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UEL0 f130 TECitNIQUE SPEC IFIC/'.TIO!! !!O. AUS l-1
' 's document f.ns been fermulated to clari fy the techo!ra.c for application l
of Weld code 7/8 procedures ris applied to AUS welding o11y. This technique util be used In accordence with Pullman Power Products Proces!, She d.
DATE:
5/17/72, REVIC IC!l:
4 DATE:
12-20-79 SlJPl%RTiliG PQR(s):
Pr quali fied f
Technicue %bci fication fr'? :
Shielded Met 61 Arc Ueldine of ASTM A-36, A-441, A-$7' ta, So, A-t tP, A-5 IS cnd A-Sl6 in e,r y applir.oble cedination in accordance
/
ul th AUS 01.1-79.
Paso Hretal: The 1ase r,etal shall con fon.1 to those listed t.bove.
Other mo teria le.
Iar.y be substituted with the approvol of the Cogninnt Velding Engineer.
p., v: r..: tt,1 Th ; < i.na s : This techniouc i:: cualified fer vielding of roterials of unlimited inickne:s in accordance with AUS D1.1-79.
FIfler Hetal: 'The filler metal shall conform to AUS SFA 5.1, Type E-7018 I
y 'Jfon of veldtsn: Velding will be done in all positions. Ucid progression wa i l be vert i cc-a - up.
)
Per hee t and Inf e.re ss Temncenture:
Preheat and Interpt,:: terrperature shall 1
conform to tho:e specitied below:
SASE METAL ill!CIMESS MillliMI FRE!! EAT MAXilt0Mo !1TERPASS l
f (Ac t u.1 )
U F F
Up to 3/h" 50 'F.
SuG'F.
l Over 3/4" through 1 1/2" 150 F.
500 F.
l 0
Over 1 1/2" through 2 1/2" 225 F.
500 F.
i Over i 1/2" 300 F.
500 F.
l ifnen metal ternperature is belovt 70 F material will be fitrac dried. The preheet l
renoircracnt of a joint is established by the thici.str member being joined.
The l
- preheat applice to both sir!cs of the joint and to the entire length of the joint
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a minimura distance as shown below:
l T'.'PE OF VELD KATCDIAL THIC!!flFSS(t)
Mill!!'UM.D ISTA::CF F"0!! P0 f flT OF UELD DETO~ilT Fillet, Partial f3inche:
3 inches Pen.(,1/4t, ca d
~~~~~~
Dase netal Depairs
,5 3 Irrher.
,(t) thickness'of port 1/4 t
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icil Per,ctretion.
All Thickness 2t Pcr i 101 Pcn.,> ];
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B708190445 870814
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- WPS No._AWS 1-1 PAGE 2 0F 3 f
Cleanliness: All weld preps will be free of rust, scale, grease, and other contaminants for at least 1" from the weld prep edge.
Veld Parameters: Welding parameters are spectfled in the table on page 3 of 3.
Welding Technique: The welding technique shall be as follows:
A)
BEAD WlDTH - All welding will be accomplished using the stringer bead technique. Weaving is allowed on the cover pass only to a maximum of 5 times the electrode diameter.
B)
INTERPASS CLEANil10 - All weld beads will be f ree of all slag prior to continuation of welding.
NEEDLE GUNS shall not be used for any cleaning operation.
C)
DEFECTS - All visable defects, i.e.,
porosity, crater cracks, cold lap, shall be removed prior to the continuation of welding by grinding or or filling.
D)
RUN-OFF TABS AND BACKING STRAPS - Run-of f tabs and backing straps will be used whenever possible.
Run-off tabs should be removed.
Backing straps need not be removed unless specified by the owner or his desig-nated representative.
Removal of run-off tebs shall be accomplished oy I
thern'cl cutting wi thin I/8" of the wcldr ;t and then blended into the base metal by grinding.
Alternatively, removal may be entirely accom-plished by grinding.
Removal of backing straps will be accomplished by grinding or gouging to sound metal, and then back welded as needed.
When any' thermal process is used, the applicable preheat requirements are ' mandatory.
Preheat may be maintained during grinding as desired.
E)
BASE METAL BUILD-UPS - Base metal build-ups will conform in all aspects to this procedure.
