified minimum wall and the pipirs system has been pressure tested the NCR 'shall be forwarded to Mechanical Engineerits for disposition. For systems that have not been pressure tested, Welding Engineering shall disposition the NCR as specified in paragraph 2.
4.
Engineering approval for NCR's dispositioned to " Rework" as specified in paragraph 2 is not required. Engineering approval shall be required on the resulting Repair Process Sheet prior to i?cuance.
5.
All NCR's for Vendor furnished N stamped components will require Engineerirg disposition or approval.
t 6.
Radiography and rehydro of welded repairs to welds after hydro and prior to stamping is required only if the condition is a result of an excavation which exceeds the lesser of 3/8" or 10% of the section thickness for Class I applications with Section Thickness being defined as the measured actual wall thickness adjacent to the area of repa ir.
CP-CPM 6.9D Rev. 6 DCN #3 08/03/84 Sheet 2 of 5
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CPSES NUMEER REVCSION DATE PACE JOB 35-1195 CP-CPM 6.9D 6
01/12/84 42 of 58 For Class II and III systems radiography and rehydro of a repair weld to welds is required if the repair cavity exceeds one of the following:
a.
1/3 t for t 4 h".
b.
k" for
"<t<
2h ".
c.
The lesser. of 3/8" or 10% t for t > 2 ".
For base metal repairs after hydro and prior to stamping radiography of the weld repair is required for all classes of construction except that rehydro is not required provided the cavity depth does not exceed those limits allowed for in repairs to welds.
3.19.6 Weld End Prep Repairs BOP -
Wald end preps shall not be repaired by welding without the written resolution of the PWE, Construction and the Owner /
Engineer, except as noted below.
1 L
Q,B0P Maximum depth of repair without site engineerirg approval is 3/8 inch deep (a RPS is required for this repair). On Westinghouse supplied items W concurrence is required for all repairs.
Q.
Mt or PT of weld and preparations in material less than 2 inch in thickness is not required after grindin6 or the addition of filler metal. Radiography of the completed weld is considered adequate.
I Q.
Any RT's after weld prep repairs exceeding the lesser of 3/8 inch or 10% of the section thickness may be accomplished after the joint when final RT is required by applicable specificatio ns.
Surfacing of weld end preps for fit-up purposes shall be accomplished by one or more stringer beads being deposited on an unbroken surface.
The surface shall be free of irregularities exceeding 1/32 inch in depth.
Surfacing required for fit-up to "T" fillet veld joints shall be accomplished by stringer beads deposited on the larger surface of the two joining members.
CP-CPM 6.9D Rev. 6 DCN //3 08/03/84 Sheet 3 of 5 W
i BROWN &' ROOT, INC.
PROCEDURE EFFE CTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 6.9D 6
01/12/84 43 of 58 3.19.7 Base Metal Repairs to Bulk Material For bulk piping materials in storage, the repaired item shall be banded to identify the nonconformance report number or other documentation by which it was repaired. The band may be removed after the item is inserted into a piping system. The repair documentation shall be filed with the documentation for piping subassemblies.
3.19.8 Repair of Arc Strikes Q
Arc strikes found on weldments or base materials may be repaired in accordance with the following requirements:
1.
For arc strike removal in stainless steel items, not
~
requiring rewelding, perform the following:
s.
Blend grind or buff; b.
For Class 1 Piping, perform a liquid penetrant examination of the removal areas; see Note below.
Verify that minimum wall thickness remains by UT c.
or mechanical measurement; d.
Perform a visual examination of the repair area.
2.
For are strike removal in carbon steel not requiring rewelding, perform the following; a.
Blend grind or buff; b.
For Class 1 Piping, perform a liquid penetrant or magnetic particle examination of the removal area; See No te.
Verify that minimum wall thickness remains by UT c.
or mechanical measurement; d.
Perform a visual examination of the repair area.
NOTE :
Westinghouse approval required on Westinghouse items.
3.
Documenta tion a.
Docunentation of are strikes not requiring welding shall be prepared in accordance with the applicable QA procedures. Upon receipt of the QC Inspection Report, work may be accomplished in accordance with the repair sequence listed on the Inspection Report.
Arc strikes requiring welding shall be documented on a RPS in accordance with paragraph 3.19.4.1.
CP-CPM 6.9D Rev. 6 DCN #3 08/03/84 Sheet 4 of 5 s
9 BROWN & R00r, INC.
PROCEDURE EFFECIIVE CPSES NUMBER REVISION DATE PACE JOB 35-1195 CP-CPM 6.9D 6
01/12/84 44 of 58 b.
Westinghouse approval required for Westinghouse-supplied items.
3.20 WELDER QUALIFICATION WQTC PWE Walder qualification shall be in strict compliance with Specification WES-031.
All welders shall be trained in accordance with the proper codes, WPSs, BPSs and other project requirements. All welders s'.all be under the direct supervision of the applicable CFS.
When the CFS submits a welder to the WQTC for qualification or training, a properly executed " Request for Walder/ Brazer Training and/or Testing" form (Figure 6.9D-13) shall accompany the welder.
3.20.1 Qualification Worksheet Once a welder / brazer per formance qualification test is complete, all applicabla data shall be tabulated on the proper worksheet (Figures 6.9D-14 and 15).
Welder / Brazer Update Status shall be as defined in WES-031.
3.20.2 Additional Requirements All Welder / Brazer qualification shall be carried out using the requirements of the Schedule of Standard Tests (WES-16).
