ML20205D791

Rev 7 to Spec CS-P207, Pipe Support Field Fabrication & Installation

ML20205D791
Person / Time
Site:	San Onofre, 05000000
Issue date:	04/18/1980
From:	BECHTEL GROUP, INC.
To:
Shared Package
ML20205D766	List: IA-85-249, Further Response to FOIA Request for Eight Categories of Records Re Ee Kent Allegations Concerning Midland,Palisades & San Onofre Nuclear Power Plants.Forwards App F Documents. App F Documents Also Placed in PDR ML20205D762 ML20205D791
References
FOIA-85-249 CS-P207, NUDOCS 8510170092
Download: ML20205D791 (39)

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CS-P207, Rev. 7 April 18, 1980 QUALITY CLASS I, II, III, AND IV

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DED PLANT DESIGN CONSTRUCTION SPECIFICATION FO R. TIIE SOUITIERN CALIFORNIA EDISON COMPAhT SAN ONOFRE NUCLEAR GENERATING STATION UNITS 2 & 3 SAN ONOFRE, CALIFORNIA SPECIFICATION NO. CS-P207 PIPE SUPPORT FIELD FABRICATION AND INSTALLATION

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JOB 10079 BECHTEL POVER CORPORATION NORWALK, CALIFORNIA EDM SONGS 2 & 3 CONTROU ISSUEQ 753 -

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o CS-P207, Rev. 7 April 18,1980 CONSTRUCTION SPECIFICATION REVISION RECORD

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S AN ONOFRE NUCLE AR GENERATING STATION UNITS 2 & 3 REVISION REVISION NUMBER DATE

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e Rev. 0 9-22-75 Initial Issue: Title Page, Pages 1, ii, and 1 thru 15.

Rev. 1 6-22-76 Title Page, Pages 1, 11, 6, 10, 11, 12, 13, 14, 15, 16 and Appendix 4L (Pages 4L-1 and 4L-2).

Rev. 2 9-9-76 Title Page, Pages i and 11 Rev. 3 9 26-78 All Pages Rev. 4 10-11-78 Title Page, Pages 1, 11 and added Page ia.

The following Field Change Requests (FCR's) have been incorporated into Construction Specification CS-P207, Pipe Support Field Fabrication and Installation, Revision 3, dated September 26, 1978:

1 FCR No. 3796-P, dated 10-8-76, has been revised and incorporated as Paragraph 6.2.1 and Figures 7 and 8.

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2.

FCR No. 4160-P, dated 11-5-76 All items of this FCR, except for Item a.

No's, 3, 17, 23, 24, 25 and 27, have been deleted and are not applicable to this specification.

b.

Iten No. 3 is incorporated into Figure 8.

c.

Item No. 17 is incorporated as Paragraph 6.6.

d.

Item No's. 24 and 27 are incorporated into Paragraph 5.3.

Item No. 23 is incorporated into e.

Paragraph 6.1.

f.

Item No. 25 has been incorporated as follows:

1) Paragraph 7.17 is now Paragraph 6.10

2) Paragraph 7.18 is now Paradraph 6.9

3) Paragraph 7.19 is now Paragraph 5.10 s

4) Paragraph 7.20 is now Paragraph 6.4.6 N..V PP+9 9 9 llte 79l 3/79 i

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CS-P207, Rev. 7 April 18, 1980

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CONSTRUCTION SPECIFICATION REVISION RECORD SAN ONOFRE NUCLE AR GENERATING STATION UNITS 2 & 3 REVISION REVISION NUMBER DATE Rev. 5 10/19/78 Title Page, Page 1, ia, added ib,11 and Page 10.

The following changes have been made to Revision 4 of Construction Specification CS-P207, dated 10-11-78.,

1.

Item No. 1. Page i of Revision Record Sheet, delete FCR No. 3796-P, dated 10-8-76.

2.

Item No. 2, Page i of Revision Record Sheet, delete FCR No. 4160-P, dated 11-5-76.

3.

Item No. 7. Page ia of Revision Record Sheet, delete FCR No. 6205-P, dated 3-28-77.

4.

Change Item No. 11, Page la of Revision Record Sheet to read as follows:

a.

FCR No. 11710-S, dated 2-3-78, has been incorporated as Paragraph 5.5.1.

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b.

FCR No. 11954-S, dated 3-9-78, has been incorporated as Paragraphs 5.5.2 and 5.5.3.

5.

FCR No.11479-S, dated 2-16-78 is incorporated as Itan No. 3 of Paragraph 5.1.3.

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'd." FCR No. 18169-S, dated 9-29-78 is incorporated as Paragraph 5.17.

7.

Page 10, Paragraph 5.5.1 has been changed to incorporate FCR No. 11710-S.

8.

Item No. 17, Page la of Revision Record Sheet, delete FCR No. 16824-S, dated 9-29-78.

9.

Item No.16, Page in of Revision Record Sheet, change FCR No. 16653-P to 16653-S.

• Each technical change to this specification is identi-fled by a black bar (with the applicable revision number) in the margin of the af fected revised page.

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CS-P207, Rev. 7 April 18, 1980 t

k CONSTRUCTION SPECIFICATION REVISION RECORD i

SAN ONOFRE NUCLEAR GENERATING STATION UNITS 2 & 3 REVISION REVISION NUMBER DATE

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Rev. 6 8/22/79 Title Page, Pages i, ia, ib, ic, ii, Pages 1 thru 25.

FCR No. 1185-P, dated 12-3-75 was incorporated in Rev. 1 FCR No. 1539-P, dated 2-4-76 was incorporated in

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FCR No. 7464-S, dated 6-10-77 is incorporated as modified in this revision and corrects erroneous statement (Item 8) in Rev. 4 1

FCR No. 11710-S, dated 2-3-78 was incorporated as

=odified in Rev. 5 and corrects erroneous l

statement (Item 11) in Rev. 4.

