ML20214U857

Rev 0 to NCIG-03, Training Manual for Inspectors of Structural Welds at Nuclear Power Plants Using Acceptance Criteria of NCIG-01

ML20214U857
Person / Time
Site:	Diablo Canyon
Issue date:	07/23/1985
From:	NUCLEAR CONSTRUCTION ISSUES GROUP
To:
Shared Package
ML20214U804	List: DCL-86-342, Forwards Proposed Changes to FSAR Chapter 17,to Be Incorporated Into Appropriate FSAR Update Rev,Pending Approval ML20214U857
References
NCIG-03, NCIG-3, NUDOCS 8612090424
Download: ML20214U857 (62)

Text

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Enclosure 5 NCIG-03 07/23/85 Rev. O I

TRAINING MANUAL FOR INSPECTORS OF STRUCTURAL WELDS AT NUCLEAR POWER PLANTS USING THE ACCEPTANCE CRITERIA 0F NCIG-01 b

NOTICE This document was prepared by the Nuclear Construction Issues Group (NCIG).

Neither NCIG, members of NCIG, nor any person acting on their behalf: (a) makes any warranty, express or implied, with respect to the use of any information, apparatus, method, or process disclosed in this document or that such use may not infringe privately owned rights, or (b) assumes any liabilities with respect to the use of, or for damages resulting from the use of, any informatlon, appa-ratus, method, or process disclosed in this document.

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i TABLE OF CONTENTS Page Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Participating Organizations and Personnel. . . . . . . . . . iv

1.0 INTRODUCTION

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, 1.1 Background . . . . . . . . . . . . . . . . . . . . 1-1 1.2 NCIG-01 Acceptance Criteria. . . . . . . . . . . . 1-2 1.3 Scope. . . . . . . . . . . . . . . . . . . . . . . 1-3 1

1.4 Purpose. .. . . . . . . . . . . . . . . . . . . . 1-4 1.5 Quality Concerns . . . . . . . . . . . . . . . . . 1-4 1.6 Engineering Justification. . . . . . . . . . . . . 1-5 1.7 Implementation . . . . . . . . . . . . . . . . . . 1-7 2.0 GENERAL INSPECTION GUIDELINES . . . . . . . . . . . . .  ?-i I

2.1 Introduction . . . . . . . . . . . . . . . . . . .  ?

2.2 The Inspector. . . . . . . . . . . . . . . . . . .  ?-?

2.3 General Inspection Concepts. . . . . . . . . . . .  ?-

I 2.4 Measurements . . . . . . . . . . . . . . . . . . .  :-4 2.5 Discontinuity Length . . . . . . . . . . . . . . .  ?-t 2.6 Work Requiring Repairs . . . . . . . . . . . . . . .t 2.7 Records. . . . . . . . . . . . . . . . . . . . . .  :*

2.8 Limited Scope Inspections. . . . . . . . . . . . .

2.9 Reinspection of Painted Welds. . . . . . . . . . . -

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NCIG-03 07/23/85 Rev. O I TABLE OF CONTENTS (cont.)

Pace 3.0 ACCEPTANCE CRITERIA AND SPECIFIC INSPECTION GUIDELINES. 3-1 3.1 Introduction . . . . . . . . . . . . . . . . . . . 3-1 3.2 Acceptance Criteria and Guidelines . . . . . . . . 3-1 3.2.1 Weld Cracks . . . . . . . . . . . . . . . . 3-2 3.2.2 Fillet Weld Size. . . . . . . . . . . . . . 3-2 3.2.3 Incomplete Fusion . . . . . . . . . . . . . 3-9 3.2.4 Weld Overlap. . . . . . . . . . . . . . . . 3-11 3.2.5 Underfilled Craters . . . . . . . . . . . . 3-13 3.2.6 Weld Profiles . . . . . . . . . . . . . . . 3-17 3.2.7 Undercut. . . . . . . . . . . . . . . . . . 3-21 3.2.8 Surface Porosity. . . . . . . . . . . . . . 3-29 3.2.9 Weld Length and Location. . . . . . . . . . 3-31 3.2.10 Arc Strikes . . . . . . . . . . . . . . . . 3-34

. 3.2.11 Surface Slag and Weld Spatter . . . . . . . 3-34 APPENDIX A - Alternative Acceptance Criteria . . . . . . . . A-1

(- APPENDIX B - NRC Acceptance Letter . . . . . . . . . . . . . B-1 APPENDIX C - Workmanship . . . . . . . . . . . . . . . . . . C-1 i

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NCIG-03 07/23/85 Rev. O PREFACE This document has been prepared and issued i

under the auspices of the NUCLEAR CONSTRUC-TION ISSUES GROUP (NCIG). NCIG was formed by several utilities for the purpose of develop-ing a common approach to the resolution of issues at nucle'ar power plant construction sites. The first issue considered by NCIG was in the area of acceptance criteria for and inspection of welds in certain supports l

( and structures. NCIG-01 contains NCIG's reso-lution of that issue. This document addresses the training of inspection person-nel in the use and implementation of NCIG-01.

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PERSONNEL D.E. Dutton, Chairman Georgia Power Company / Southern Company Services R.F. Reedy, Technical Manager Reedy Associates R.A. Thomas, Licensing Advisor Georgia Power Company / Southern Company Services M. Axelrad, Legal Advisor Newman and Holtzinger J.G. Adkins Southern Company Services F.C. Bretsmeister Bechtel Group, Inc.