The Welder Qualification Matrix shall be used to assure correct welder / brazer qualification in accordance with procedure WES-16.
Welders qualified Sar restricted access welding shall be identified by a special designation in Schedule of Standard Tests and Welder / Brazer Qualification Log.
3.21 POST-WELD HEAT TREATMENT QCI for Q
CENERAL All PWHT to ASME Section III and ANSI B31.1 requirements shall be per formed as required by this document.
The per formance of PWHT shall be the responsibility of the PS.
Monitorirg and documentation o f PWHT shall be done under the direction and control of the Pipe Department.
The selection of the proper PWHT equipment to be used and the proper method of application shall be the responsibility of the PRE.
CP-CPM 6.9D Rev. 6 DCN #3 08/03/84 Sheet 5 of 5 M_'=.-,
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NUMBER REVISION DATE PAGE CPSES CP-CPM 6.9D 6
I2 $3; 45 of Su Distribution of PWHT equipment to construction shall be the responsibility of the PS.
Documentation pf PWHT shall be the responsibility of the Pipe Dept.
Prior to PWHT, the blank recording chart shall have a "PWHT Control Form" (Figure 6.9-D-16) stamped on it by the responsible operator.
The responsible operator shall record all the required information on the "PWHT Control Form" stamped on the recording chart.
Upon the completion of the PWHI on a weld the portion of the recording chart showing the entire PWHT cycle shall be removed from the temperature recording machine.
The section of recording chart showing the PWHT cycle and the "PWHT Control Form" stamped on the recording chart shall become part of the documentation accompanying the Weld Data Card for the weld that the PWHT was performed on.
QC verification of the time-temperature chart for ASME III welds shall be made on the Post Weld Heat Treatment Check List contained on the RDC package (Fig. 6.9D-22).
When the WDC is returned to the WDCC for final acceptance, the FINAL APPROVAL line on the "PWHT Control Form" stamped on the recording chart shall be signed and dated by the PWE.
3.21.1 Heating Method The method of heating and cooling for PWHT shall be accomplished by resistance, furnace or induction heating for all pipe diameters greater than 2 inches nominal. This shall enable the required heating and cooling rate, metal temperature, metal temperature uniformity, and temperature control to be adequately maintained.
3.21.2 Time and Temperature Requirements The holding times and temperatures shall be in accordance with the specified welding procedure and within the minimum holding times and termperature ranges specified in Table 6.9D-1 and 2.
Time, temperature and heating and cooling rates shall be entered on the Weld Data Card by the PWE.
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NUMBER REVISION DATE PAGE CPSES
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3.21.3 Heating and Cooling Rates (ANSI 331.1, Piping Systems)
If resistance or furnace heating is the method selected for postweld heat treatment, the following shall apply:
For 2 inches and under (Nominal Weld Thickness):
the rate of heating shall not exceed 600*F/hr.
For (Nominal Wall Thickness) 2 inches and over: The rate of heating shall not exceed 600*F/hr divided by thickness in inches.
For Allis-Chalmers applications heating rate will be 550*F/hr divided by thickness in inches not exceeding 300*F/hr nor less than 100*F/hr. Cooling rates shall be 500*F/hr divided by thickness in inches, not exceeding 250*F/hr.
If performing post-weld heat treatment by the induction method, the following shall apply:
For thickness less than 1 inches (Nominal Weld Thickness),
the rate of heating shall not exceed 600*F/hr.
For thickness lh inches and over (Nominal Weld Thickness),
the rate of heating shall not exceed 400*F/hr.
When local heating is done the weld shall be allowed to cool slowly from the PWHT temperature. A suggested method of retarding cooling is to wrap the weld with insulating blankets and allow it to cool in still air.
The difference between thermocouple readings during the soaking period shall not exceed 100*F.
3.21.4 Heating and Cooling Rates (ASME SECTION III, Piping Systems)
The heating and cooling rate for post-weld heat treatment of P-1, P-4, P-3, and P-5 base materials shall be as follows:
Above 800*F, the rate of heating and cooling shall not exceed 400*F/hr. divided by the maximum thickness in inches of the material being heat treated, but in no case more than 400*F/hr. Cooling from 800*F may be done in still air for any metal thickness.
i PROCEDURE EFFECTIVE BROWN & ROOT, INC.
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47 of 58 Regardless of thickness, the rate of heating and cooling need not be less than 100*F/hr.
During the heating and cooling period, no variation in temperature greater than 250*F is permissable between any two thermocouples.
The rate of heating shall not exceed the rate of cooling specified in this section.
3.21.5 Joint Preparation The minimum width of the band on each side of the weld to be post-weld heat treated shall be the width of the weld reinforcement plus 2 inches. For Allis-Chalmers applica-tions, the heated band width shall be two (2) times wall thickness of the thicker member or the width of the weld plus 2 inches, whichever is greater. All paint, dirt, grease, oil, and other foreign matter shall be removed from heated areas prior to applying post-weld heat treatment.
Post-weld heat treatment of welded joints shall require that the entire band be brought up to a uniform temperature over the circumference of the heated pipe section.
A gradual diminishing of temperature outward from the edges of the band shall be maintained.
Internal drafts or chimney effect cooling during post-weld heat treatment shall be avoided. Valves shall be in the open or cracked position. Open-ended pipe shall be temporarily sealed up-stream and down-stream of the welded joint to reduce internal heat loss.
Weather protection against rain and wind exposure shall be provided during periods cf inclement weather.
Insulation directly over the heating element or heat source shall be Kaowool, Babcock and Wilcox, or equal, and shall be backed as required with additional insulation material.