11193-S dated 2-3-78 is invalidated.

i The following Specification Change Notices (SCN's) and l

FCR's have been incorporated into this Con-i

,I struction Specification CS-P207. Rev. 6:

SCN No.'s CS-87, dated Nov. 6, 1978 i

CS-88, dated Fov. 6, 1978 CS-95, dated Dec. 12, 1978 l

CS-112, dated Mar. 29, 1979 CS-113, dated Mar. 29, 1979 CS-114, dated Mar. 29, 1979 as modified CS-115, dated Mar. 29, 1979 i

t CS-117, dated April 2, 1979 as modified i

CS-153, dated August 8, 1979 J

CS-154, dated August 8, 1979 I

CS-156, dated August 8, 1979 -

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CS-157, dated August 8, 1979 I

FCR No. 24485-S dated 3-21-79 26041-S, dated 4-25-79 26533-S, dated 5-8-79 as modified 1

l 26528-S, dated 5-7-79 as modified S-508, dated 6-27-79 i

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CS-P207 Rev. 7 April 18, 1980 CONSTRUCTION SPECIFICATION REVISION RECORD SAN ONOFRE NUCLEAR GENERATING STATION UNITS 2 & 3 REVISION REVISION NUMBER DATE

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Rev.7 4-18-80 Title Page, Page id, ii, and 1 and 4 thru 44 The following FCR's and SCN's have been incorporated into this Construction Specification CS-P207, Rev. 7 :

2 SCN No.'s CS-160, dated 9-25-79 4

CS-183, dated 12-18-79 CS-190, dated 1-24-80 FCR No.'s S-17, dated 8-21-79 incorporated into Rev. 6 as modified j

S-751, dated 6-20-79 S-810, dated 7-11-79 S-2219, dated 8-17-79 as modified S-3611, dated 10-18-79 as modified S-3613, dated 10-19-79 as modified S-3694, dated 10-31-79 as modified S-3757, dated 11-6-79 S-3837, dated 11-21-79 S-3925, dated 12-10-79 as modified 1

S-4133, dated 1-21-80 as modified S-4546, dated 2-27-80 S-4657, dated 3-5-80 as modified S-4662, dated 3-12-80 i

S-4663, dated 3-7-80 as modified S-4664, dated 3-7-80 S-4760, dated 3-26-80 S-4896, dated 3-28-80 as modified S-4908, dated 4-3-80 as modifie'd 4

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April 18, 1980 SPECIFICATION NO. CS-P207 PIPE SUPPORT FIELD FABRICATION AND INSTALLATION TABLE OF CONTENTS Paragraph No.

Title Page 1.0 Scope.

1 2.0 Abbreviations.

1 3.0 Governing Codes and Specifications.

1 4.0 Material Fabrication and Procurement.

3 5.0 Installation.

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Attachments

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Figure 1 Figure 2 Figure 3

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- Figure 4 Figure 5 Figure 6 Figure 7 4

Figure 8 f.

Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 j

Figure 19 Figure 20 Figure 21 Figure 22 1

1 Figure 23 7

Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 j

Figure 29 Figure 30 Figure 31 Figure 32 i

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CS-P207, Rev. 7 April 18, 1980 f

SPECIFICATION NO. CS-P207 PIPE SUPPORT FIELD FABRICATION AND INSTALLATION

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1.0 SCOPE This specification states the conditions and requirements for the field fabrication and installation of permanent pipe supports for all piping project classifications (A through V), for the San Onofre Nuclear Generating Station, Units 2 & 3.

All work will be accom-plished in accordance with this specification and the approved Engineering Design Drawings.

2.0 ABBREVIATIONS The abbreviations listed below, where used in this specification, shall have the following meanings:

AISC - American Institute of Steel Construction ANSI - American National Standards Institute ASME - American Society of Mechanical Engineers

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ASTM - American Society of Testing and Materials AWS - American Welding Society 4

3.0 GOVERNING CODES AND SPECIFICATIONS

~ The work shall be performed in accordance with the applicable sections of the codes, standards, and specifications listed below.

1.

ASME Boiler and Pressure Vessel Code (hereinafter referred to as the Code),Section III, 1974 Editian with Summer 1974 Addendum, Nuclear Power Plant Components, with Applicable 7

Code Ceses.

2.

ASME Boiler and Pressure Vessel Code,Section II, Material Specifications, Parts A, B, and C, 1974 Edition with Summer 1974 Addendum.

3.

ASME Boiler and Pressure Vessel Code,Section IX, Welding Qualifications.

4.

ASME Boiler and Pressure Vessel Code,Section XI,

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Inservice Inspection of Nuclear Power Plant Components, 1974 Edition and Addenda only Through Summer 1975 7

Addenda.

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22.

Technical Specification S023-409-2, Nuclear Service Pipe q

Supports, Hangers, and Accessories.

23.

Technical Specification S023-409-14, Shop Fabrication of Non-Nuclear Service Piping.

24.

Technical Specification S023-409-16, Non-Nuclear S'ervice Pipe Supports, Hangers, and Accessories.

25.

Technical Specification S023-409-23, Shcp Fabrication and Material Supply for Nuclear Service Integral Attachment Pipe Supports.

26.

Technical Specification S023-509-1, Instrument Tubing and Fittings.

4.0 MATERIAL FABRICATION AND PROCUREMEh7 Materials used for fabrication of pipe supports shall be as specified on the pipe support drawings and this specification.

Vendor Supplied Structural Steel Supports 4.1 Vendor supplied structural steel pipe supports shall be fabricated in accordance with Technical Specifica-f, tion 5023-206-1, S023-206-18, S023-409-1, S023-409-2, or S023-409-23.

4.2 endor Supplied Attachments i

Vendor supplied pipe support attachments to the piping shall 3

be fabricated in accordance with Technical Specifica-tions S023-409-1, 5023-409-14, or 5023-409-23, as applicable.

4.3 Component Standard Supports Component Standards Supports, whether purchased as individual items in bulk quantities or assemblies, shall be fabricated in accordance with Technical Specifications S023-409-2 or SO23-409-16, S023-409-23, or S023-509-1, as applicable.

4.4 Field Stocked Structural Shapes, Non-Code All field stocked non-code structural shapes and associated apparatuses (nuts, bolts, fasteners, etc.) shall be purchased to Quality Class II requirements in accordance with Specifica-tion S023-206-18.

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Field stocked structural shapes for Code. pipe supports shall be purchased in accordance with Drawing 90004 and Specifica-tion S023-409-1, S023-409-2, or S023-409-23, as applicable.

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1 CS-P207, Rev. 7 April 18, 1980

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5.1.6 Dimensions between piping shown on pipe support drawings are for reference only.