T.O. Brown Reedy Associates W. Connell Illinois Power Company J.A. Curtin Stone and Webster M.V. Davis American Welding Society J.C. Finneran Texas Utilities Generating Company D.A. Gerber Reedy Associates R.M. Grant Kansas Gas and Electric Company R.M. Jessee Tennessee Valley Authority P. Karpa Bechtel Power Corporation E.C. Kistner Philadelphia Electric Company R.E. Monroe Pacific Gas and Electric Company G.F. Mcdonald Public Service of New Hampshire C. Peshek, Jr. American Institute of Steel Construction L.M. Petrick Ebasco Services A.F. Raatz Georgia Power Company l (~ Duke Power Company A- R. Rouse Commonwealth Edison Company W.J. Shewski Duke Power Company M.S. Sills Pacific Gas and Electric Company S.M. Skidmore R.J. Small Sargent and Lundy J.P. Thomas Niagara Mohawk Power Company N.C. Wall American Welding Society W.H. Weber Union Electric Company J.D. White Tennessee Valley Authority H.G. Ziegenfuss American Welding Society -

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REPRESENTATIVES AND COMMITTEES Designated Utility Representatives W. Connell G.F. Mcdonald D.E. Dutton W.J. Shewski J.C. Finenran M.S. Sills R.M. Grant S.M. Skidmore J.D. Hologa J.P. Thomas R.M. Jessee W.H. Weber E.C. Kistner VWAC Technical Consnittee J.G. Adkins R.M. Jessee F.C. Breismeister P. Karpa T.O. Brown R.E. Monroe J.A. Curtin L.M. Petrick D.E. Dutton R.F. Reedy D.A. Gerber R.J. Small

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VWAC Training Manual Comittee J.G. Adkins A.F. Raatz F.C. Breismeister R.F. Reedy T.O. Brown R. Rouse R.E. Monroe J.D. White .

Codes and Standards Contacts / Advisors VWAC Training Manual C. Peshek, Jr. M.V. Davis H.G. Ziegenfuss N.C. Wall

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SECTION'1.0 \

INTRODUCTION

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l.0 INTRODUCTION

1.1 Background

The Nuclear Construction Issues Group (NCIG) was formed by several utilities for the purpose of developing a common approach to issues at nuclear power plant construction sites.

The first issue considered by NCIG covers visual acceptance criteria for inspection of completed structural welds. The resolution of that issue is contained in document NCIG-01,

" Visual Weld Acceptance Criteria f or Structural Welding at Nuclear Power Plants" (VWAC).

VWAC development involved the participation of a number of

. different organizations:

e Utility Companies e Architect / Engineers e The American Institute of Steel Construction (AISC) e The American Welding Society (AWS)

This Manual provides a common basis for training of the Inspectors responsible for final acceptance inspection of completed structural welds using the NCIG-01 Acceptance Cri-teria.

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1.2 NCIG-01 Acceptance Criteria The AISC Specification (l) and AWS D1.1 Code (2) per-mit the development and impl emen t a t t'on 'of al tern a t i v e ac c ep-tance criteria for structural welds when the owner, the Engi-neer, and regulatory authorities agree. NCIG requested and received the support of the appropriate organizations for these common acceptance criteria.

The NCIG-01 Acceptance Criteria are alternatives to those given in AWS D1.1. The development and use of alternative acceptance criteria different f rom those specified in AWS D1.1 is permitted by the Code. Engineers, owners and con-structors have operated under this permission for many years.

In the 1985 Edition of AWS 01.1, a new paragraph 1.1.1.1 was 1 added to state that alternative acceptance criteria may be used when appropriate. The AWS has stated that this new paragraph is a clarification of what has always been allowed.

For convenience the new paragraph and the associated Commen-tary are presented in Appendix A.

In addition, NCIG has obtained acknowledgement f rom the AWS and the AISC that the use of alternative acceptance eriteria is acceptable. The U.S. Nuclear Regulatory Commission has reviewed the NCIG-01 Acceptance Criteria" and has accepted the use of that document. A copy of the NRC acceptance let-ter is provided in Appendix-B.

(1)' AISC, " Specification for Design, Fabrication and Erection of Structural Steel for Buildings."

(2) AWS, " Structural Welding Code - Steel, D1.1."

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1.3 Scope The Engineer (I) will identify the structures to which the NCIG-01 Acceptance Criteria will be applied. NCIG-01 is intended to be used with design and construction specifica-tions for nuclear power plants for new work and where the structures have already been designed, fabricated, and erected. Examples of typical structures to which these cri-teria apply include, but are not necessarily limited to, steel components such as:

e Main building frame members and connecting members; e Supoorts for equipment, components and piping,(2) cable trays and conduit, and HVAC ducts; Miscellaneous steel including bracing and stiffeners; e

embedments; stairways and handrails; doors and door frames; window frames, gratings; covers, etc.

1.4 Purpose The purpose of NCIG-03 is to provide a training manual to be used as a uniform basis for inspector instruction with regard to the Acceptance Criteria of NCIG-01.

(1) The Engineer, as used in the manual, is the individual or the organization designated by the owner as being responsible f or the design of the structure being welded or inspected.

(2) Excluding component supports stamped in accordance with the ASME Code,Section III, Subsection NF.

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Many projects have developed specific acceptance criteria for inspection of structural welds. However, there are no consistent criteria from site to site. NCIG-01 provides unifort. Acceptance Criteria which can be used by numerous projects in a consistent and controlled manner.

Nonconf ormances were previously documented at some projects because of insignificant deviations from the AWS 01.1 Code.

These very minor deviations have no detrimental effect on the load-carrying capability of the structure, do not require repair or rework, and usually are resolved or dispo-sitioned 'use-as- is' by the Engineer. The purpose of NCIG-01 is to provide practical Acceptance Criterta for visual inspection which can eliminate unnecessary repairs, the associated paperwork and reduce costs without any reduc-tion in safety.

1.5 Quality Concerns The purpose of the NCIG-01 Acceptance Criteria is to provide a reasonable basis for accepting welds. The acceptance cri-teria given in all codes and standards are es tablished by reasonable people to be implemented in a reasonable f ashion.

It is improper to reject welds which could be accepted by practical application of the NCIG-01 Acceptance Criteria.

Common sense, knowledge of the Inspection Guidelines, and good judgement are an Inspector's most valuable tools.

NCIG-01 was developed to address some of the difficulties associated with the inspection of structural welds. The AISC " Quality Criteria and Inspection Standards" states that "there are times when repair work creates higher residual 1-4

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stresses and does more harm than good." NCIG-01 was written to achieve the goal of eliminating unnecessary repairs wi th-out lowering quality standards. Practical application of the Acceptance Criteria and Inspection Guidelines presented in this Training Manual should minimize repairs which may be harmful to the structure.