F) WELD PROFILES - Weld profiles will be as follows:
1 J
1)
Groove Welds - maximum reinforcement of 1/8" and shall blend smooth-ly into the base metal in accordance with the typical joint details and weld profiles, page 3 of 3 l
I 2)
Fillet Welds - size in accordance with the field drawing (+1/8,
-1/16 for 10% of weld length) and profile in accordance with the typical joint details and weld profiles, page 3 of 3 l
l l
- 3) The final surface will be smooth enough as not to interfere wi th N.D.E. operations.
Preheat may be maintained during final surface conditioning operations.
- 4) T-Joints and Corner Joints Groove Welds - maximum reinforcement of 1/8" and sball biend smoothly into the base metal with reentrant l
l configurations in accordance with the typical Joint details and pro-j i
files, pago 3 of 3 i
N *'
a
'j rumnon e oween > rouuct:,
WPS flo.
Aus 1-l PAGE 3 of 3
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7 DATE:
12 20-79
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WEi,DIt'C PARA}'ETERS u ^'G 7 H F 1 L L E f: METAL C tlP R E ?it TRAVEL WELD VOLT SPECC f"<[
Y ct PHOCES$
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ggggp All S):AW E7010 3/32 DCne 65-120 27 2
100-165 31 2
1/8 5/32 140-220 34 3
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3/16 180-275 36 3
- Kwd.num APPROVALS:
Prcparcd by: g.5 8-</f &,,- /2-25-7/'Cogni2 ant WeIding Enginecr f t./ 7 0[;'f Q.,A. flanager h
Approve <8 by, w
__ Approveo by:
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C E. Representaelvs e
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t' itJTEftOFFICE CC2255POMDEHCE I
TO File DATE December 4, 1979 FRO M liarold Karner,. QA/QC Manascr
$UBJ CCT.........A...S..$..1..S..T.. A..t.l..T...QA../..QC.....M.. A..tl A...G..E..R....
Mr. Virgil Casey is hereby appointed assistant QA/QC Manager.
During th,e 111 ness of Mr. Don Geske and the arrival of my-self, he has been responsible for this posi tion.
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Harold Karner QA/QC Manager HK: pm i
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g Pullman Power Products j
i PORM T-12 6 rev. 7/6/78 re v.
1/ 3/ 79 rev. 3/29/79 DIT43LO CX1YC'!.!CCL 2.2 PO'TER P*J!.7T i
PAGE 1
OF
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1 QUALITY AUDIT SI""_'L2Y *EPORT SIT of0. : 29 FILE NO.:X W')IT '9.TE : 4-23-82
- .CTIVITY AUDITED l i
DISTRIstTIO.'1 TURE RESTRAINT INSPECTION T!!LE
!c, 8833XR, Proc. 8833XR-1, hCRfDCl-79-RM-010 DPICTOR OF OA A.A.
ECK 1243, 212, 201, 267, 0Al#152, PG&E 3523 REsIr m CcNSn.. pgR.
a, Ryan
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? C 'P OS2 OF ACDIT1 SUP p..
pp.rA AUDI-'In sgg qTygos i
A'"'I' EAN A SON
.CHEDULED FIELD CA/OC MANAGER W. VADNCD J
OT:iE R I V.P. E CT. CCNS'"R.
P. t FypNS Brasher, R. Faull, J. Watson, P. Dawson, PG&E J. AMMON vinn FILE
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A..\\. R.
"'O DE E
S UM.'!A RY j
I INSPECTION X t
An unscheduled audit was performed on various areas of the Rupture Restraint program to verify conformance with the documented instructions.
procedures and drawings for accomplishing the work.
There are Program Deficiencies witTthe groove welds installed on Rupture Restraints.
1 4
Full penetration welds less than 9/16" in thickness installed since July 1979 have not been ultrasonic examined as required by " Corrective Action to Prevent Recurrence" to PG&E Nonconformance Reports GCl-79-RM-010 and #DC2-79-RM-Oll.
These NCR's required that "all Pipe Rupture Restraint welding, except for fillet welds smaller than 1/2", accomplished under Spec. 8833XR will be examined by Magnetic Particle Inspection in addition to the presently required Ultrasonic Inspection". The " presently required Ultrasonic Inspection" requirement of Spec. 8833XR, in effect on 6-7-79 and 6-21-79 when the NCR's " Corrective Action to Prevent Recurrence" were approve was that complete ultrasonic inspecticn shall be made on all connections utilizing full penetration welds.
Since July 11, 1979, only rupture restrair full penetration welds 9/16" and greater in thickness have received UT exam-inations.
A number af full penetration groove welds do not comply with ESD 243 an:
AWS Code Requinnents concerning weld reinforcement.