5.1.7 Beam attachments shown located on centerline of structural steel'may be located off of the centerline pro-vided relocation is documented on an Engineering approved FCR to the pipe support drawing. The FCR need not be incorporated on the pipe support drawing.

5.1.8 A mismatch between structural steel centerline and the attachment centerline shall be allowed up to 1/8 the width of the structural steel bearing surface.

See Figure 2.

5.1.9 Pipe support members shall be installed according to the dimensions shown on the drawing.

Lengths of items indi-7 cated in the Bill of Material are for reference only.

5.2 Clearances / Shimming 5.2.1 Clearance between pipe wall (or pipe attachment) and structures, or framing (except U-bolts) serving as a guide, axial stop, rigid stop in direction perpendicular to pipe only, or three way stop, shall be as shown in Figure 3.

5.2.2 Clearances in the Nonrestraint Direction for

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Supports 5.2.2.1 The nonrestraint direction for supports ss defined as follows:

For noncritical lines, clearances exceeding 1/8 inch between pipe O.D. or pipe attachment and supplementary steel on either side or for critical lines clearances exceeding 1/16 inch. See Figure 4.

e 5.2.2.2 For clearances in the nonrestraint direction'-

for supports, the tolerance on clearances between pipe wall (or pipe attachment) and structural framing in the unrestrained direction is il inch for pipe support designs issued subsequent to January 25, 1977 and

+1 inch, -0 inch for pipe support designs issued prior to January 25, 1977. See Figure 4 for examples.

5.2.2.3 For clearances called out as " min.", the tolerance shall be

-0, +=. The tolerance, +=, may be any distance further to any steel, adjacent pipe, or other obstruction provided that the function of the support in the restrained direction is not impaired; but cannot be closer than the specified minimum 7

clearance.

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For supports requiring close tolerances due l

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to the load envelope, support clearances will be given

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a specific tolerance (i.e. clr. X i Y) and indicated on the pipe support drawings.

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CS-P207, Rev. 7 April 18, 1980 1

TABLE I - MINIMUM SIZE OF FILLET WELDS Material Thickness of Minimum Size of Thicker Part Joined Fillet Celd Inches Inches To 1/4 inclusive 1/8 Over 1/4 to 1/2 3/16 Over 1/2 to 3/4 1/4 Over 3/4 to 1-1/2 5/16 i

Over 1-1/2 to 2-1/4 3/8 Over 2-1/4 to 6 1/2 Dver 6 5/8 NOTE:

1) In joints connected only by fillet welds, the minimum size of fillet weld to be used shall be as shown in the above table. Weld size is

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determined by the thicker of the two parts joined, except that the weld size need not 7

exceed the thickness of the thinner part joined unless a larger size is required by calculated stress.

2) This table is applicable to minimum weld design requirements for ASME Section III,

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Subsection NF as depicted by ASME Section III, Appendix XVII, Table XVII-2452.1-1.

3) Additionally, this table is in conformance to minimum weld size requirements for AISC application in accordance with AISC's Manual of Steel Construction, Section 1.17.5, for minimum size of fillet welds.

5.2.9.3 Welding of shim material together to obtain I

correct thickness shall be accomplished with square groove welds as shown in Figure 5, Detail E.

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5.3 Concrete Fasteners 5.3.1 Field installation of concrete expansion anchors shall be in accordance with Construction Specifications CS-C8, Design, Installation, and Testing of Concrete Expansion i

Anchors and this specification.

5.3.2 Deviations to Construction Specification CS-C8 and this specification shall be documented on an FCR to the pipe support drawing.

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5.3.3 Concrete fastener locations may deviate from those f

specified on the drawings provided the requirements of Con-(-

struction Specifications CS-C8, Tables I and II, and this i

specification, are not violated.

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April 18, 1980

-l Torque the bolt to 350 f t-lbs, with a c.

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tolerance of +50 f t-lbs, -0 f t-lbs, immediately. No retightening or retorquing shall be performed after the epory has set except verification torquing as required i

at buyoff by Quality Control.

5.3.6.3 Pipe support assembly drawings requiring j

A-325 bolts which have been issued prior to November 14, 1977 which require 1-3/4 inch diameter holes in the concrete are to be grouted in a manner similar to that used for rockbolts. " Angled" or

" skewed" 7/16 inch diameter holes for 1/4 inch diameter i

pipe threads for grout and 1/2 inch diameter for vent hole will be drilled in the backing plate and/or anchor plate adjacent to the bolts to facilitate grouting.

1.

Method of Installation i

Install backing plate, bolts, washers, and support or anchor plate. Torque the bolt to 350 ft-lbs, with a tolerance of +50 fc-lbs,

-0 ft-lbs, imme'diately and then grout. No retightening or retorquing may be performed j

after the grout has set except verification

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torquing as required at buyoff by Quality Control.

1 2.

Alternate Method of Installation Coat the shaft of the bolt with Burke a.

Release HD III or equivalent. Coating length on the shaft to be equal to the wall or floor thickness plus 1 inch.

b.

Install backing plates, bolts, washers, and support or anchor plate.

After grout has cured per manufacturer's c.

requirements, the nut may be removed for installation of the support plate or anchor plate and retorqued to 350 ft-lbs with a tolerance of +50 ft-lbs, -0 ft-lbs.

5.3.7 Structural washers, or spacers cut from small diameter pipe may be used on concrete fastener installations to secure proper-embedment depth. Maximum height shall be 1-1/2 inches.

Minimum pipe schedule shall be schedule 80 carbon steel.

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CS-P207, Rev. 7 April 18, 1980 f

Connections using ASTM A-325 bolts shall be made in accordance with AISC " Specification for Structural Joints using ASTM A-325 or A-490 Bolts," Construction Specification CS-C5 and this specification. -

2.

Connections described in (1) above, may be welded instead of bolted provided the original support configuration is maintained. Weld size and length shall be as shown in Table II.

See Figure 6 for example.

3.

When drawing requirements specify otherwise, only one end of structural steel spans with slotted bolt holes having loads in direction of slots need be connected i

as in (1) or (2) above.