Workmanship must be controlled and welds must be produced that are of the quality required by AWS Dl.1 or other applicable construction codes. (See Appendix C.) Final acceptance inspection is not an appropriate or timely method for control of in-process workmanship. At individual pro-ject sites, supplemental controls for in-process work may be specified. NCIG-01 does not restrict or prohibit the imple.

mentation of such in process controls.

1.6 Engineering Justification

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The structural effect of each discontinuity for which Accep-tance Criteria are provided has been subjected to critical engi neering evaluation and has been reviewed by the h*:.

Engineering analysis and calculations have been made to c cr-firm the acceptability of the NCIG-01 criteria. In additier to calculations, the justification for the Acceptance : -

teria contained in NCIG-01 considers past experience aa: a t

number of conservatisms inherent in engineering desig* c' j structural welds. Some of these are:

e Both base metal and weld metal strengths are usually '

nificantly higher than the minimum specified values o'

• form the basis of design.

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e Small welds are rarely loaded to allowable stress limits because their size is determined by material thickness rather than by design conditions, e An undersize condition in one portion of a weld may be associated with oversize, convexity and reinforcement in other portions of the same weld.

e Convexity and reinforcement do not reduce the load carry-ing capacity of the weld.

e Penetration into the base metal which increases the effec-tive size of the weld is not usually considered when determining the required weld size.

e Structures are designed using conservative load defini-tions, load combinations, analysis techniques, and design

( methods, e Designers specify fillet weld size by rounding-up to the next larger weld size.

e Member sizes and material thicknesses are usually selec-ted by the designer based on manufact'urer's standards.

As a result, these structures are usually fabricated using material that exceeds the size or thickness needed to satisfy design requirements for area or load carrying capability, i

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l 1.7 Implementation  ;

This Training Manual is based on the Acceptance Criteria contained in NCIG-01 and provides Inspection Guidelines for implementing those Criteria.

Each Project is responsible for reviewing NCIG-01 to assure that its use is consistent with the design and analysis of the structures to be inspected. The Engineer is responsible for specifying the structures to which the Acceptance Cri-teria apply. The application and distribution of the Accep-tance Criteria and Inspection Guidelines shall be controlled in accordance with applicable document control procedures.

The Acceptance Criteria contained in NCIG-01 are intended to C be used for final acceptance inspections (and any later rein-spections) of completed structural welds. When approved by the Engineer, these Acceptance Criteria are also applicable to the reinspection of welds which have been previously inspected using other acceptance criteria.

Visual weld inspections are to be performed by qualified personnel, trained to perform inspection activities. These inspections are to be performed in accordance with Project Procedures and the Project QA Program. This Training Manual does not change the qualifications of the Inspector in any way, nor is it to be used as a basic weld inspection train-ing manual.

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NCIG-03 07/23/85 Rev. 0 SECTION 2.0 GENERAL INSPECTION GUIDELINES (f

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NCIG-03 07/23/85 Rev. 0 2.2 The Inspector The Inspector, as used in this Training Manual, is the per-son performing acceptance inspections of completed welds using the Acceptance Criteria of NCIG-01. The Inspector may work for the owner, the Engineer, a contractor, the NRC, or other party.

2.3 General Inspection Concepts In Section 3.0, Acceptance Criteria will be stated and spe-cific Guidelines given for determining if a completed weld is acceptable or rejectable. However, there are a number of inspection concepts that apply to more than one of the Accep-tance Criteria. These common inspection concepts are dis-cussed in this section. Remember, the common inspection

'(. concepts will be used in making your accept-reject decision for the individual Acceptance Criteria where the concepts apply.

e The Inspector shall perform the required inspection and determine acceptance or rejection separately for each Acceptance Criteria.

e The Inspector is responsible for assuring the weld size meets the NCIG-01 Acceptance Criteria, e The Inspector should direct his attention to areas test are potentially rejectable and need not make d et a ' : e d measurement in areas of obvious compliance with the Acce:-

tance Criteria. Continuous or near continuous measw ee-ments for determining weld size are inappropriate; s:st checking is acceptable provided questionable areas are inspected.

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NCIG-03 07/23/85 Rev. O e The required inspections are intended to evaluate and verify that the work is acceptable. They are not intended to upgrade or downgrade the level of workmanship or impose more stringent criteria or examination methods.

Concerns regarding workmanship, if any, should be handled in accordance with Project instructions.

e Acceptance inspection should be performed promptly after welding has been completed so that deficiencies, if any, may be identified and resolved in a timely manner.

e Visual inspection of welds is normally performed on the as-welded surface. Surf ace conditioning by grinding, buffing, filing, etc., is not required and may not be advisable for visual inspection. Grinding could mask other unacceptable conditions.

t e Lighting, natural or artificial, should be bright enough and placed so the surface area can be clearly viewed.

Lighting is adequate when the Inspector can resolve a black line 1/32 inch wide or less on an 18 percent neu-tral gray card placed on the surface to be inspected.

With experience, the Inspector should be able to judge the adequacy of lighting without ref erring to such a card.

e Visual examination relies on the Inspector's ability to detect the conditions being checked using his normal eye-sight (with corrective glasses, if the Inspector normally uses them). If a condition is so small that its rele-vance can not be determined with ordinary eyesight, the condition is acceptable.

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e If a magnifying lens is used it should provide a magnifi-cation of approximately 5 to 10 times. Higher magnifica-tions are not needed and should not be used.

e Tape measures and metal scales are suitable for measuring length and location of welds.

e Metal scales may be used for measuring the size of welds, but some Inspectors prefer fillet weld gages as being more convenient and appropriate for checking the size of fillet welds. Continuous measurement of size over the full length of the weld is neither required nor expected.

e Fillet weld sizes are specified in 1/16 inch increments by the Engineer. When measuring fillet welds, measure-ments shall be rounded-off to the nearest 1/16 inch by

'k. the Inspector. The use of gages for measuring fillet weld size is described in Section 3.0.

e Measuring devices (tapes, scales, gages, etc.) should be graduated in increments compatible with the applicable significant unit, e.g., 1/16 inch increments, rather than decimals. Micrometer type devices are not necessary.

2.4 Measurements Many of the welds that the Inspector will inspect are described by dimensions that specify the size, length or location. Dimensions are verified by measurement. The dimensional units on drawings and in the specifications may provide guidance with regard to how closely you need to mea-sure.