The reinforcement on these welds excaeds the maximum tolerance allowed by these specifications.
i
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These welds were identified by Pullman QC Inspectors as being out of toleran<
but at the direction of PG&E Inspector were accepted.
RE SP O'.lS I3 LE COSTACT:H. Karner P!EPAF.ID Bl: H. Hudson TITL: : 0A/QC Manacer TITLO : Internal Auditne 0.'.T2 : 8-3-8 L
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e Pullman Power Products 6 A rav. 7/6/78 TV j
ro v.
3/ 30/79
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J DIA3LO CA'iYO i :1UCIIAn PAGC 2
OI' 2
l PO'CR PIAIT
(
1 QUALITY AUDIT SUM 2'.ARY RCPORT neDIT MO.: l 29
) PIL2 NO.: IX l
';U DIT Dr/n : la-23-82
)
A. A. R.
COD::
EU!EARY j
The QA/QC Manager has determined that pG&E's written approval on the QC Comment Sheet attached to the weld process sheets is legitimate authoriza-tion to deviste from ESD 243, Contract 8833XR, and AWS Code Requirements.
k 1
1 In addition, a number of other groove welds were accepted by Pullman QC Inspectors (without PG&E authorization) which exceeded the reinforce-ment tolerance.
i 1
A number of full penetration groove welds were identified that were ultrasonic examined but did not have ultrasonic examination record forms, which identified the work and area of examination, stored in the documen-i tation package as the historical document required to substantiate Quality l
Assurance.
These records could not be located by the NDE Technician or the QA Inspector in charge of documentation.
l 1
(
Groove welds were found that had a transition that goes from the face of the weld to below the plane of the base metal surface.
One groove weld i
1 was found with undercut that exceeded ESD 243 tolerance.
Another weld had 1
1 bumps on the face, while a third had sharp surface irregularities.
Two welds which had gaps in their fit ups were audited to determine if the correct site fillet welds had been installed to compensate for the gaps.
The welds were installed with the correct size fillet weldr..
The documentation package for one rupture restraint was audited to determine if the Field Warehouse Requisition for two items were included.
The requisitions were in the package but one did not list the field weld 1
2 numbers involved and the other did not have the signature of the ware-houseman who filled the order, l
1 A thermal cutting process performed to QAIp152, was audited.
The Field Engineer provided to production a "INFORMATION ONLY" copy of a j
i 3
controlled document.
Drawing Control issued the copy without receiving from the Field Engineer a " Drawing Request", listing the required informa-tion about the copy. The Field Engineer filled out a material requisition and provided hold tags to insure proper Class I traceability for the 1
3 material being cut out ant;l'to be reinstalled at a later date.
But the QC Inspector did not verify, prior to cut out, the material requisition list-ing the items to be removed.
The material was stored in a Class I storage area with proper traceability.
I(
~ 70NSIDLE CONTACT: H. Karner PREP ARCD BY : H. Huoson E: 0A/0C Manaaer TITII : Internal Auditor DATE: 8-3-82
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3/ 30 / 79 DIABLO' CANYON NUCLEAE POWER PLANT' PAC I
(
AUDIT ACTION' EQUEST
)
FILE.MO:l[
UNSCHEDULED
/
X AUDIT NO.:.
29 A.A.R. MO, 4
/f J
PG&E NCR#DC-T-79-RM-010 03SER7ATION: CODER 1
Aw.a.v.Lu. AUDIT::D r PG&F NCRf 0C2-79-RM-011 AUDIr DATER 7-82 REmt aCr DOCUMENTS : gner_ ggqqyo_ NroanrT_70 eu nin_ Nrosnr9 7o DM-0T1 e, nc 8832Yo.
1 FINDING:
1.
" Corrective Action to Prevent. Recurrence" listed on PG&E Nonconformance Reportz
- DC1'-79-RM-010 (datt.d 6-6-79) and #0C2'-79-RM-011 (dated 6-21-79) has not been fully, implemented.
The requirement that "all Pipe Rup.ture Restraint welding, except. for fillet welds smaller than 1/2", accomplished under Spec. 8833XR will be examined-by Magnetic Particle Irscaction in addition to tha prs:antl.y
--C:,r t f r,0cd O r, pa g e 2'--
FINDDirJ BYr H. Hudson DATE: 7-82 ACK ' D 3Y :
DA"'! :
SUSPECTED CAUSI The requirement of: Spec. 8833XP, Section 2.7.21, which was in effect on 6-7 and 6-21-79 when the NCR's " Correct 1ve Action to Prevent Recurrence" were approved, was not utilized to implement corrective action :
--Continued on page 3--
(
?rCQK" ENDED COREC"'IVE ACTION:
1.