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TABLE II - WELD SIZE AND LENGTHS FOR

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STRUCTURAL STEEL JOINTS Nominal Bolt Diameter Number of Bolts Weld Linear Length Size 5/8" 1

3 1/4 1

2 5-1/2" 1/4 i

3 8"

1/4 4

10-1/2" 1/4

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3/4" 1

4" 1/4 2

7-1/2" 1/4 3

9" 5/16 4

12" 5/16 1"

1 5-1/2" 5/16 2

11" 5/16 3

13-1/2" 3/8 4

17-1/2" 3/8 i

5.4.11 Bolt size may be increased within AISC limitations.

5.4.12 Open ends of structural tubing shall be capped as in Figure 7, Details a and b, in lieu of details shown on pipe support drawings. Cap plates shall be installed in all 7

areas and need not be shown on pipe support drawings.

1 5.4.12.1 A partial penetration square groove weld with 1/8 inch weld penetration may be used in place 4

of the full penetration square groove veld called for in Figure 7, Detail C.

5.4.12.2

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Cap plates shall be purchased as Quality Class II material, but installation is Quality

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7 Class IV.

Seismic class is not applicable.

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l 5.6 Components

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5.6.1 Visual Examination Acceptance Criteria for ASME Section III, Subsection NF Pipe Supports 5.6.1.1 The weld meets or exceeds specified size requirements.

Either or both fillet weld legs may exceed design size by 3/16 inch for welds up to and including 5/16 inch fillet, and 1/4 inch for welds t

larger than 5/16 inch fillet. Welds may be longer than specified. Continuous velds may be accepted in place of intermittent welds.'

5.6.1.2 The fillet leg dimension may not under run the nominal fillet size by more than 1/16 inch for i

1 more than 10 percent of the veld length.

l For flange to web joints the undersize may not be within two flange thicknesses of the weld end.

5.6.1.3 Porosity and slag shall not be cause for rejection.

5.6.1.4 Convexity height may be accepted without limit.

Rollover (overlap) not exceeding 1/8 inch is j

acceptable provided the toe or fusion line of the weld remains visible for examination.

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5.6.1.5 The height of reinforc'ement of butt welds on each face of the weld shall not exceed the following:

Nominal Thickness, Maximum Reinforcement, In.

In.

Up to 1, incl.

3/32 Over 1 to 2, incl.

1/8-Over 2 to 3, incl.

5/32 over 3 to 4, incl.

7/32 over 4 to 5, incl.

1/4 Over 5 5/16 5.6.1.6 There are,no cracks or linear indications in the weld exceeding 1/16 inch.

5.6.1.7 Thorough fusion exists between the weld metal and base metal, except as permitted as rollover 7

in Paragraph 5.6.1.4.

5.6.1.8 Undercut (underfill) not exceeding 1/16 inch may be accepted for the full length of the weld pro-vided it does not encroach on minimum design thickness.

s For members welded from both sides, the criteria shall 7

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be applied independently except that the cumulative depth shall,not encroach on the minimum design thickness.

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Table III

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TORQUE REQUIREMENTS FOR MECHANICAL SHOCK SUPPRESSOR, SWAY STRUT, AND SWAY BRACE ASSEMBLIES (FT-LB) i Suppressor Size 1/4 & 1/2 1

3 10 35 100 I

Load Stud Jan 20 65 145 280 485 1050 2

i Nut (Item 1)

Bolt Jam Nut (Item 2)

Thread Size, UNC 2

j 3/8 - 16 20 1/2 - 13 30 3/4 - 10 65 65 t

i 1-8 f

i 145 1-1/4 - 7 280 l

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2 1/2 1050 1050 Extension Piece 40 40 80 100 150 220 Jam Nut (Item 3) 4 i

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CS-P207, Rev. 7 April 18, 1980

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such as double nutting or upsetting threads by staking shall be used to prevent nut rotation. Match marks shall be placed on the nut and protruding bolt point to provide visual verification of proper nut rotation.

5.6.7.3 Bolts used for FGD-P-96 clamps (with sashers between clamp ears) shall be installed snug tight.

A Code approved locking method, such as double nutting or upsetting threads by staking shall be used to prevent nut rotation. Staking of threads shall be in accor-dance with Paragraph 5.6.12 of this specification.

5.6.8 Bolts used for Grinnell Figure 40 riser clamps shall be installed snug tight. A Code approved locking method, such as double nutting or upsetting threads by staSing shall be used to prevent nut rotation. Staking of threads shall be in accor-dance with Paragraph 5.6.12 of this specification.

5.6.9 Two and three bolt pipe clamps furnished by ITT Grinnell or Sanwa Tekki and used in applications other than with mechan-ical shock suppressors, sway struts, and sway braces shall be installed and tightened per Paragraph 5.6.10.

In addition, for assemblies under the jurisdiction of subsection NF of the Code, a locking method such as double nutting or upsetting threads by staking shall be used to prevent nut rotation.

7 Staking of threads shall be in accordance with

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Paragraph 5.6.12 of this specification.

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o 5.6.10 As an alternative to Paragraph 5.6.9, two or three bolt clamps may be installed per the following procedure:

1.

Tension bolts shall be tightened last. This bolt is identified as follows: One of the bolts contains a pipe spacer. The clamp bolt on the opposite, side of the pipe is the tension bolt.

2.

The tension bolt shall be tightened until all slack is taken up and then tightened with an additional 1/2 turn. Slack is "taken up" when the clamp initially " grabs" on the pipe's outside diameter.

i For smaller clamps this is indicated by an inability to move the clamp axially by hand.

3.

Match marks shall be placed on the nut and the pro-truding bolt point to provide visual verification to the inspector of proper nut rotation.

5.6.11 The substitution of mechanical shock suppressor rear brackets furnished by Pacific Scientific on ITT Grinnell Figure 306 and Figure 307 units shall be in accordance with

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the information shown in Figure 31.

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CS-P207, Rev. 7 April 18, 1980 TABLE IV - ACCEPTABLE WELDS ON BECHTEL STANDARD 40

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AND 40A ANCHOR STRAPS FOR PIPING OF STANDARD 7

WALL THICKNESS AND HEAVIER **

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Nominal

• Pipe Size b (Weld Size)

X (Weld Length)

Y({to{WeldSpacing) 1 2-1/2 7/8 1-3/4 3

3/16 1

2 4

3/16 6

1-1/2 3

1/4 2

4 8

1/4 2-1/2 5

10 1/4 4

12 3-1/2 7

1/4 4

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I 14 1/4 4-1/2 9

8 16 3/8 5

10 18

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20 5-1/2 11 6-1/2 13 24 7-1/2 15 Note:

Oneweldshallbeginonthepipe{. The last weld to end on or beforeoppositepipe{.