The insulation not in direct contact with the heat source may be of a lesser grade. The thermal insulation shall extend to each side of th weld joint at least four pipe diameters or 24 inches, whichever is less.
l PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 JAN 1 'o.,A 48 of 58 CP-CPM 6.9D 6
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3.21.6 Thermocouples Thermocouple lead wires shall be Type K or equivalent chromelalumel, alumel, annealed and purchased with a certification of compliance to ANSI MC 96.1.
All thermo-couple wire buried within the weld joint thermal insulation wrapping shall be electrically insulated with suitable ceramic insulators except at the hot junctions. The insula-tion and general condition of the thermocouple wires shall not show excessive wear or poor appearance. The rmocouple wires shall be attached to the weldment by tack welding or
[
mechanical means, ensuring that the wires are held firmly I
in metallic contact with the weldment. All thermocouples attached by tack welding shall be removed exclusively by Srinding.
Probe type thermocouples shall be type K Chromel/Alumel and shall be purchased with a certificate of calibration.
Calibration temperature shall be 1150*F.
Probe type thermocouples shall be attached to the weldment by the use of thermocouple clips lightly tack welded to the work piece.
Field requisitions for the thermocouples and thermocouple extension leads shall be prepared by the Piping Super-
- intendent and submitted to the Calibration Lab Supervisor for review in accordance with CPM-13.1.
3.21.6.1 Extension I.eads.
Thermocouple extension wires shall be chromel-alumel, accompanied by a certificate of compliance to ANSI MC96.1 and be compatible with the thermocouple wires. Splicing of short lengths to make up long runs is not to be permitted.
Insulated quick coupling thermocouple connectors such as Thermo-Electric Type KX or equal shall be used. The extension wire shall be in good condition.
Damaged or mutilated leads shall be discarded. Extension wires shall not be used for any other purpose and shall be procured in 50-ft or 100-ft lengths.
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NUMBER REVISION DATE l
CPSES JOB 35-1195
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CP-CPM 6.9D 6
3.21.6.2 Temperature Instrumentation.
The temperature control and recording instruments shall be in good working condition and equipped with automatic cold junction compensation.
A temperature recording showing the PWHT cycle shall be made of each weld subjected to post-weld heat treatment. The chart speed shall be selected to assure a concise record of time and temperature.
For ASME III and. ANSI B31.1 applications cooling curves need only be recorded to 800*F providing insulation is not disturbed.
The selection of ink color for recording charts shall be based upon a selection that will enable the charts to be
" xeroxed".
3.21.7 Other Requirements 3.21.7.1 Dissimilar P-No. Welds.
When materials of two different P-number groups are joined by welding, the applicable post-weld heat treatment shall be that specified in Section 3.21.2 for the material requiring the higher PWHT temperature range.
(P-8 base material excluded.)
3.21.7.2 Dinaimilar Wall Thicknesses When post-weld heat treating components having different thicknesses are welded together, the post-weld heat treatment requirements of Section 3.21.2 shall apply to the thickness of the weld, pressure retaining material, or the thinner of the sections being joined, whichever is less for ASME III applications. For ANSI B31.1 applications, thickness shall be defined as the thicker of the components being joined.
3.21.7.3 Nonpressure-To-Pressure Retaining Parts When nonpressure-retaining materials are welded to pressure retaining materials, the post-weld heat treatment tempera-ture and hold time of the pressure retaining material shall control.
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 JAn;'c,,,4 50 of 58 40 CP-CPM 6.9D 6
3.21.7.4 Repair Welds Af ter PWHT (ASME Section III. Piping Systems)
Components or items that have been repaired by welding shall subsequently be post-weld heat treated upon completion of the repair, unless exempted below.
1.
Limited weld repairs to P-1 material utilizing Al weld filler material may be without PWHT or af ter the final PWHT, provided the following requirements are met:
2.
Before repair, the excavated area is examined by either magnetic particle or liquid penetrant methods.
3.
The depth of the repair shall not be greater than 3/8 inch or 10% of the base thickness, whichever is less and the individual area shall not be greater than 10 square inches.
4.
The welding procedura used shall be in accordance with the ASME Sect'.on III, Division 1 Code.
5.
The applicable Qualification Test Plates and repair weld examination shall performed in accordance with ASME III, Subsection NB-4642.4 and 5.
3.21.8 Thermocouple Location Typical thermocouple placement is shown in Figure 6.9D-17.
At least 4 recording thermocouples, plus a control and a spare thermocouple shall be used. The thermocouples shall be placed to ensure that the complete circumference and width of_the heated band is represented.
Actual thermocouple placement shall be as required by the PWE.
3.21.9 PWHT Af ter Bending and Forming BOP Cold working of carbon steel items to correct minor dimensional discrepancies may be permitted without subsequent post-weld heat treatment, providing approval is obtained from the Owner.
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NUMBER REVISION DATE PAGE CPSES 4
l JAN19geal JOB 35-1195 51 of 58 g
CP-CPM 6.9D 6
At no time during the post-weld heat treatment cycle for carbon steel pipe shall water or liquid cooling medium be employed.
Post-weld heat treatment of austenitic stainless steels is not mandatory unless required by the applicable welding procedure.
3.21.9.1 Heat Treatment After Bendin2 or Forming for Pipe. Pumps, and Valves 1.
P-No.(s) 3, 4, and 5 pipe or formed portions of pumps or valves that have been heated for bending or other forming operations shall receive a heat treatment in accordance with Section 3.21.2 or a full-annealins, normalizing, and tempering treatment.