All' Unit #I and #II Rupture Restraint full penetratio,n welds; including Generai Repair Welds, less than 9/16" irr thickness, instajJed since July 1979, be u.itrasorrte examined.
-Continued on page' 4-DUr DA"'r:
CORECTav.:. ACTION TAKEN:
TAKE_Y Br:-
APPROVED BY :'
l S""DS TO: PNir RECUR.ETCE -
s O
l TAITN*Br:-
APP ~ ROVED Br:-
ECLLCW UE::
AwAv Ad. COMPLIES' WI.T!9 AEPROVEC CORRECTIVE AC"'mN IF NO - Et. EASE EXPLAINr YES NCT s
SYt DATE:
c A.A. R CLOSED BY :.
DATE r t
I APPROVED BY $
DAIE:
u
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..f,.
i
.,m
[3/30/79
[
DIADLO CANYON PAGE 2
OF" 4
q NUCLEAR EONER PLANT.
i AUDIT ACTIOY REQUEST'
(
[
UNSCHEDULED gr NO :.
X AUDIT NO.
29' A. A. R'.
N C' :-
4 PG&E NCR#DC1.-79-RM-010
.SEIt7ATION CCDCr 1
Au.i.vT.Tr lww.nw r PG&E NCR#0C2-79-RM-011 7'82 j
r.Dr:: DATES r
- FERCNCE DOCUME".iTS r, Soec. 8833XR. NCR#001-79 RM-010. NCRdDC2' 79 RM-011. Proc. 8833XR T
]
IDING CONTINUED:
required Ultrasonic Inspection" has not been implemented in regards to full' penetra. tion.
I welds less than 9/16" in thickness.
Spec. 8833XR, Section 2.7.21 states that "ecmplete-ultrasonic inspection shall be made on all connections utilizing full penetration welds". l This requirement was "the presently required Ultrasonic Inspection" in effect during Jun! l 1979.
Since July 11, 1979, as a result of the approval by PG&E and implementation by Pullman of QA Instruction #143 - NDE Requirement - Structural Welding, only Rupture j
Restraint full penetration welds 9/16" and greater effect.ive throat have received. ultra-l sonic examination.
Full penetration welds. less than 9/16" effective throat have not bee: l subjected to ultrasonic examination as. required, by Spec. 8833XR, Section 2.7.21 which wa.
in effect when the NCR's " Corrective Action to Prevent Recurrence" were approved.
This.
) a noncompliance to PG&E Nonconfonnance Reports #DCl-79-RM-010 and #DC2-79-RM-011 (Correc Action to Prevent Recurrence,. Item #1) and Spec. 8833XR, Section 2.7.21.
(
l The Nondes'tructive Testing requirements, of "Diablo Canyon Rupture Restraint General. Repa.
Procedure #8833XR-1" dated 6-7-79, have not been fully implemented.
The requirement tha
" completed weld repairs are to be nondestructively examined in accordance with the requ.i ments of Engineering Specification 8833XR" has not been. implemented in regards to full penetration welds Tess than 9/16".j_n_ thickness.
Engineering Specification 8833XR, Secti n
2.7.21 states that " complete ultrasonic inspection shall be made on. all connections util
- ing fu.11 penetration welds".
This specification requirement was. in effect on 6-7-79.
Since July.11,1979, a result of the approval by PG&E and the implementation by Pullman of QA Instruction.#143 - NDE Requirement - Structural Welding, only Rupture Restraint fu penetration welds 9/16" and greater effective throat have received ultrasonic examinatic The. ultrasonic.' examination of other welds. (fall penetration welds less than 9/16" effec-
' throat) har no!: taken place as required. by Spec 8833XR' which was in effect wher: Procedu 8833XR~-T was issued.
This is a. noncompliance to Procedure 8833XR-1.TT and Eng'neering Specification. 8833XR, Section 2.7.2T.
NOTE: Procedure #8833XR-1 is a.n additiona.T corrective. action required
- by PG&E NCR#DCT-7 RM-010. to further add controls. (specia.1 processer). for the welding and testing: of' defec-rupture restraint welds. to be repaired.