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• Veld size shall be per the pipe support assembly drawing.

• • W lding of anchor straps to Schedule IOS and 20S pipe shall be e

in accordance with the pipe support drawing and not Table IV.

{7 5.7.4 Pipe protection saddles shall be attached to the pipe with fillet welds at each outer rib.

Pipe protection saddle welds shall be as shown in Figure 8.

5.7.5 Welding of Nuclear Anchor Straps Whenever the full penetration continuous longitudinal weld with 1/4 inch cover fillet is not possible to produce on nuclear anchor straps 151, 151A, 152 and 152A, the following weld configuration is an accept-able alternate:

See Figure 9.

5.7.6 Fabrication Tolerances of Field Fabricated Pressure

/

Boundary Attachments used for axial restraints or guides shall be 1/16 inch.

7 I

19

~.-

am, t

• • M"'

.,y7

--r-,

T**

• V

T~*

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'I CS-P207, Rev. 7 April 18, 1980 5.7.16 Where weld buildup is required to permit proper fitup i

of wrapper plates, dummy stubs, and lugs, the weld buildup shall be made in accordance with appropriate weld procedures.

All weld buildup shall be performed prior to fitup on the pipe.

5.7.17 When pipe support drawings indicate the use of, FGD-P-89, -96, -97 or -127, the appropriate alternate configurations may be used as follows:

Original Alternate Configuration

[

Configuration FGD-P-96 (Figure 18)

Figure 19 FGD-P-97 (Figure 20)

FGD-P-345 (Figure 21)

FGD-P-127 (Figure 22)

FGD-P-346 (Figure 23)

FGD-P-89 (Figure 24)

FGD-P-89 (Figure 25) 7 FGD-P-89 (Figure 26)

FGD-P-351 (Figure 27) or FGD-P-382 (Figure 28) 5.8 Hardware and Coatings e

5.8.1 Bearing plates shall be purchased to Quality Class III Requirements.

5.8.1.1 For bearing plate assemblies inside the containment, the assemblies shall consist of one bronzite plate (ASTM-B-169) of 1/4 inch minimum thick-ness and one stainless steel plate (Type 304, 10 gauge) of 1/8 inch minimum thickness.

5.8.1.2 For bearing plate assemblies outside the conta inment, the assemblies shall be coated with " Teflon" and consist of either stainless steel plates (Type 304, 10 gauge) or carbon steel plates (A-36, 10 gauge).

5.8.2 Welding shall be in accordance with the " Structural Welding" portion of this specification.

5.8.3 Sliding metal to metal surfaces, excluding axial restraint lugs, pipe protection saddles and piping to structural steel, shall be lubricated.

Listed lubricants are to be used in accordance to requirements of Construction Specifi-cation CS-GP208, Allowable Consumable Material For Use During Construction.

1.

"Lubriko" (Graphite Elevator) Grease

/

2.

"Never-Seez Pure Nickel Special (Nuclear Grade) 7

('

No. NG-165."

3.

Engineering Approved Equal.

21 weh"N*

m -

.a:-

' ?

CS-P207, Rev. 7 April 18, 1980

(

5.8.5 Nongalvanized threads of hanger rods shall be coated with the acceptable lubricant per Construction Specification CS-GP208, Allowable Consumable Material For Use During Construction.

The following lubricants are acceptable:

7 1.

NSW Select-A-Torg 505.

2.

Fel-Pro N-5000.

4 23

=

=wm-,,

.-p

e CS-P207. Rev. 7 April 18, 1980 "0"

FOR NOMINAL PIPE SIZE GREATER TH AN 1-IN CH, "0" = 2t + 4 O R 6-INCL 4ES WHICHEVER IS GREATER LEADING EOGE OF ATTACHMENT OF PtPE SUPPORT b

OETAll a SUPPORT TO PIPE WELD *

"O "

g (1) 9

(

l l

GREATER THAN 1-INCH OIA.

FOR NUCLEAR CLASS 1 PIPE AND CODE CLASS 2 PIPE GREATER THAN 4 INCH IN DIA.,

"O " a 21 + 2 g

LEADING EOGE (1) CLEARANCE IS NOT I

OF ATTACHMENT APPLICABLE BECAUSE OF PIPE SUPPORT VOLUMETRIC EXAMINATIONS FROM OTHER SIDE ONLY.

]

DETAllb I

i SUPPORT TO FITTING WELO' 7

' NOTE: APPLICABLE TO CODE CLASS 1 FOR NOMINAL PIPE $1ZES GREATER THAN 1"p AND LARGER AND FOR CODE CLASS 2, GREATER THAN 4-lNCH NOMINAL PIPE SIZE AND ALSO LISTED IN THE LINE DESIGNA-TION LIST AS REQUIRING INSERVICE INSPECil0N.

FIGURE 1,

[

MINIMUM CLEARANCES REQUIRED FOR VOLUMETRIC EXAMINATION OF CIRCUM.

FERENTIAL WELDS FOR CODE CLASS 1 AND 2 (DENOTED ON LINE DESIGNATION

~

LIST AS REQUIRING INSERVICE INSPECTION) '

O 24 I

. - - - - - ~ ~ - - - - - - - * ' ~~ ~ * ~ ~

r m

-a

CS-P207, Rev. 7 April 18, 1980

/

l m

_a e--

.- a i

o

'+

o

(

l

-a

- MISMATCH 8ETV4EEN

--==

H STEEL (AND l

ATTACHMENT (

FIG URE 2.

no e

25

., ~.'.._._.

9 CS-P207, Rev. 7 April 18, 1980 CLEARANCE Y + Y <2A OR 2 g

2 g

A

~

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w a

a hi

-O 1

o e

_'IM kM

~l,h!.' '

~

c Wu s

(y

_ MD t

t Hi s

X e

g

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X2

(-

CLEARANCE 4

W CLEARANCE X+X2 < 2A OR 2B 1

X + X < 2A OR 2B 3

4 C

O

'~

O

)

L._; u t;

r-Z g-

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CLEARANCE Z+Z2 <2A OR 28 SECTION A A DEFINITIONS A=

OlMENSION SHOWN ON PIPE SUPPORT ORAWING FOR CRITICAL LINES (ANALYSIS BY STRESS GROUP, S, ON PIPE SUPPORT ORAWINGl IDEAL DIMENSIONS SHALL BE 1/16-INCH.