Inspecticn is based on using measurements expressed as feet, inches, or fractions of inches. The following tabulation 2-4

NCIG-03 07/23/85 Rev. O shows the smallest measurement unit used for dimensions that you may have to verify. (Smallest measurement units are sometimes referred to as 'significant units'.)

Dimension Smallest Measurement Unit (Significant Unit-Inches)

Undercut depth 1/32 Groove weld size (See Section 3.2.6)

Fillet weld size 1/16 Porosity 1/16 Incomplete fusion, overlap 1/8 Weld Length (Underlength) 1/8 or 1/4 Slag 1/4 Weld location 1

( When taking or recording measurements, dimensions should be rounded off to the nearest significant unit. ' Rounding off' is the technique of deciding how to express a measurement that falls between significant units. The rules for round-ing off are as follows:

Rule 1: If the observed measurement is less than 1/2 the significant unit, report the next -lowest value (mul-l tiple of the significant unit).

Rule 2: If the observed measurement is equal to or more l than 1/2 the significant unit, report the next high-l est value.

An example of the rounding-off technique is given below:

A weld l e n g th is measured and is found to be 10-3/8 inches. NCIG-01 specifies that the length 2-5 i

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NCIG-03 1 07/23/85 Rev. O j of welds greater than 3 inches long may be less than the specified length by 1/4 inch (the signifi-cant unit). Should the measurement be reported as 10-1/4 inches or 10-1/2 inches? The correct answer is 10-1/2 inches since the observed 3/8 inch is 1/8 inch larger than 1/4 inch and exactly 1/2 of the significant unit (1/4 inch). Rule 2 applies.

2.5 Discontinuity Length It is intended t h a t y o u _e_s t i m a t e t h e t o t al length of a dis-continuity and not make precise measurements except when the length of the discontinuity appears to be close to the Accep-tance Criteria limit.

2.6 Work Requiring Repairs The Inspector shall identify areas that do not meet the

{ Acceptance Criteria. The identification may be on the struc- ,

ture or by use of drawings, sketches, or records in accor- f dance with Project requirements.

2.7 Records Records of inspections or reinspections -shall be developed and retained in accordance with Project requirements.

2.8 Limited Scope Inspections Some of the inspections which you perform may be of limited

- scope. For example, an inspection may be made only to ver-1 2-6

NCIG-03 07/23/85 Rev. O ify that a random sample of fillet welds are of the proper size. If all of the welds-in the sample are acceptable (that is, they meet the NCIG-01 criteria for size), that is the information which should be reported. It is not expected or necessary that the Inspector look for other con-ditions; however, if any other potentially rejectable condi-tions are noticed, these should be reported separately in accordance with Project requirements. It is quite possible that these potentially rejectable conditions have aircady been evaluated and accepted.

2.9 Reinspection of Painted Welds The Engineer may authorize visual reinspections of painted cr coated weld surf aces that have already been inspected in the uncoated condition. The inspection of some weld condi-tions, such as weld size, craters, undercut, length and loca-tion are not affected by paint.

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l SECTION 3.0 ACCEPTANCE CRITERIA AND SPECIFIC INSPECTION GUIDELINES C

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NCIG-03 07/23/85 Rev. 0 3.0 ACCEPTANCE CRITERIA AND SPECIFIC INSPECTION GUIDELINES 3.1 Introduction This Section states the NCIG-01 Acceptance Criteria and pro-vides specific Inspection Guidelines for use when inspecting welds in nuclear power plant structures and supports.

These Acceptance Criteria and Inspection Guidelines have been developed using appropriate engineering evaluation.

Consideration has been given to the conditions which may be experienced in service by the types of structures and materi-als to which NCIG-01 is applicable.

The following is a list of conditions that will be covered

-( in this Section:

Cracks Undercut Weld Size Porosity Incomplete Fusion Arc Strikes

Weld Overlap Length and Location Craters Slag and Spatter i Weld Profiles l

3.2 Acceptance Criteria and Guidelines Welds shall be acceptable by visual inspect. ion using the Acceptance Criteria and Inspection Guidelines given in this Training Manual.

These Acceptance Criteria are intended to be used for the final acceptance inspection of welds in the uncoeted condi-tion.

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NCIG-03 07/23/85 Rev. O These Criteria may also be used for subsequent inspections after the welds have been coated, with the concurrence of  ;

the Engineer (l). Reinspections related to weldment cracking may require the removal of the coating or the use of appropriate magnetic particle inspection.

Remember that every condition or discontinuity that is seen in a weld is not necessarily rejectable. Each condition must be evaluated using the applicable Acceptance Criteria.

3.2.1 Weld Cracks Acceptance Criteria: The weld shall have no cracks.

Inspection Guidelines: Weld cracks shall be identified by visually examining the weld and heat affected zone. Visu-( ally detected cracks shall be identified. The use of magni-fication devices for detection of cracks by visual examina-tion is generally not required. However, additional tools, such as a flashlight or a magnifier, may be appropriate for further investigation.

3.2.2 Fillet Weld Size Acceptance Criteria: A fillet weld shall be permitted to be less than the size specified by 1/16 inch for 1/4 the length of the weld. Oversized fillet welds shall be acceptable if the oversized weld does not interfere with mating parts.

Inspection Guidelines: When measuring weld leg size the Inspector should use appropriate measuring devices (i.e.,

(1) See paragraph 2.9 l

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NCIG-03 07/23/85 Rev. O scales or fillet weld gages). Apparent undersize weld areas are the most appropriate locations for measuring weld leg size. Such areas can be determined while reviewing the entire weld length. Areas of the weld that appear to be undersized shall be examined based on the requirements of the Acceptance Criteria considering the undersize allowance, and rounding-off to the nearest 1/16 inch. In Figure 3.2.2-1, areas A, B, C, D, and E (and related cross-sec-tions) show typical weld areas which should be considered for weld size measurement. Back lighting is not required and should not be used to determine the adequacy of the weld size.

If the Inspector is concerned about the possible interfer-ence of an oversize weld with a mating part, he should refer to the appropriate drawing.