2.
P-No.1 pipe or formed portions of pumps or valves with a wall thickness greater than 3/4 inch that have been cold bent or formed shall receive heat treatment in accordance with Section 3.21.2.
3.
P-No(s) 3, 4, and 5 pipe or formed portions of pumps or valves with an outside diameter greater than 4 inches and a wall, thickness greater than 1/2 inch that have been cold bent or formed shall require a heat treatment in accordance with Section 3.21.2.
3.21.9.2 Exemptions From PWHT Af ter Bending or Forming If the conditions described below are met, heat treatment af ter bending or forming is not required.
Carbon steel pipe or portions of pumps and valves that have been bent or formed at a temperature of 1650*F or higher shall require no subsequent heat treatment, providing the requirements of the ASME Section III, Division 1, Paragraph NB-4213 have been met.
Carbon steel and ferritic alloy steel pipe or portions of pumps or valves with sir.es and wall thicknesses less than specified in Subsection 3.21.9.1 above may be cold bent or formed without a heat treatment following bending.
PROCEDURE EFFECTIVE !
BROWN & ROOT, INC.
NUMBER REVISION DATE l
FAGE CPSES l
I JOB 35-1195 gzy 9, woi l 52 ot 59 CP-CPM 6.9D 6
3.21.10 ALIGNMENT BY LOCALIZED HEATING Localized heating may be applied for minor adjustments.
These minor adjustments shall be on a case-by-case basis as approved by the Owner and shall be in accordance with the following:
1.
Localized heating of carbon steel piping may be accomplished utilizing a suitable gas heating torch or electrical resistance heating coils.
2.
The temperature of the heated areas shall not exceed 1200*F. Where heat is applied utilizing a gas torch, temperatures shall be monitored with a contact pyrometer or temperature indicating crayons.
3.
The heated area shall be allowed to cool in still air.
No blown air or liquid shall be used to accelerate cooling.
4.
Owner approval shall be obtained on a " Heating Alignment Form" (Fig. 6.9D-20) which has been properly prepared by Welding Engineering.
Heating for alignment shall not be performed on stainless steel material or carbon steel piping requiring Charpy impact values.
3.21.11 CONTROL OF INTERPASS TEMPERATURE FOR SS BASE MATERIAL Demineralized water may be used on the adjacent base metal (at least " away from weld) to control the interpass temperature on stainless steel welds.
This may be achieved by using kaydrys soaked with water and the excess water removed. Care shall be exercised not to bring any water into direct contact with hot weld material.
Demineralized water for this purpose may be obtained from the MDS and will be issued, ia suitably marked containers.
NOTE:
Specific approval on a case by case basis must be obtained from Westinghouse for components or material supplied by Westinghouse.
e
~
1 PROCEDURE EFFECTIVE l BROWN & ROOT, INC.
NUMBER REVISION DATE l
E'd 53 of 58 3.22 BRAZING OF COPPER PIPE OR TUBE 3.22.1 Base Metal The base metals to be brazed shall be listed on the BPS.
The diameter and thickness of pipe or tube to be brazed shall be limited to the ranges specified on the BPS.
Brazers shall be limited to the diameter and thickness range listed for the applicable Standard Test (Reference WES-16).
3.22.2 Processes The requirements of this standard shall be applicable to Manual Torch Brazing (ASME Section IX H101 when applicable).
1.
Filler Metal.
The brazing filler metal shall be as listed on the applicable BPS. Brazing filler material shall be controlled in accordance with Appendix 6.9B.
2.
Heating.
Brazing shall be done using a hand-held oxy-fuel torch.
While acetylene is preferred as a fuel gas, other gasses may be used providing approval is obtained from the PRE.
When acetylene is used as a fuel gas, pressure settings at regulators shall be approximately 3:1 for oxygen and acetylene, respectively.
A neutral flame shall be used.
Brazing shall be done within the temperature range specified on the BPS.
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE
~
CPSES JOB 35-1195 iLEN y ~, 34 CP-CPM 6.9D 6
C 54 of 58 3.
Cleaning.
Brazing surface shall be prepared in the following manner:
a.
Wipe surfaces with solvent.
b.
Clean with emery cloth to bright, shiny surface, c.
Rewipe with clean, dry rag.
4.
Flux The brazing flux shall be as specified on the BPS.
Brazing flux shall be controlled and issued from the FWTC.
5.
Joints.
Brazing joints shall be as specified on the BPS.
6.
Technique.
Brazing surfaces shall be sparingly and uniformly fluxed for a distance equal to the engagement length plus k inch.
Joints should be assembled immediately af ter fluxing.
The assembled joint should be inspected for uniform joint clearance.
The entire joint shall be quickly and uniformly raised to the brazing temperature.
When the joint is at the brazing temperature, brazing filler metal should be fed into the joint. Care should be taken to maintain heating of the entire joint while filler metal is fed into the joint to ensure proper capillary action. At the completion of brazing, a uniform fillet should appear at the opening of the joint.
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 JA//
CP-CPM 6.9D 6
~ ~ G3' 55 of 58 7.
Defects The following defects are unacceptable:
a.
Evidence of lack of solder flow.
b.
- Pinholes, c.
Non-continuous fillets at face of joint.
d.
Icicles (should be removed).
8.
Qualification.
Brazers and Brazing Procedure Specifications shall be qualified in accordance with the ASME,Section IX Code when required by governing specifications.