B = DIMENSION SHOWN ON PIPE SUPPORT ORAWINGS FOR NON-CRITICAL LINES (ANALYSIS BY PIPE SUPPORT GROUP OR ITT GRINNELL, P OR G ON PIPE SUPPORT ORAWING) IDEAL CLEARANCES SHALL BE 1/8-INCH.

Y ANO

• Y IS THE DISTANCE TO THE LEADING EDGE OF PIPE NOT TO THE PIPE C g

2 7

/

FIGURE 3

~

CLEARANCES FOR RESTRAINED DIRECTIONS 26 r e

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i, -

1 CS-P207 Rev. 7 April 18, 1980 a

1

)

i I

a 1

1 I

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$j CLEAR ANCEIN THE

+ UNRESTR AINED TOLERANCE DIRECTION FOR DRAWINGS ISSUED I

• (AFTER JAN. 25,1977. ti INCH j

_.y._

.y_

l

• (BEFORE JAN. 25,1977. + 1. INCH 2

0-INCH

(.

i f

• 31/8" FOR NON-CRITICAL

>l/16"FOR CRITICAL l.

f.

I

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FIGURE 4.

4 TOLERANCE ON CLEARANCES FOR UNRESTRAINED DIRECTIONS a

s I

1 1

1 i

i 4

7 l

1 e

1 l

27 j...

.j_.,......._.,_.

=

CS-P207. Rev. 7 April 18, 1980 SHIM LENGTii.X

\\

S/

(

)

SHIM GJ//

0 y

v 4,

/

r"- m SHIM

/

l

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ALTERNATE

'WELDTO S /

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DETAll A

~

SHIM WIDTH. Y DETAIL A DETAll B

+ 5/16" SHIM LENGTH SHIM LENGTH SAME AS AXIAL STRUCTURAL WIDTH AT

-0" STOP THIS POINT

~

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(

0

(\\

0 c

0

),

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SHIM

!,_ + 5/16" r-

- 0, SHIM r-WP) S/ -

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DETAIL C DETAIL D S

O 1

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0 rm

~

DETAll E S = WELD SIZE X= STEEL WIDTH + 5/8"(SHIM MAY BE OVERSIZED A MAXIMUM OF 5/16" 0N EITHER SIDE OF THE WIDTH OF THE 7

STRUCTURAL MEMBER, LESS IF NOT REQUIRED TO ACCOM-PLISH NECESSARY WELD)

Y= SEE PAR AGRAPH 5.2.4 FIGUR 5.

SHIMMING i

(Sheet 1 of 2) 1 28 e.

CS-P207, Rev. 7 April 18, 1980 k

/

SHIM LENGTH, X

(

)

SHIM w

o

--A o

. -.4 SHIM-

'r j

TUBE f

_ S /

N WELD TO STEEL DETAIL F I

SHIM WIDTH, Y k

DETAIL F DETAIL G g

' SHIM LENGTH SAME O

I !

AS Si clUCTUllAL STEEL WIDTF' AT THIS POINT

(+0 -1/I*')

(

l' 0

(-

0 l,

/l

)

~~

H Q_

Q N

AXIAL STOP TUBE STEEL DETAll H FIG URE 5.

SillMMING (CONTINUED)

(Sheet 2 of 2)

~;

W 29 mW

, me e

M mo@,

g

-em-eh*

9 y

N=

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CS-P207 Rev. 7 0

April 18, 1980 s

e M

e l

T

(.

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,,,x L

N'

./

EXAMPLE WELDING AREAS FIGURE 6.

/

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30 we w,

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CS-P207 Rev. 7 April 18, 1980 1/4 MIN. TYPICA L

+

+--1/2 WALL THICKNESS l

l I~I f

I

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,l 7

I L-8_

- 1/4" DIA HOLE' 1/4" OtA HOLE LOCATED *

(b ~__~_ _

LOCATED IN LOWER

'IN LOWER SIDE OF SIDE OF MEMBER MEMBER ~

SECTION A-A TACK SECTION B-B (WELD 2-SIDES f)

B B f i-l I

i o

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i 1/8" MIN.

l l

l 1/8" MIN.

l l

l 1

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/ TACK WELD DETAll A DETAll B

'NDTE: EXISTING WEEP HOLES BETWEEN 1/8" TO 1/2"lN DIAMETER ARE PERMISSIBLE AND NEED NOT BE REDRILLED.

7 q

i l

+

l L __ __ J SECTION C-C 1

Cf C

i" OR MAY BE TACK V

((

WELDED 2 SIDES a

l l

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i 1/4" MINIMUM i

l l

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4 7

DETAIL C

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D END CAP DETAILS e

}.

31 3.___.___._....,_

7 7

j CS-P207, Rev. 7 April 18, 1980

(

1

\\(

s t

A

/ EA. 0 UTER RIS S/

\\ TYP. 2-Sl0 ES 1

A=

i

/ EA. 0 UTER RIB S/

\\ TYP 2-SIDES i

S = WELO SIZE INDICATED ON PIPE SUPPORT ORAWING

)

S = WELO SIZE SECTION A A DENOTED ON OR AWING FIGURE 8.

i PIPE SA00LE WELD DETAIL

(.

i WELO TO BE INDICATED ON PIPE SUPPORT ORAWING

$ V (TYP, ACH GUSSET

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TYP SECTION 3-8

\\

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• WELD SIZEINDICATED 4

8 f

3 ON PIPE SUPPOR T

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h ORAWING l

FIGURE 9.

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Y s

i, h

1 l

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l

_ _ _ - -. -- -. - _.-.=- _.

CS-P207 Rev. 7 April 18, 1980 1

(

l 1.5 MAX 8

o

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sNNN 1.5,MAxj 7

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FIGURE 13 l

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k "CLEARA' ICE 0

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0.125" MAX t

FIGURE 14.

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FIGURE 15 l

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34

- w = : u

- _a v -n, ?

.m,-

v

-w- - - - -- -

.., -. =.

.-s-

+

____-- =.

0 CS-P207. Rev. 7 4

April 18, 1980 t

i 1

I

^>

N x ?c.

X = WELD SIZE s

/

,,.6 W

'Wx a

y ' 'm x o r.

l X" R AClVS ITYP.)