The Inspector should estimate the length of the portion of

. {- weld which is undersize. Continuous measurement of size over the full length of the weld is not required or desira-ble.

In some cases, Project Procedures may require the Inspector to provide additional information if a weld is rejected for being undersize. For example, the Inspector may be required to report if other welds in the same weldment or connection have oversize welds. This information is for the Engineer's l

use in evaluating the undersize condition and should be docu-mented in accordance with Project requirements.

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A B C D' E Undersize Undersize Undersize Concave Crater Both Horizontal Vertical (Undersize legs Leg Leg Throat)

Cross-sections through segments shown above.

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Fillet Weld Gages: The leg size of fillet' welds may be mea-sured with a scale or one of the commercially available fil-let weld gages. When measuring weld size of. concave welds with a fillet weld gage, remember that even though the fil-let weld throat is measured, the reading on the gage is the fillet weld leg size.

The Acceptance Criteria all'ows 1/4 of the weld length to be 1/16 inch less than specified. A way to determine the acceptability of the weld is to use a fillet weld gage which is (or has been set to) 1/16 inch less than the specified size to make the initial visual inspection. Any portion of the weld which is undersize can be easily located without making numerous, unnecessary measurements. The actual size of the fillet weld is important only when it is undersize by a rejectable amount. Remember to apply the rounding-off technique, even to portions that appear to be undersize by ,

1/16 inch.

The Inspector shall determine that there are no portions of the weld which are rejectable for undersize. Then a gage of the specified size (or a gage set to the specified size) should be used to check any segments of weld which may be less than specified to determine whether the total length of these segments exceeds 1/4 the length of the weld.

I i Comparator Type Fillet Weld Gage

< Comparator type of fillet weld gages consist of a set of metal strips. Each gage in the set has profiles at the cor-ners which are shaped to permit a comparative measurement of

, the leg size of typical fillet welds. These gages are avail-able in leg size increments of 1/16th inch. Smaller incre-3-5 l

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NCIG-03 )

07/23/85 i Rev. 0 l

4 ments are not necessary for measurement of structural fillet  ;

welds.

The correct use of this type of gage is illustrated f n Fig-  ;

ures 3.2.2-2 and 3.2.2-3. This type of gage can be used to measure the leg size of fillet welds directly or to deter-mine the eff ective leg size by checking the throat of a con-cave weld.

Other Multi-Purpose Weld Inspection Gages-Fillet weld leg measurements can be made with other multi-purpose inspection gages. However, the comparator gages previously discussed may be more convenient to use. Gages with increments in decimals or millimett.s should not be used. Fillet weld sizes are to be measured to the nearest 1/16 inch (in fractions, not in decimals nor in milli-

b. meters).

i 36

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NCIG-03 07/23/85 Rev. 0 3.2.3 Incomplete Fusion Acceptance Criteria: In fillet welds, incomplete fusion of 3/8 inch in any 4 inch segment, and 1/4 inch in welds less than 4 inches long, is acceptable. For groove welds, incom-plete fusion is not acceptable. For fillet and groove welds rounded end conditions that occur in welding (starts and stops) shall not be considered indications of incomplete fusion and are irrelevant.

Inspection Guidelines: Inspection for incomplete fusion shall be performed by visually examining the weld. The wet-ting and flow of weld metal at the fusion line is the best indication of fusion. Incomplete fusion in fillet welds which does not exceed 3/8 inch in any 4 inch segment of weld or 1/4 inch in welds less than 4 inches long is acceptable.

Incomplete fusion in a groove weld is not acceptable.

.{

Indications of incomplete fusion at the starts and stops of a weld which are observed only at the weld root are not typi-cal of the fusion in the main run of the weld. (See Figure 3.2.3.) This apparent incomplete fusion is acceptable when there is fusion at the weld toe.

Measurements of incomplete fusion length shall be rouncec-off to the nearest 1/8 inch.

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NClG-03 07/23/85 Rev. O IRRELEVANT INCOMPLETE FUSION

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NCIG-03 07/23/85 Rev. 0

-3.2.4 Weld Overlap Acceptance Criteria: Overlap is acceptable provided the criteria for weld size and fusion can be satisfied. When fusion in the overlap length cannot be verified, an overlap length of 3/8 inch in any 4 inch segment, and 1/4 inch in welds less than 4 inches long, is acceptable.

1 Inspection Guidelines: The area of any overlap shall be inspected to assure weld size and fusion requirements are met. Generally, in an overlap condition if incomplete fusion occurs, it will be short in length. The visual obser-vance of the wetting and flow of weld metal at the fusion line is sufficient indication of fusion. Portions of i ndi-v idual weld risoles or weave patterns which overlap arh not a ccncern when there is fusion on each side.

When fusion at the overlap area cannot be verified, the length of overlap should not exceed the equivalent of 3/8 inch in any 4 inch length or 1/4 inch in welds less than 4 inches long. Overlap in excess of 3/8 inch (or 1/4 i nch) ,

length is acceptable when fusion and weld size can be veri-fled. (See Figure 3.2.4.)

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Overlap length shall be rounded-off to the nearest 1/8 inch.

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Wetting / fusion visible; Accept regardless of length Section A-A Figure 3.2.4 3 - 12

NCIG-03 07/23/85 Rev. 0 3.2.5 Underfilled Craters Acceptance Criteria: Underfilled craters shall be accepta-ble provided the criteria for weld size are met. Craters which occur outside the specified weld length are irrelevant l provided there are no cracks.

Inspection Guidelines: The length of the weld shall be visu-ally examined to locate the craters. Craters within the specified weld length are to be evaluated using the accep-tance criteria for undersized fillet welds (Section 3.2.2) or groove welds (Section 3.2.6). (See Figures 3.2.5-1 and 3.2.5-2.) Craters outside the specified weld length are irrelevant (see Figure 3.2.5-3).

Weld size in crater areas shall be evaluated by rounding-off to the nearest 1/16 inch.

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Craters should be visually inspected for cracks.

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3 - 13 I

NCIG-03

- 07/23/85 Rev. O CRATERS - FILLET WELOS

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NCIG-03 07/23/85 Rev. O CR ATERS - GROOVE WELDS i

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NCIG-03 07/23/85.