3.23 SOLDERING OF COPPER PIPE OR TUBE 3.23.1 Process The soldering shall be performed using a hand-held oxyfuel l
torch. Oxyacetylene is the preferred mixture to be used in the.lo.rch but other fuel may be used if prior approval is
'obtained from the PWE.
1.
Base Metal.
This standard is intended for soldering material thickness between 0.031 inch and 0.130 inch with a maximum OD of 3 inches.
The base material shall conform to at least one of the following:
ASTM B61 ASIM B62 ASTM B68 ASTM B75 ASTM B88 6
+
I
i PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION
.DATE PAGE CPSES JOB 35-1195 Jg ', _34 y
CP-CPM 6.9D 6
56 of 58,
'3 2.
Soldering Alloy.
The bare filler wire for soldering shall conform to ASTM B32 Grade 95TA.
3.
Flux.
The flux shall be a non-acid type (Example: "Nokorode" manufactured by W. M. Dutton Company or an approved equal).
4.
Positions.
This standard is intended for soldering copper piping and tubing in the following positions:
- a. Flat - Flow Position. _
- b. Vertical - Downflow Position
- c. Vertical - Upflow Position d.
Horizontal - Flow Position 5.
Soldering Temperature.
The soldering temperature shall fall within the range of 475'F to 525'F.
6.
Preparation of Base Material.
To ensure that tube or pipe ends coopletely bottom in the fitting, the ends shall be cut 9ff square with a suitable tool (tubing cutter). Cutting tools that deform the pipe or tube ends shall not be used. Any burrs left after cutting shall be removed.
The inner surface of the socket fitting shall be cleaned with a fitting cleaning brush or emery cloth.
The external surface of the pipe or tube shall be cleaned with a tube and cleaning brush, or emery cloth, for a distance from the end equal to the socket engagement length plus h inch. All surfaces to be soldered shall be cleaned with isopropyl alcohol prior to applying flux.
m
I PROCEDURE EFFECTIVE BROWN & ROOT,.INC.
NUMBER REVISION DATE PAGE CPSES l
JOB 35-1195
.M N y p,_~,,
j 57 of 56 CP-CPM 6.9D 6
7.
Joint Design.
I Soldering shall have a lap joint configuration. The length of lap (engagement between pipe or tube and fitting) shall be from.68 inch to 1.14 inch with a joint clearance of.001 inch to.005 inch.
8.
Soldering Technique.
Soldering shall be accomplished in the following manner:
a.
The surfaces shall be elecned in accordance with "6" above.
b.
The tube shall be sparingly fluxed for a distance from the end equal to the engagement length plus is inch.
c.
The tube shall be inserted in the fitting so that the end of the tube is bottomed firmly against the shoulder stop in the fitting.
d.
The entire joint shall be uniformly raised to the soldering temperature by the use of a hand-held torch. After the joint has reached the appropriate soldering temperature, solder shall be fed into the clearance between the tube and fitting. Complete distribution of the solder shall be assured when the molten solder produces a uniform fillet at the edge of the fitting.
9.
Defects.
The joint shall be considered unacceptable if there is any evidence of lack of solder flow, pinholes, noncontinuous fillets at the face of the joint, or icicles in the joint.
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195
- 4h i ;;,,f
o 58 of 58 CP-CPM 6.9D 6
10.
Repair of Defects.
If any of the defects as noted above appear, the joint shall be reheated to soldering temperature and if 4
needed, more solder shall be added to the joint. If
,-the defect consists of excess solder being present
.(e.g.,
icicles) the excess solder shall be removed, J
after the joint is reheated to soldering temperature, by scraping or may be blown away with air.
11.
Soldering Personnel.
Personnel who solder shall not be required to pass any qualification tests but shall be knowledgeable of the proper techniques pertaining to soldering and shall be capable of performing such techniques.
WW m
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES
- ,"Alll 2 g 1 Of 1 JOB 35-1195 CP-CPM 6.90 6
TABLE 6.90-1 PWHT for ASME SECTION III, PIPING SYSTEMS Minimum Holding Time at Temperature P-Number Holding For Weld Thickness (Nominal)
QW-420 Temperaturo 4 in.
Over 4 tr..
Over 2 in.
Over 5 in.
SECT. IX Range or less to 2 in.
to 5 in.
1 1100-12500F 30 Min.
I hr./in.
2 hr. plus 15 2 hr. plus min. each add-15 min.
itional inch each addi-over 2 inches tional inch over 2 in.
4 1100-1250 F 30 Min.
1 hr./in.
I hr./in.
5 hr. plus 0
15 min.
each addi-tional inch over 5 in.
5 1250-14000F 30 Min.
I hr./in.
I hr./in.
5 hr. plus 15 min.
each addi-tional in.
over 5 in.
,1 Exemptions to Mandatory PWHT in table NB-4622. 3-1 are applicable.
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES l
JOB 35-1195 CP-CPM 6.90 6
S'I 12 T33-1 1 Of I FIGURE 6.90-1 Weld Techniaue Sheet WELD TECHNIQUE SHEET (Sample for Information Only)
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2 De intergass tancerseru (anove 15 cF1 shall to cascad using tas: erst:re indicating crayens or an secreved eeual.
3.
The nue=ar of weld bases ney vary wita see:1cn thickness.
4.
The starts and st.es of all tacz welas saall te tacerts by grinding so that
. tse initial pass can ;reserly c=nsus:e tse tacs.
5.
Tact weles wnica are used at :ne root of joints sna!1 he c=muleta :eestration 8.