.a CLLOW UP ::. ACTIVITY CO!TLICS. WI.T10' ADEROVED CORRECTIVC ACTION
.F NO - PLEASE EXPLAIN :
YES N
DATE:
..A.L CLOSED. Br::
DATE:
GERQVED Br=
DATE:.
e-
[ 3/ 30/7!7 f
DnDLO CMYON NUCLEAR POtTEIt PLAN; PAGE.
3 Or 4
(
AUDIT ACTION. REQUEST' l
[
UNSCHEDULED cs. NO :
X AUDIT NO :
29:
A A.R' NO :
4-ACTIVITrAhDEUD:. PG&E NCR#0C2-79-RM-011 GNATION. CODE.:.
1 PG&E NCR80CT-79-RM-010 l
1
>I= DA m 7 82
.. ~..
i'ERCNCE DOCUMENTS r Spec. 8833XR, NCRfDCT-79-RM-Ol C, NCRfDC2~-79-RM-Oli, Proc. 8833XR-T PECTED CAUSE CONTINUED:
tead PG&E instructed Pullman to utilize PG&E UTtrasonic Procedure #3523 for UT examina.tions.
I l
all rupture restraints welds after the, existence of rejectable defects 'were identified in ture restraint field welds.
ESD 234 - Ultrasonic Inspection AWS-01-0-69, which was used' to all structural groove welds prior to July 11, 1979, was deleted from use at Inis time.
rasonic% examination per PG&E #3523 was. included in QA Instruction #143 which was Approved Construction by PG&E Resident Engineer V.L. Ki1Tpack and C.A. Hemstock on 7-11-79.
PG&E rasonic Procedure #3523 does not address full penetration welds. less than 9/15" in thicknes ause PG&E #3523 does. not address these type. welds and: no other UT procedure was utilized.
ch addressed these type welds, rupture restraint full penetration welds less than 9/16" ckness were deleted from UT examination.
QAI#143 was incorporated into ESO 243 - Pipe-turo Restraint requirements on 6-9-8T-'revis. ion,. which war approved by PG&E Resident Enginee
(
Ammon and by B.Torstrom on 2-17-82 Per PG&E Lead QC Engineer J. Bratton, a PG&E signed:
poval on a. QAI or ESD is not a legitimate' authorization to deviate from Spec. 8833XR requ.ir ts.
The Internal Auditor is unable: to find any other authorization to deviate from: Spec 3XR requirement that complete ultrasonic inspection. sha11 be made on all connections, utih-g full penetration welds.
.h *. %o & a?th.A.d d-bo
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ACTD.M CO!TLIES WIT 1I. ADPROVED CORRECT."/C ACTIOY NO - PLEASE EXPLAIN :
YES No.
(
DATE :-
i DATE::
L.R'. CI.CSLIII B.r:
l
? ROVED: Br=
DATE:
j l
~
_ _____N
l7,g,7g i..iy a wsuum a c us,cs. v s mw,
,. 3/30/70 k
DIADLQ CANYON PAGE 4
Or 4.
NUCLCAR' POWER DLANT
(
AUDIT ACTICN 1EQUCST e
UNSCHEDULED NO.:
X' AUDIT NO :.
29-K.K R ' Ntr. r e
PG&E NCR#0C1-79-RM-011 SERVATIOtr COEs.-
1 Awiv1TT AUDITCD PG&E' NCR#0C1 79-RM:.010' l
TDIC DATE.x 7-82 1
TERENCr DOCMIENTS:. Soec. 8833XR, NCR#0C1-79-RM-010, NCR#0C2-79-RM-011, Proc. 8833XR-1 3MMENDED CORRECTIVE ACTION CONTINUED:
E50 243 be revised to include UT examinations of full penetration werdfYess tharr 9/1 '"-
in thickness.
A Ultrasonic Procedure be pmvided. and approved for use on Ruptur.e Restraint welds which addresses full penetration welds less than 9/16" in thickness.
)
.. +
'.,,x.
.. ~..,
t VLLOT UP:
ACTIVITr CotTLIES. W'tTir APPROVCD' COR. Rhus ACTION.
7 NO - EICASE E:TLAIN:-
YES.
NO,
)
4 DATE:
DATE.:
0 %Rb CLOSED'BY:
bTE" GEROVI2n Br::
..y.
_. g
~
CE CORRESPONDENCE
(
August. 13,. 1982.
F QA/QC Manager, E. Earner I
mcM.