Rev. O CRATER OUTSIDE SPECIFIED LENGTH Specified-Length 3 0) 3 3'

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Crater outside specified length; Disregard.

Check craters for cracks.

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Figure 3.2.5-3 3 - 16

NCIG-03 07/23/85 Rev. 0 3.2.6 Weld Profiles Acceptance Criteria:

e The faces of fillet welds may be convex, flat, or con- 4 cave, provided the criteria for weld size are met.

e The faces of groove welds may be flat or convex.

e Convexity of fillet and groove welds are not criteria for acceptance and need not be measured.

- e The thickness of groove welds is permitted to be a maxi-mum of 1/32 inch less than the thinner member being joined.

Inspection Guidelines: Fillet weld convexity need not be

( measured as part of the acceptance inspection. Fillet weld concavity is acceptable provided the requirements for weld size are met. Fillet weld size shall be evaluated in accor-dance with 3.2.2.

Groove weld reinforcement need not be measured as part of the acceptance inspection.

When evaluating groove weld thickness, the 1/32 inch unue -

size allowance is a maximum value. It is equivalent to rounding off the thickness to the nearest 1/16 inch; that is, if the thickness of a groove weld is 1/32 inch less than the specified trickness, it is acceptable; if it is under-size by more than 1/32 inch, it is to be rejected.

See Figures 3.2.6-1, 3.2.6-2 and 3.2.6-3 for examples of acceptable fillet, groove and flare bevel weld profiles.

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3 - 17 l

NCIG-03 07/23/85 Rev. O FILLET WELD PROFILES

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NCIG-03 07/23/85 Rev. O GROOVE WELD PROFILES

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NCIG-03 07/23/85 Rev. 0

( FLARE BEVEL PROFILE

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• NOTEThe profile shown is acceptable for flare bevel welds specified to be flush. If other fill requirements are specified, refer to Project specifications for acceptance requirements.

Figure 3.2.6-3 3 - 20

NCIG-03 07/23/85 Rev. 0 3.2.7 Undercut

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Acceptance Criteria:

e For material 3/8 inch and less nominal thickness, under-cut depth of 1/32 inch on one side for the full length of the weld, or 1/32 inch on one side for 1/2 the length of the weld and 1/16 inch for 1/4 the length of the weld on the same side of the member, is acceptable. For members welded on both sides where undercut exists in the same plane of a member, the cumulative lengths of undercut shall be limited to the lengths of undercut allowed on one side. Melt-through that results in a hole in the base metal is unacceptable.

e For materials greater than 3/8 inch nominal thickness, undercut depth of 1/32 inch for the full length of the weld and 1/16 inch for 1/4 the length of the weld on both sides of the member is acceptable. When either welds or undercut exist only on one side of the member or are not in the same plane, the allowable undercut depth of 1/3?

inch may be increased to 1/16 inch for the full lengtn of the weld.

i l

Inspection Guidelines

The criteria for determininc t*a acceptance of undercut are depth and length. The metho: **

be used for determining acceptable depth is primarily visua .

Potentially rejectable areas may be evaluated using a scs .

l comparative sample, or suitable gage to determine the ca: **

l of undercut.

The Acceptance Criteria refer to s i tuations where unca- ,

may exist on both sides of the member and in the same o's*-

Sketch A of Figure 3.2.7-1 illustrates undercut on ont, -

side of a member. Sketch B shows undercut on both sides Sketch C is an examp;e -*

a member and in the same plane.

3 - 21 I

l l

NCIG-03 07/23/85 Rev. O undercut on both sides of a member but not in the same I plane.

Undercut on opposite sides and in the same plane of a member reduces the net cross-sectional area of the member and has a cumulative effect. For example, in Sketch B, the total length of undercut is determined by adding together the length of undercut on each side of the member; for material 3/8 inch and less nominal thickness the total length of undercut shall not exceed the length of undercut that would be allowed if there was undercut on only one side of the member.

- In Sketch C, the undercut on one side is not in the same plane as the undercut on the opposite side of the member and therefore, the length of undercut at each location is to be evaluated independently.

'b Undercut depth is to be estimated to the nearest 1/32 inch and undercut length is to be estimated to determine compil-ance with the undercut length criteria. Some examples of allowable undercut are shown in Figures 3.2.7-2 through 3.2.7-5. These Figures show the length and depth of under-cut which is acceptable. They also show continuous lengths of undercut; however scattered, discontinuous and shorter lengths of undercut are obviously acceptable.

There are suf ficient margins in these criteria so that it is not necessary to sum isolated intermittent undercut (i.e.,

1/4 inch here, 5/8 inch there) to develop the total length of undercut. When these figures show undercut on both sides of the base metal, the undercut is assumed to be in the same plane. As long as the Acceptance Criteria for undercut depth, length, and melt-through are met, the fact that under-3 - 22

NCIG-03 07/23/85 Rev. O cut on one side of a member may be directly opposite and in the same plane as undercut on the other side of the same 4

member is irrelevant.

Melt-through that results i n a hole through the structural members is always unacceptable.

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NCIG-03 07/23/86 Ree. O EXAMPLES OF ACCEPTABLE UNDERCUT i

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NCIG-03

, 07/23/85 Rev. 0 EXAMPLES OF ACCEPTABLE UNDERCUT

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NCIG-03 07/23/85 Rev. 0 EXAMPLES OF ACCEPTABLE UNDERCUT

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NCIG-03 07/23/85 Rev. 0 3.2.8 Surface Porosity l

Acceptance Criteria: Only surface porosity whose major sur-f ace dimension exceeds 1/16 inch shall be considered rele-vant. Fillet and groove welds which contain surface poros-ity shall be considered unacceptable if:

e The sum of diameters of random porosity exceeds 3/8 inch in any linear inch of weld or 3/4 inch in any 12 inches of weld; or Four or more pores are aligned and the pores are sepa-

~

e rated by 1/16 inch or less, edge to edge.

Inspection Guidelines: Porosity is generally less than 1/16 inch in diameter. Thus, relatively few pores are relevant.

When it is necessary to use a measuring device, a 1/16 inch wire and a tape or scale should be adequate. If the 1/16 inch wire can be inserted in a pore, the pore is relevant.