OR GREATER CONTOUR OF " FILLET"WELO (TYP.)

FIGURE 16 7

'h (TYP.

g i

I li il

/

i FIGURE 17 ALTERNATE WELOING FOR FGD P 107 AND F00 P 300 i

7 1

i '

35

-- - _____ --,_=,=_:_- _______ __ ~____.

\\

CS-P207, Rev. 7 April 18, 1980 ORIGINAL CONFIGURATION (SEE NOTE 91 1

\\

. UI6 !18 FGO-P-96 PIPE GulDE I

y L_.

FLAT BAR l

I

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l FIGURE 18 (CSP 200, DETAIL 7.3)

F 00-#-96 ALTERNATE CONFIGURATION 7

AME RICAN STO.

WASHE R (NON.

C00El AS REQ'O SEE NOTE I

,.'s

- 1/16. C L R s

g wee m.e

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pE

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w

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1/4 /

1/4* a 1/2" a 1 1/2" LUG 2RE0'O 3/18 /

CLAMP MAY BE ROTATED t

60' M AX FIGURE 10 (CSP 206, D ETAll 7.7) k(

O 36 m-

,e m amme,me < am s: -

o

-e w

+

e

~ s a-

-n s a

..._.__,.........._w.....,

CS-P207. Rev. 7 April 18, 1980 l

ORIGINAL CONFIGUR ATION

~

4

\\

TYP./

V r

T WELD FG O.P.97 i

r, i

l i-

+-

"l

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g 7

FIGURE 20 PIPE GUIDE FGD P.97 ALTERNATE CONFIGURATION t

1 1/16" CLR. TYP ISEE NOTE 3) r FGO.P-345 h

Y l

- 1" MIN., SEE NOTE 1 l,

i e

p FOR -4 &.5 ONLY j

i i

i e

' l'k h'

ll \\

i 1/2 R MIN.,SEE NOTE 1 j

p - --

FOR -4 &.5 0NLY i

l i

i i.

FOR WELOING SEE NOTES 2.4,5,&6 I

A c

- 3/8 MIN,SEE NOTE 1 FIGURE 21 PIPE GUIDE FGD P 345 t

4 37

. ~.....

...?

.2....._

CS-P207, Rev. 7 April 18,1980 ORIGINAL CONFIGURATION

~

F G D.P.127 g

4 t

^

,TYP.

y g

p WELO l{-

)

\\

j l

h SUPPORTING STRUCTURE FIGURE 22 PIPE GUIDE, FGD P.127 I

7 ALTERNATE CONFIGUR ATION

'~

~

g f, g,,,,

- 1/2" MIN., SEE NOTE 1

$EE NOTE 3_

FOR 4 &.5 ONLY 3. _. _. y--,,.

.g.,,,.y il r

FOR WELDING SEE NOTES 2.4,5,&6

- s 1/2R MIN.,SEE NOTE I FOR.4 &.5 0NLY

-- r

=

3/s"HlN.,$EE NOTE 1 FIGURE 23 PlPE GUIDE, FGD P.346 I

7

~

h 38

. =

-+

+:

CS-P207, Rev. 7 April 18, 1980 ORsGINAL CONFIGURATION F G O.P-89

'7 a

+

ht (C$.P206. DETAIL 7.2)

FIGURE 24 PIPE GUIDE, FGD P 89

(

7 ALTERNATE CONFIGURATION F G O.P-83 1/18" C L R.

(SEE NOTE 2) TYP, 9

TwtLD

'/

_J

w!!-

N

/

TYPISEE NOTES 2 & 7)

SUPPORTING

~

/ N STRUCTURE T WELD FIGURE 25 PIPE GUIDE, FGD P 89 e

6 S

39 a

@ ygv., - c r.eM<

t

CS-P207, Rev. 7 e

April 18, 1980

('

ORIGINAL CONFIGURATION

~

F G D-P-89

~

TYP/ V T

+

~~

WELO r.

J FIGURE 26 PIPE GUIDE, FGD P 89 F G D-P-351 i

ALTERNATE CONFIGURATION NO.1 4

4

-l/16" CLR.(SEE NOTE 3)

I l

(ISEE NOTES 2 & 4)

~

FIGURE 27

'#'8 PIPE GUIDE, FGD P. 351 SEE OTE 3 ALTERNATE CONFIGURATION NO. 2 2

t/16",CL A. TYP 15E E NOTE 3) l5f E NOTE

- 1/2" MIN., SEE NOTE I FOR I

I l

l' i

4 1

-4 & 5 0NLY o

e i..

n

\\

TYP I

V ll I/2 R MIN.,SEE NOTE I 1/4 ISEE NOTES Al

/

Ig FOR -4 & 5 0NLY 2,4.5,&6)

T uru SEE N0f E I FIGURE 28 PlPE GulDE, FGD P 382 r

l C~

k 40

-- = : - r

?

-^

r=

i CS-P207 Rev. 7 April 18, 1980

(

GENERAL NOTES (APPLICABLE TO FIGURES 18 THRU 30 ONLY):

1.

Field may trim either or both side legs within given limits to eliminate interferences, for -4 and -5 only.

2.

If structural steel to which these alternatives are attached. is thicker than 3/4 inch, the weld size shall be as shown in table given below, except that the weld need not exceed the thickness of the thinner part joined unless otherwise noted on drawing.

1 Material Thickness of Thicker Part Joined, Weld Size, Inches Inches 4

>3/4 1 1-1/2 5/16

>1-1/2 1 2-1/4 3/8

~

3.

When 1/16 inch typ. clearance is specified, total cumulative clearance both sides shall be 1/32 inch minimum and 1/8 inch maximum for alternate configurations FGD-P-345, -346, -351, and -382.

7 4.

When pipe support drawing specifies 3/8 inch weld sire, weld require-ments for

-1,

-2, and -3 sizes of alternates may be as shown in Figure 29.

(

5.

When -4 and -5 sizes of alternates are trimmed as allowed in Note 1, the weld size "S" shall be as specified on the pipe support drawing.

6.

For non-trimmed alternates, FGD-P-345 and -346, sizes -4 and -5, 3/8 inch veld size "S" is acceptable even though the pipe support drawing specifies 9/16 inch weld size.

shown in Figure 30.

Weld det.sils shall be as 7.