The non-casumaale elec:rsas for tse Gas tungsten Ar: :r:cass saali. nform ta AVI A5.12 Class GdTh-1 (17. Thor 14ted fungstan) or Class DiTn-2 (2:
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PROCEDURE EFFECTIVE PAGE BROWN & ROOT, INC.
NUMBER REVISION DATE l
CPSES JAllJ2 gj 1 Of 1 JOB 35-1195 CP-CPri G.90 6
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PROCEDURE EFFECTIVE !
BROWN & ROOT, INC.
NUMBER REVISION DATE l
PAGE CPSES M I 2 its.g.
1 Of 1 JOB 35-1195 CP-CPM 6.93 6
TABLE 6.90-2 PWHT for ANSI B 31.1 PIPING SYSTEMS Minimum Holding Time at Temperature P-Number Holding l
QW-420 Temperature For Weld Thickness (Nominal)
SECT. IX Range Over 4 in.
Min. Time or over 4 in All within Nom. Size or Walls Range over 3/4 Over 0.15C 1
1100-12000F 1 hr/in.
1 hr/in 1 hr/in 1 br.
4 1300-14000F 1 hr.
5 (less than l
5% Cr) 1300-14250F 1 hr.
(2 hr. for Allis Chal mers)
(5% Cr and Higher) 1300-14250F 2 hrs.
1.
Local PHWT of welded branch connections shall be performed by heating a circumferential band of the pipe to which the branch is welded. The width of the heated band shall extend at least 1" (inch) beyond the weld joining the branch.
2.
Other notes to table 131 of Reference W apply.
i PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 6.9D
'I I fI J B,24 6
m FIGURE 6.90-3
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BROWN & ROOT, INC.
NUMBER REVISION DATE j
PAGE CPSES l
JOB 35-1195 CP-CPit 6.90 6
JAll12 384 FIGURE 6.90-4 1
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PROCEDURE EFFECTIVE BROWN & R007, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1 95 CP-CPt1 6.90 6
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Esca bag sha*1 be placed at least 20* fran tne joint.
2.
The purge gas inlet and outlet shall be put in place as shoun before inflattag t!w bags.
3.
Inflate bags sleely with hand pump.
4.
Af ter bags are completely inflated, the argoe purge can be started.
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 6.90
' ' 22 T!B(
6 FIGURE 6.90-5 TYPIC.AL 1/2* Plyocard (Tyo.
1/4* W Outlet Located at Top lo*- 5200*F Preneat 1/4" Plyboard (Typ.)
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Material. 011 and 2.
Diamatar naboer gasket to be 1/8" greater than pipe I.D.
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l PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 6.9D 6
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES 1 Of 1 JOB 35-1195 CP-CPM 6.9D
'12 1991 6
FIGURE 6.9D-7 Consumable Insert Design
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NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPf1 6.9D 6
A312 E4 I Of 1 FIGURE 6.90-8 Joint Details for C'onsumable Inserts
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES 6
1 0 i934 1 of 1.
JOB 35-1195 CP-CPM 6.90 FIGURE 6.90-9, Butt Joints with Backing r--- 2/ ',5=
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x sh 2n-Butt weld with Backing Requiring no Counterboring NOTE: The butt weld end prepartion shall be in accordance with that portrayed in the applicable graphics of Figure 6.90-8.
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPf1 6.90 l 6
J4l1 22 33,,
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PROCEDURE EFFECIIVE CPSES NUMBER REVISION DATE PAGE a
JOB 35-1195 CP-CPM 6.9D 6
1/12/84 2 of 2 FIGURE 6.9D-11 TYPICAL Socket Weld Fitup Socket welds shall have a minimum end gap of approximately 1/16 inch prior to welding and a minimum engagement length as follows:
Nominal Pipe Size Minimum Engagement Length 1/2 inch & smaller 1/4 inch Over 1/2 inch to lls inch 3/8 inch 2 inches 1/2 inch Cases where the 1/16 inch retraction encroaches on the minimum engagement dimensions shall be submitted to the Owner for resolution.
In cases where the above engagement cannot be met due to grinding away of the socket depth durir.g weld removal for reuse, a minimum of k" engagement is acceptable.
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES II I E #34 1 Of 1 JOB 35-1195 CP-CPit 6.90 6
I FIGURE 6.90-12 i
DELTA FERRITE LOG
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INSTRUCTIONS The number of the instruction steps belcw correspond to the numbers shown on the attachment.
1.
The system and line containing the weld tested; 2.
The size category of welds listed on the DFL; 3.
A unique number assigned to each delta ferrite check j
within each size category; 4.
Weld number; 5.
Applicable WDC number;
. 6.
Test results (accept / reject);
7.
Measuring instrument Serial Number and Date Calibrated; 8.
Comments (This area would be used to document any recuired repair and/or joint removal, and would list any appli-cable documentation);
- 9. Responsible Weld Technician signature and date.
PROCEDURE EFFECTIVE I BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES 1 Of 1 JOB 35-1195 CP-CPM 6.9D
- '1121934 l 6
FIGURE 6.90-13 Request for Welder Training and/or Testing mosst rai m:ca rutarns =cien nstinc name Craft Onte TM!alNs: Des CNe Tr:Intag Hours (3:ecify)
Tartas:
D= C=
MATSIAL: Q1ste Dipe
> Ostataless Caiu=' mas Esw(:secifr)
, Cliataltic(!pecify beta) to Pant 135(ES):
a TNT TTPE:
C**
OO G'" *-
Cm CC C==*te :asert Ceem ca Caecting sep C2cm C2 C Otner(saecifr)
Ottm(semi-auts) OC mr spec:ac cactt..x3 me/at c:rvers:
- 3uperviser's Up4Carg MTE: iltis fcre is for 14FfC schedulf ag purposes and east be c=sofetad Jy craft and submitted ts WQTC prter to the surt of tra. stag and/or tasttag.