Counting the number of random pores which are over 1/16 inch in diameter within one inch and twelve inch spans will pro-vide adequate information for weld acceptance. The Accep-tance Criteria allow up to 6 random relevant pores in any 1 in:h of weld or up to 12 random relevant pores in any 12 inches of weld.

When evaluating aligned porosity, a 1/16 inch diameter wire can be used to size the pores and check the edge to edge 3 pacing of the pores. If the size of a pore is 1/16 inch or less it is irrelevant and need not be counted; if the spac-ing between any two relevant pores exceeds 1/16 inch, those pores are irrelevant for the purpose of evaluating aligned porosity.

See Figure 3.2.8 for examples of aligned and random poros-ity.

3 - 29

NCIG-03 07/23/85 Rev. 0 POROSITY

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' Porosit'y Aligned porosity 2

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! Figure 3.2.8 3 - 30

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-NCIG-03 07/23/85 Rev. 0 3.2.9 Weld Length and Location Acceptance Criteria: The length and location of welds shall be as specified on the detail drawing, except that weld lengths may be longer than specified. For weld lengths less than 3 inches, the permissible underlength is 1/8 inch and for welds 3 inches and longer the permissible underlength is 1/4 inch. Intermittent welds shall be spaced within 1 inch of the specified location.

Inspection Guidelines: Welds shall be visually inspected to determine that they are in the locations shown on the design drawings. Weld length shall be measured to the tolerances

- designated on the drawings. When the design drawings do not provide tolerances for weld length and location, an under-length of 1/8 inch is acceptable for welds less than 3 inches long and 1/4 inch for welds 3 inches long or longer.

Welds may be longer than specified.

Boxed weld ends (end returns) are part of a single, overall weld length. Boxed ends are not to be considered separate w el d s . (See Figure 3.2.9.)

Welds are usually designated as full length of t h e m e:% - -

continuous. The length of continuous welds need not be -t-sured. When a length dimension is specified, it usst -

+*

applies to intermittent welding, such as, "3 inches lo".

12 inches center-to-center," or, "6 inches long at 12 ia -

The total sum of the lengths c' center-to-center."

intermittent welds is more important than the actual Either way, e of the individual intermittent welds.

inch or 1/4 inch tolerance, as applicable to segment ' ..

is acceptable if no other tolerance is given.

A 3 - 31

NCIG-03 07/23/85 Rev. O Intermittent welds shall be located within-1 inch of the specified.

• cation. Intermittent welds shall be terminated in accord 6 e with Project requirements.

Weld lengths shall be rounded off to the nearest 1/8 inch for welds less than 3 inches long and the nearest 1/4 inch for welds 3 inches long or longer. Measurements for the location of intermittent welds shall be rounded off to the nearest i nch.

C 2 3 - 32 i

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NCIG-03 07/23/85 Rev. 0

. BOXED WELD ENDS I

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NCIG-03 07/23/85 Rev. O I

3.2.10 Arc Strikes Acceptance Criteria: Arc strikes and associated blemishes are acceptable provided no cracking is visually detected.

Inspection Guidelines: No ipecial inspection is required for detection of arc strikes. Arc strikes are usually found near the weld and the Inspector should review them while performing inspections for other weld condition. Arc strikes and the asscciated blemishes should be visually exam-ined for cracks. Visually detected cracks are unacceptable.

- 3.2.11 Sy_r_ face Slag and Weld Spatter A_c_ceptance Criteria: Slag whose major surface dimension is 1/8 inch or less is irrelevant. Isolated surface slag that remains after weld cleaning and which does not exceed 1/4

( inch in its major dimension, is acceptable.

ered to be isolated when it does not occur more frequently (Slag is consid-than once per weld or more than once in a 3 inch weld seg-ment.) Spatter remaining after the cleaning operation is acceptable.

Inspection Guidelines: Inspection for surface slag and weld spatter shall be performed by visually examining the length of the weld and adjacent base metal areas. Slag measuring 1/8 inch or less is irrelevant.

The 'once per weld' limit stated in the Acceptance Criteria applies to relevant slag in welds that are 3 inches or less in length. In welds greater than 3 inches long, relevant size slag should be separated by 3 inches or more.

(

3 - 34 4

NCIG-03 07/23/85 Rev. 0 a'

Areas of slag not meeting the Acceptance Criteria may be removed by the Inspector, if convenient, or the weld should i be cleaned again and re-inspected.

Surf ace slag has no ef f ect on the load carrying capacity of the weld and is not harmful to the weld as long as it does not mask some other discontinuity; therefore slag dimensions should be estimated only; detailed measurements need not be

{ made. (Cleaning required f or subsequent processing, such as painting or NDE, is not addressed in this Training Manual.)

C 1

7 3 - 35

NCIG-03 07/23/85 Rev. O i

APPENDIX A ALTERNATIVE ACCEPTANCE CRITERIA i

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NCIG-03 07/23/85 Rev. 0

.( ,

APPENDIX A ALTERNATIVE ACCEPTANCE CRITERIA f

The AWS D1.1 Structural Welding Code allows the use of alterna- ,

tive acceptance criteria when agreed upon by the owner, the Engi-neer, and the constructor. This fact is clarified in the 1985 edition of AWS D1.1. A new paragraph 1.1.1.1 has been added

-which states:

. "1.1.1.1 The fundamental premise of the Code is to provide gen-eral stipulations adequate to cover any situation. Acceptance criteria for production welds different from those specified in the Code may be used for a particular application provided they are suitably documented by the proposer and approved by the Engi-1 4

{ neer. These alternate acceptance criteria can be based upon eval-l uation of suitability for service using past experience, experi-I mental evidence or engineering analysis considering material type, service load effects, and environmental factors."

In addition, the Commentary for this new paragraph reads:

"C1.1.1.1 The workmanship criteria provided in Section 3 of the

! Code are based upon knowledgeable judgment of what is achievable by a qualified welder. The criteria in Section 3 should not be j considered as a boundary of suitability for service. Sultability for service analysis would lead to widely varying workmanship criteria unsuitable for a standard code. Furthermore, in some cases, the criteria would be more liberal than what is desirable and producible by a qualified welder. In general, the appropri-ate quality acceptance criteria and whether or not a deviation is harmful to the end use of the product should be the Engineer's 4

i i A-1 i

.__ . _ _ ~ _ _. ___ _ _._.~._ _ _ _ _ _ _ ._.