Internal. Auditor, H. Hudson suaject Requirements to change Specification. 8833IE. is relation to UT of Full Penetration Welds less. than. 9/16" in thichess Unscheduled Internal Audit 129 identified that Specification 8833IE, Section 2.7.21 requirement to ultrasonic inspect all full penetratica velds has. not been. fully implemented since July-1979 in regards to velds less than 9/16" in thichess. Duriry our discussicus about-this findirg it var brought up that QAIll43, which only addressed full penetration velds greater than 9/16" in thiebess, was approved by P0&E's Resident Engineer V.L. Iillpack and C.A. Hamstock.
You indicated that you felt this was adequate to delete the requirement of ultrasonic inspection of fn11 penetration velds less tha=
o'16" in thichess.
I disagree based en the requirements of the Geeral C"Ad -
tions of Specification 8833IE, paragraphs. 5.5 and 5.6.
i 1.
Pn11"an does not have documented instructicus fr:s PG&E to specifically delete from ultrasonic inspectiere full penetration velds less. than 9/16*
i t
in th1 chess which. is required by-Specificatic= 8833XE,. Section 2.7.21.
2.
General. Condition, paragrmhc.5.5,. states. that Centractor shall prepare-j any specification required. is additice to Specification 8833IE, subject-to the appuv 1 of Ccustru.;. ter ' The paragraph.goes en the say "Not v1.th, stW4nf such, app 4wv.1, Contractor shall be responsible for the accr.ract,
. practicability, and correctness of such specifications, calenlations, and drawings,. all of which. shall not operate to change the Specification.
or Ccmpanys drawings unless Contractor suW ts a written statement clearly d4cating the requested. changes.ani obtains Ccust a tor's written.prdcr 4
approval thereof".
P"11-has. not submitted a written statement. to PG&E d.early *~" ra that fn11 penetration velds lesr tha.tr 9/16" is thichess will be deleted
- frez ultrasonic inspectio= requirements of Specificatica 8833IE, Sectd-2 7.21.
ESD 243,, prior to. July 1979,. required all. full penetra:ica uelds.
to be ITf inspected QAI143isuL.J.LLodi to end!.ppuved by PG&E i= July 1979,.
did not clear 17 indicate and in fact did not eyes addrear full penetratten.
, velda less than 9/16" in. thichaar QAIf143 addressed the fact that only J
full penetration velds 9/16"' and greater effective-threat W 11 be inspected per PG&r Ultrasonic N==4natica Procedure 13523 This QAI superceded ESD 243 UT requirements.
Pn11 has; not complied with the General Conditdcss that "a. Written statsmant clearl7 indicating the requested changes" :nst be submitted to PG&E in order to delete full penetration velds less t
- t 9/16" in th1 chess from ultrasonic inspection Since Pn11 - has cat. net.
this requirement, it is responsible for the inaccuracy and incorrectness of QAIf143 and the current ESIT 243 vhich har operated. to change. Specifica-tien. 8833IR. requirements fer UI' inspection i /
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QA/QC Manager, Harold Karner mt August 13, 1982.
Requirements to change Specificatics 8833XR in relation to UT of Pull.
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Penetration Welds less than 9/16* in thickness
- c.. :m 3a General Condition, paragraph F.F, also states that _"in the event-of conflitt between. the: Spe"t N cation or Companys drawings and Contractors specification,. c=1 m1 =*4 ens,. or drawings, the forser shall. prevail".
Since P"11==" has not met the General conditiona for requesting changes to Specification 88332, QAIf143 and the current ESD 243' are in conflict with Specification.8833XR.requirenant that all.
ness) penetration velds (4 nelnd4"a velds less than 9/16" in thick-full be UT inspected.
These-two procedures do not include for UT imspection velds that are required by Specification 8833XE.
In this conflict of ultrasonic requirements, the Specification 8833IP.
requiramant sna11 preva.tl. and ?n1' m"
shouli C av=*e all full
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penetration velds less than. 9/16" in thickness.
4.
General Condition, paragraph 5.6 states, ' Requests by Ccraracto:-
for any changer is the requirements of the Specificatics and draw-ings shall, be brenght to. the attandon. of Constructor for written approral of h r maer".
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P"11-a has not specific ='17 brcughti Le-attention-of the Cca-structor 'that it planned to delete f"
penetration velds less tt;an 9/16*'in thi chesa frem. ultrascnic inspection.. Per the General.
Ccaditions any change has to. be brought tc. tha. attentice of Ccust=c-
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tor.