(Lauer portise ta to comeleted by ' GT4 3.3. leo. __
laege M.
Syunal Oste Training Star.ed Cate Testing Started Oate Testing Casaleted Date Test Results TUT IE1H00: @ @.
@!' ! O!!ME
.!NO! CATI 53:
CDet0ET5.
l Quellffcatfee Test
- e'aing Ligineer (Ws No.
i Quellfica. tion Test
- gee,
( s.
P-s
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES 1 of 1 JOE 35-1195 CP-CPM 6.9D 1 ', 094 l 6
FIGURE 6.90-14 g 7$se 4tqging i
4 tructur:1 jala.Ing.
5
- sutletng c
a tner PWOMAng G;ALIFICATICH WCRE 5FE.IT 4111.rigns 1ectricat
_ (Instruent aus 6 Lass. inrst..t.4.)
s.4. 4.
c;oca e.
syncoi goosa : o.
Samede N Test No.
WS Ms.
PARAMETERS:
Caen Joint Type: CCS [W33 C; [Fttleg Process (es)
Preneet:
F.(Min.) 177:
F.(Maz.)
Position (s)
% sfon 8955 Pitae u nt se es vot s
!=
e il Same Metal I
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to 1
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/
C.I.: 512e Type Ctass C.w.anical C Raatogrionte C N ero h t/Lat No.
Plate:
Pipe:
Ft11st:
Trade Name
- 3 " "
s3 9 M 'T IF G
i i 1,
M Amst: 3fze Class 25
- s 2F N' **
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""'i Trade Name F111: Sfze Class X = Accepted Heat /Lat No.
- 0 = N ected Trees Name Specimens ;er Positten Ft11: Stre Class Meet /Lat No.
In Process Test verification Trade Name I ggsas CFinal unleingCurrent(Typel Gracnantcal Chatograonic Purge Gas now his M
grigistsetery
[ Wsatista m y Shielding Gas Flew hte M
This block for CC use :nly.
wnLis ts cas A *.nia; Amanter No.
hnge fyveel Assigned Coltrettoe Cue seltester Ms.
hnge g, g.,,,
m Celfbratios Que Guyges Analyser w Celt h eties See
~
uGTC Oate
,M
PROCEDURE EFFECTIVE l BROWN & ROOT, INC.
NUMBEit REVISION DATE l
FAGE CPSES JOB 35-1195 CP-CPM 6.90 6
12 7334 1 of 1 FIGURE 6.90-15 i
O!nstrument SRAZING PERFOAMAKCZ QUALIFICATICM wtx SMIT anRE (Last. isrst. n.4.s s.s. No.
Glocs M.
1/stol 5 cat.1
- Standard Test No.
' alps No.
PAAAMETTAS Code Taus. Range
'F to
'F Presses (es)
Length of Las puettion(s)
Seen Metal g gg; eterial to 7yp,7,,,
=
C a tton D
C Peel asetw u
Position (QS 442) gggg(g} }
Thickness to H ll e m tal Vertical-Com-(B) 3828 F-*.
C1 ass verticat.co-(C)
N'*WL** "-
Horizontal.no=(c) _
rrede Name Mue I
- Accected 0
- Rejected N8 Ut **
1;ectmens ;er Position Trade D me Type Heat Source Asserts Angelator Setting:
Gingen Fuel In-Process Test veriftcation 71p $12e CRoot CFinal O neca.aicai C=adioiriaate satisfactory C Unsatisfactory This block for QC use only.
Cannants fyseal Assigned c4.teness asa nqu-Ase sv
PROCEDURE EFFECTIVE l BROWN & ROOT, INC.
NUMBER REVISION DATE j
PAGE CPSES l
6 US.'112 334 1 of 1 f
JOB 35-1195 CP-CPM 6.90 i
FIGURE 6.90-16 PWHT Control Fom (Stamp)
PWT CONTRCL FCRM I30. NO.
WELD NO.
DATE TLT MTHIAL THICX.
DIAM.
ETH00 0F HEATING IEATING RATg cF./hr-CCOLING RATE CF./hr iELD POSITION: C2G C5G C6G THERMOCOUPLE SERIAL NO.'s:
TOP-BOTTCM-RECCRDING RECORDING CCNTROL CONTRCL DARE SPARE OTHER OTHER TEMPERATURE RECCRDER NO.
CALIBRATION DATE E3PIRES CWRT No.
CHART SPEED CPERATCR WELD TECHNICIAN CATE FINAL APPROVAL CATE
PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES i
,..K11 2 ~c.,'
JOB 35-1195 CP-CPM 6.90
.l 6
1 Of 1 I
FIGURE 6.90-17 Typical Thermocouple Placement for PWHT A
f g A&C
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a PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES f
t JOB 35-1195 CP-CPM 6.9D i 6
l cJfy
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o PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES !JI2/12 hg 1 of 1 JOB 35-1195 CP-CPM 6.90 6 FIGURE 6.90-19 TYPICAL FITTING-TO-FITTING SOCKET WELDED CONNECTION (REDUCING INSERT TO SOCKET WELDEDT) SMALLER +V ) b-SIZE PIPE $3, y's k WELD D 4 !i 4 REDUCING ?n SS INSERT +. j 2 Ig 'P $ja , WELD C ~ kN ( M' [ SOCXET WELDED T h ?Y/ ~ ^ %j/j,7i!/7//h 19 m 4, h D B @ :MRA\\)Ns NNgNNWf\\)c ' / L///y//.//////##M#44 s &7/ M a s s a s s /4 - Emmm'MNRM i'R4N}M9N k - 7' /O', f \\ LARGER SIZE PIPE NOTE: 1. Fillet weld size of welds A, B and C shall be based on the nominal wall thickness of the larger size pipe.