NCIG-03 07/23/85 Rev. O decision. When modifications are approved, evaluation of suita-0

'bility for service using modern fracture mechanics techniques, a history of Satisfactory service, or experimental evidence is recognized as a suitable basis for alternate acceptance criteria for welds."-

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NCIG-03 07/23/85 Rev. O i

APPENDIX B NRC ACCEPTANCE LETTER

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• .*' , , UNITED sf ATEs Re

{ g NUCLEAR REGULATORY COMMISSION

. .; t wASHipeCfgsd.D.C.20555

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\ , , , , , **' JUN 2 61985 j

Mr. Douglas E. Dutton, Chainnan Nuclear Construction issues Group Southern Company Services P. O. Box 2625 Binningham, Alabama 35202

Subject:

Visual Weld Acceptance Criteria for Structural Welding at Nuclear Power Plants (VWAC) Revision 2 The staff has completed review of the subject document prepared by the .

Nuclear Construction Issues Group. We have concluded that VWAC Revision 2 represents a technically acceptable approach for visual inspection of j

structural weldments of nuclear power plants that are under .the purview of Anerican Welding Society Standard D1.1 or other non-ASME class structures.

WAC is, in our opinion, not applicable to inservice inspections that are required by Section XI of the ASME Code.

Applicants and licensees wishing to commit to the WAC must document their comitment in the fann of an amendment to the Safety Analysis Report for l each power plant. The staff's processing of these amendments can be

{j expected to be expeditious if no significant exceptions are taken to WAC L Revision 2.

We believe it particularly important that unifonn training be provided to QC inspectors in the-implementation of WAC Revision 2 to assure consistency of application. The NRC staff, particularly regional inspectors, should be provided opportunities to review your training program and to observe the conduct of the training.

If you have any questions regarding this matter, please do not hesitate to contact us.

Sincerely, J es P. t Acting Director vi sion of gineering I (fice of Nuclear Reactor Regulation cc: V. Stello H. R. Denton J. M. Taylor i

Q 5'? N' 54 g -

4

NCIG-O' 07/23/85 Rev. 0

(

APPENDIX C WORKMANSHIP l

C-1

NCIG-03 07/23/85 Rev. 0 APPENDIX C WORKMANSHIP The workmanship provisions of Section 3 of AWS D1.1 are appropri-ate for in-process quality control purposes. The determination of whether corrective action is necessary to assure good workman-ship during production shall be made in accordance with the

, in-process welding control requirements of the Project, o

Prior to the 1985 edition of AWS 01.1, paragraph 3.1.1 read:

"3.1.1 All applicable paragraphs of this Section shall be observed in the production and inspection of welded assemblies and structures produced by any process acceptable under this

[ Emphasis added.]

{ Code."

From this, some people inferred that Section 3 applied to visual i nspection of welds. However, the 1985 edition clarified the i ntent of 3.1.1 by deleting the words, 'and inspection'. The revised paragraph now reads:

"3 .1.1 All applicable paragraphs of this Section shall be i

observed in the fabrication of welded assemblies and structures produced by any process acceptable under this Code."

In addition, the Commentary was revised to emphasize that Section 3 pertains to workmanship criteria. The 1985 Commentary for this paragraph reads:

"C3.1.1 The criteria contained in Section 3 are intended to pro-vide definition to the producer, supervisor, engineer and welder C-1

. ,c . - - - - . . . - - - - - - , - - - - - - , _ , . . . - . , , . . _ . - - - - . - . - - - - - - , - - - - - - - - , . , , - . , - , . - . - - - _-

NCIG-03 07/23/85 Rev. O of what constitutes good workmanship. Compliance with the cri-teria is achievable and expected. If the workmanship criteria-are not generally met, it constitutes a signal for correct!ve action."

The Acceptance Criteria and Inspection Guidelines presented in this Training Manual apply to inspection of completed welds and it is concluded that NCIG-01 has no effect on the in-process work-manship standards contained in Section 3 of AWS 01.1. The work-manship provisions of Section 3 of AWS Dl.1 and other construc-tion codes are necessary for in-process quality control purposes.

The determination of whether corrective action is necessary to assure good workmanship during production shall be made in accor-o dance with the in-process welding control of the Project.

C-2

PGandE Letter N3.: DCL-86-342 ENCLOSURE 6 i

1091S/0048K

%, ONivUle)sUAUGs

! ~% NUCLEAR REGULATORY COMMISSION Enclorura 6 g -a wAsMINGTON C. C. 20555 p ggg

%...... JUN 2 61985 Mr. Douglas E. Dutton, Chaiman Nuclear Construction Issues Group Southern Company Services P. O. Bo'x 2625 Birmingham, Alabama 35202

Dear Mr. Dutton:

1

Subject:

Visual Weld Acceptance Criteria for Structural Welding at Nuclear Power Plants (VWAC) Revision 2 The staff has completed review of the subject document prepared by the -

Nuclear Construction Issues Group. We have concluded that VWAC Revision 2 represents a technically acceptable approach for visual inspection of structural weldments of nuclear power plants that are under the purview of American Welding Society Standard DI.1 or other non-ASME class structures.

YWAC is, in our opinion, not applicable to inservice inspections that are required by Section XI of the ASME Code.

Applicants and licensees wishing to comit to the VWAC must document their comitment in the form of an amendment to the Safety Analysis Report for each power plant. The staff's processing of these amendments can be l expected to be expeditious if no significant exceptions are taken to VWAC Revision 2.

We believe it particularly important that uniform training be provided to ,

QC inspectors in the implementation of VWAC Revision 2 to assure consistency of application. The NRC staff, particularly regional inspectors, should be provided opportunities to review your training j program and to observe the conduct of the training. .

If ycu have any questions regarding this matter, please do not hesitate to contact us.

Sincerely, J s P. t Acting Di, rector vi sion of thgineering ffi ce of Nuclear Reactor Regulation i

cc: V. Stello H. R. Denton J. M. Taylor N) lW&&

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