This changer was not addressed in QAIf143 when 1. vas e d
- by PGE and thus not brenght. to the attention of Ccustmeter that a
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- change in' Specification 88332E requir b ent was being nade.
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i Specification 8833XE, Section 2.7.21, requires.m full penetra 1c velds to be ultrasenic inspected.
?"1'-=
a QAIf143 and the w. e t ESU 243 do not i=plement' this requirement.
There is n6 docunented instruc-tions fren PGE to delete ultra. sonic. Inspection of B11 penetration velds less; than 9/16" is 'h4 "Wess.. QAIf143 which deleted-the requirenant ed the current ESB-243 do not meet the General Conditd""= of Speed "d catien.
8833%E. for changing the Specification requirements. P"1 '-=w is i=. non-m14 ="ce to Specificatica 88332,. S'ectiom 2.7.21. by not perfc r ultra-sonic' inspemens os full. penetra. tion. velda. less-than 9/16"' is thickness OM bhw
Enrold Hudson i
I Internal Auditor Diablo Canyon Nuclear Plant l
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Pioe Rupture Restraint Welds b
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Nondestructive and destructive testing Derformed und' r NCR's Or T-7.? m-Orv o
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FOR INFORMATION ONLY
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5 CA'.'SE OF NONCONFORMANCE:
The cause of nonconformance will be determinec. upon cenplstion of inspection-and. metallurgical e.tamination and. wi.TT be documented by a report to be; attached to this NCR Arior ter resolution complction sign off.
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1 7
Resolutiern
.I A)
Perform metallurgical investigat.icn and NOT inspection as directed by the-Mechanical Residen' Engineer or delegate to assure that the total scope of weld quality deficiencies is identified.
A report identifying the basis:
for determination of scope of inspection, scope of inspection and a su=ary of ins;)ection results will be attached prior to rescinic. enW eien sign-off.
Inspection results wilt be maintained on-site in accordance with t
record. maintenance procedures.
B)
All rejee. table indications, based on AWS D1.01969 edition, will be repa.i re or accepted.as is.
Those accepted. as. is will be approved by the assigned t
engineer.
Repa. irs wil.1-.either restore the ins tallation_to_,its opginaT I
design configuration or-be.to a new repair configuratiorr approved by, the-Assigned' Engineer or delegate.
If the repair. requires welding the new configuration will also be ' approved by a Departmant of En.,iv:ering, F.esearch Lead Walding Engineer or delegate.
All special processes will be approved.
I by the appropriate Copartment of Engineering.Research Lead Enginaer er dele gate.
Sketches'of welds inaccessible for inspecticn along with a statemeric identifying the nature and 'severii:y of defects found by inspection of simil.iar joint configurations wi.TT be submitted to the Assigned Engineer for his. review and dispositierr Documentation will be maintained irr
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accordarice with record maintane.nc.e; procedures. which identify :
T).' alt weldr, by numbet,. cerfs;f dered to be. of: suspect' qual ity based crr
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I the investigation resu.Tts requ. ired by item A of the resolurinn.
2.)
NDT results for welds found to be defect free.
3)
Assigned Engineer approval of weld acceptance as is, fcr inaccessible.
welds and welds found to contain rejectable defects.
i 4)
Appropriate. assigned engi.neer and lead engineer approval of repair I
configurati:,ns.
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NONCONFOR!%NCE REPORT DC1 RM - 010
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Resclntion:
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Appropriate Lead Engineer approval of 'becial processex.
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Repair processes including ali inspections required by Quality.
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Control erection procedures.
7 Corrective Action to Prevent Recurrence:
1)
All Pipe Rupture Restraint welding, except for fillet welds smaller than.
1/2", accomplished under Saee gamR will be examined by Macnetic pamMcke Inspection in additien to the eresantiv reauired Ultrasonic Inssactiert.
2)' Repairs will be designed so as to mini =ize restraint.
3)
Welding procedures and processes will be revised to minimize welding induced stresses and to improve weld quality.
4)
Any additional corrective actions; required w'ill be documented and ettiche-to this report prior to corrective. action comoleted sign off.