- 2. Fillet weld size of weld D shall be based on the nominal wall thickness fo the smaller size pipe.
e _/4"x_- t
PROCEDURE EFFECTIVE l ~ BROWN & ROOT, INC. NUMBER REVISION DATE PAGE j CPSES JOB 35-1195 CP-CPM 6.90 6 ' Ed.'ll 2 ;gg4 1 of 1 FIGURE 6.90-20 HEATING ALIGNMENT FORM HEATING ALIG!# TENT FORM i Sketch of Ifne and location of area to be heated. Type Material Mexiunse Temperature Elevation ' Location Piping Category System Drawing tiumber Line No. Idolding Engineering Engr./0wner Approval idT/QC NT&El Temperature to be monitored by idelding Technician or QC Inspector. NfE to be recorded if pymmeter is used. -e
e I PROCEDURE EFFECTIVE BROWN & P,00T, INC. NUMBER REVISION DATE PAGE CPSES I d$lll s gg JOB 35-1195 CP-CPM 6.9D 6 1 of 1 .I i FIGURE 6.9D-2i JOINT PREPARATIN FOR IN-SERVICE INSPECTION %*/ ,@AD BIend to allow smooth transtt'on /0* PE of U.T. transducer. (Typ. Both sices) t 7 b FIPE pipt r-m ~ ~ 250j Slend to allow secoth transition of U.T. transducer. i f \\ !?$ nmue gg, T I 81end to allow s=coth transition of U.T. J transducer. A a ma VALVE CR NO2ZLE s I
O- ~ PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 6.9D 6 ' MII12 T334 1 of 1 FIGURE 6.9D-22 POST WELD HEAT TREATMENT CHECKLIST POST WELD HEAT TREATMENT CHECXt!ST t Drawing # Weld f Ig Joint Preoaration Results fattials a. Pre-PWHT Visual examination completed (If acceptable. l si n WOC hold point) b. Cl niiness (all paint, dirt, grease, oil, and other foreign ustter renoved from heated areas) c. Adequate insulation (required type thermal insulation sin. of four pipe diameters or 24 inches, whichever is less, to each side of weld joint) ~ d. Protection ainst internal drafts (open ended pipe capped, etc. e. Thermocouple placement (placement as per procecure) Thermocouple I.O. f. Temperature recording instrumentation Ins t.f Calibration Cate Inst. # Calibration Date - g. Yalve preparation (valve in proper position dissembled if necessary) QC/ Inspector Signature Date
- 2. Heatiao aad Coolino nates. Holdvaa rime and re.ee ature (Werify acceptaotlity by examining the FWiT Chart) l a.
Heating Rate b. Cooling Rate c. Temperature variation 'F t (between thereccouples not exceeding 100*F) d. Holding time hours sinutes e. Holding temperatare M (d and e as required by applicable Weld Date Card) f. Has the PWHT chart been signed and dated by the operator and the Field Weld Technician 7 9 Is the PWHT chart traceable to the applicable Weld Data Card by drawing and weld numbers? QC/ Inspector $fgnature Cate
- 3. Ther=ocouele 'eaovat and 'iant visual E===vaatioa a.
Thernocouple removal (check for damage due to removal) b. Final visual examination c. Is the PWHT chart attached to the applicable Weld Data Card? d. HT or PT of removal area for Class 1 and 2 components v QC/ Inspector Signature Date E: All resalts will be answered $at (/). Unsat (X). not applicabla (N/A) unless otherwise noted. Unsat answers sill require a close out in the "Cannents" section. C0tHENT$ E e w g
.- ~ \\ s PROCEDURE EFFECTlVE BROWN & ROOT, 1NC. NUMBER REVTSION DATE PAGE CPSES o JOB 35-1195 CP-CPM-6.90 6 US4 1 of 1 FIGURE 6.90-23 WELD REINFORCEMENT & CONFIGURATION OF WELD 0LETS, SOCK 0LETS, AND MACHINED HALF-COUPLINGS LONGITUDINAL VIEW. REfuCI:4 SIZE WELOOLET OR SOCKELET FITTINGS A A Required weld deposit for reducing-sf 2e Weldolet or Sockolet. 1seld surface should be level with surface g 8 A8 and should mate a smooth (not abrupt) transition into the surface of the pipe at point C. 'xxxx s k x x, g s\\ \\ b \\\\M g s 8 TRANSVER$E VIEW. RE3;CING-31ZL WC.00LET OR SCCKOLZT FITTI 4 l a Required weld deposit for reducing size Weldolet or Sockolet . fitti. Weld surface 8C should be parallel with longitudinal e cente fne of fitting and should aske a smoothe transition at point C. A 3 I ( [r I C sj g N' N, s l MACHINE HALF-COUPLI?G l l A A Weld surface should be at a minimum level with surface / A8 and should make a smooth (not abrupt) transition into the surface of the pf pe at point C. t s l 1 e C r d k\\\\\\ \\\\ \\ i e -A -}}