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Remarks An extensive program of investigatierr,. evaluatiert and repair of rupture res.trai
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weldments.has.been completed.
e In. order to identify the cause of the nonconformance and assure that. the tetat scope of weld deficiencies has beerr identified, sampling procedurer were writte and-implemented which tested. a: sign-ificant portion of the rupture restraint wei Destructive and nondestructive testing techniques were developed and used. to*
identify the extent and nature of welds with defects Meta 11ographic stud.ies; were performed to determine causes of the defects and the best approactr t:r resa This infonnation is contained in department of Engineering Research' Reports El 80,93 and 411-80.370 sunnariring the investigation development, the NDT resu.lts the Meta 11ographic studies, Engineering Evaluations of Defective Weldments and Reconnendations. for Repair.
These reports are attached Copies of the indivic NDT inspection reports for site contractor's welds are filed with contractce's.
Erection Documentation.
The originai reports are maintained by DER.
Copies of the inspection reports for offsite fabricator's (Shop) welds are attached.
The original reports are maintained by 0.E.R.
l All welds requiring inspection which were inaccessible for inspection were indi l
vidua11y evaluated by the assigned engineer. All inaccessible weldt were sub-sequently accepted without inspection.
Statements identifying the nature-and severity of defects of similar weid configurations were not submitted to the assigned engineer along wittr the sketches of inaccessible welds as planned. sir.c this information was readily available at the-tims of the evaluations..
inaccessible welds are identiffed and a statement of acceptance is attache <r Tne-(
All ' welds with rejectable indications... based on AWS 01.0-69, were evaluatec Welds were either accepted. as is or repaired. Documentation of welds accepte with rejectable indications is filed with ensite contractor's Erectierr Occunen-ation.
A1T. repairs were approved by the Assigned Engineer or his celegate.
addition, when new configurations were used, the Assigned Engineer ar.d. the Leac In
_1iDR Weiding Engineer approved. the configuration.
All documentation ass'ocia_tec with weld repair is filed with the s.ite contractor's. Erection Occumentation_
Several Soecial ' processes (croceduras Y were accroved bv t% 1 aad (Er to further aco controls for weldine, cuttino and testino of welds to beWaldino En repairec ihese procedures 8833XR-13. 8833XR-2. and; AWS-1.-l are attachec kee. 2)acamw:t asrsb> *1 srrwase2r sze oa.nc.a-puurr A-ssazouc.d %-eme-r eb.
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5, Nondestructive and destructive testinct Derfo' med air Unit E Pice Rupture-5 Restraints welds under-the referenced NCR, identified rejectable defectr. The same i
j or similar condition may exist in Unit II I
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metallurgical examination and'will be documented by 1
thfr NCR.pHor to resolution congletiam sign-off.
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ResoTution:.
A). Performimatrilurgicai :nvestigatiem and NOT'inspectiert as direc of weld quality deficiencies is identified. Mechanical Residen A: report. identifying th'e basis for determination of scope of inspection,. scope. of inspection. and of inspection results will be attached pMor to. resalutierr ~completier off.
record maintenance procedures.Inspectierr results will be ma.intained on l
I B)
All re,jectable indications, based. on AWS 01.0 1969 edition, will be repaired or accepted as is.
Repairs wi1T either restore the installation to its o engineer.
design configuration or be to a. new repair configu' ration approved by' th}
Assigned Engineer or delegata If the repair requires welding the new.
i Lead Welding Engineer or delegateconfiguration' will alsa be apprj t
Ali speciel processes. wil.1 be approved by the appropMate Department of Eng.ineeMng Reseracfr Lead Engine gate.
identifying the nature and severity of defects.found. by I.
h,is review and dispositiert.simtTar joint configurations wiTT be submi
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Ali, welds., by' number, considered to be of suspect qualiti based ort
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the investigatiert results..requ. ired. by item A of the resolution
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Ass'igned Engineer " approval of weld. acceptance as is for.inaccess-ib weTds and welds, found; to. conteirr. refectable defects Apprdgrfata. assf 4)l
. c::niftgurtttons. gned. engineer and.Tead, eng.ineer approvatl, af repsir
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tive Action to Prevent Recurrence:
ATT. pipe Rupture Restraint welding,. except for-fiTTet welds sw.11er tharr
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1/2% accompitshed. under Spec 8833XRI wti;Th be examtned by Magnet.fc Particle Inspectiert. ist addition ta the presentTr required. UItr.asonic Inspectdort Z). Repairs. wil.T be designed. so. as. to. mfriimtze restra. int
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1 3)
Weiding procedures and processes. wi1T..be revised: to: min.imize welding.
induced: s. tresses and. to improve weldr quality.
4)
Any additional corrective actions required will be documented and attached to this report prior ta corrective action completed sign -cff.
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