When using lugs against a strap, weld around both ends as shown.

8.

Tighten so washer cannot slide. Threads to be upset or bolts double nutted.

9.

Alternate configuration to be used in ASME Code applications where FGD-P-96 clamp material is not heat traceable.

l l

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41 I

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~

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N us N TYPp 7

1/4 N

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FIGURE 29 g

9

(.

7 O"

s x

N / s/s /

3;a N 7yp sA FIGURE 30

/

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42

4.

d

^ #

CS-P207, Rev. 7 April 18, 1980

/

,i,

OPTION 10R ADDITIONAL REAR BRACKET n'

< >/

f n

2

=

d

\\

\\

%J REAR BRACKET FIGU RE 306 BY GRINNELL OR (ALL ClZES)

PACIFIC SCIENTIFIC OPTION 1 OR ADDITIONAL REAR BRACKET c

Y(

f 3 --

y REAR BRACKET FIGURE 307 BY GRINNELL (ALL SIZES)

REAR BR AC.<ET ONLY B

/

PACIFIC SCIENTIFIC s

FIGURE 31 REAR BRACKET SUBSTITUTION e

s' 7

\\

43

w. -

.. 4

~#

CS-P207, Rev. 7 9

April 18, 1980

/

/

CLAMP l

3 LOAD STUD 3

TENSION f

OR LOAD BOLT BOLT BOLT p _.

-q C -

g.

.s...._._,_____

J:.,l p -m

+-

.M i

s l= -

it.

-4

. b EXTENSION PIECE SPACE R FIRST NUT 2

(TYP) 7 (TYP)

P

/

FIGURE 32 i-

\\

MECHANICAL SHOCK SUPPRESSOR F

S e

i

/

I i

i l

~

e 44 l

m.,

.._. _ _ _. - - - _. ~ _ _ _ _. -. _ _

. ;2

't

'~0

~

o-CS-P207, Rev. 7 April 18, 1980 CONSTRUCTION SPECIFICATION REVISION RECORD SAN ONOFRE NUCLEAR GENERATING STATION UNITS 2 & 3 REVISION REVISION

~

REVISED PAGEs l

5) FCRNo.4636-S, dated 12-6-76, ail items have been deleted and are not 1

applicable to this specification except for Technical Specification S023-206-1 and S023-206-18.

6) FCR No. 5548-P, dated 2-7-77 is now j

Paragraph 5.1.4.

7) FCR No. 6205-P, dated 3-28-77 is now Paragraphs 1.1, 1.2, 5.1.1, 5.1.2, 5.2, and 5.3.1.

8) FCR No. 7464-S, dated 6-10-77, is not applicable to this specification.

9) FCR No. 8321-S, dated 10-7-77, has been revised and. incorporated as Paragraph 5.7.

1

10) FCR No. 9803-S, dated 9-2-77, Paragraph 1

6.5.2 of Revision 2 has been deleted, i

Paragraph 7.16.4 of Revision 2 is now Paragraph 5.1.6.

11) FCR No. 11710-S, dated 2-3-78, is superseded by FCR No. 11954-S, dated 4

3-9-78 which is now Paragraph 5.5.2 and 5.5.3.

12) FCR No. 12487-S, dated 4-18-78, is now Paragraph 6.11.

l

13) FCR No. 12914-S, dated 4-21-78 is incorporated in Figures 7 and 8.

14) FCR No. 14591-S, dated 6-22-78, is incorporated as Paragrah 5.4

15) FCR No. 15204-S, dated 7-27-78, is incorporated as Paragraph 6.8.

16) FCR No. 16653-P, dated 9-8-78, is incorporated as Pa,ragraph 5.1.9.

(<

e j

17) FCR No. 16824-P, dated 9-29-78, is i

incorporated as Paragraph 5.17.

}

• r.stelisee798stis S

is t

I -.

2.._.,.

.[

AD12 S02/3 L

c Southern California Edison Company

[5 P o. Box 800 2 2 44 W ALNUT GROVE AVENU E ROSEME AD. C ALIFORNt A 9 8 770 fatarmont J. M. CU R R AN October 7, 1982 6.,

.uu...

Mr. D. F. Kirsch Nuclear Regulatory Commission Region V 1450 Maria Lane Suite #210 Walnut Creek, CA 94596

SUBJECT:

Transmittal of SCE/Bechtel Audit Package Regarding Allegations by Mr. E. Earl Kent San Onofre Nuclear Generating Station, Units 1, 2 & 3 As we discussed, the enclosed subject data package is submitted for your inspection planning purposes during your upcoming investigation at San Onofre.

It is understood that the NRC is required to perform an investigation once Mr. Kent made contact with you on October 6, 1982.

If you require any other data prior to the NRC inspectioh please con-tact me or D. B. Schone.

Very truly yours,-

M

.J. M. Curran Manager, Quality Assurance DBSchone:dsg i

EncIosure i

.{

q 1

E I

s,I-nn smO-i 1

oy Ah A d / 'y V4 V

I wf,,j

~ - - - -

3w_

- w ag a ;<,7. W.K ;.=,..- L_, 3; * *Q,, gg;. ; ;, J *[

AC30 S02/3 I

.s

~

September 20, 1982 9-3.:.,.

.r. -

-Q.

.cy Mr. R. L. Patterson, Manager Division Quality Assurance Eechtel Power Corporation P. O. Box 60860, Terminal Annex Los Angeles, CA 90060

Dear Mr. Patterson:

SCE Quality Assurance Audit Report EPCS-13-82 San Onofre liuclear Generating Station, Units 2 & 3 SUEJECT:

Also Enclosed is a copy of the registered letter to Mr. E. E. Kent.

enclosed are the results of the audit conducted on Septenber 8 through 9,1902 to address allegations raised regarding the d as a result

...ere were no Corrective Action Requests (CAR's) generateThe audit of this audit.

Very truly yours, J. M. Curran Manager, Quality Assurance GPVasios:dsg h.

Enclosure H. F. McCluskey IT-$

cc:

M J. H. McCarty O

J. W. Sheppard

^.

'bec: L. T. Papay L *,. i R. Dietch K. P. 3askin i

2; J. A. Beoletto

~~

D. B. Schone/ Site QA File W-l'f "--

CDMC

^

'l l.i.

j.

4 7

.i 3

,i-I

.s:omW~'~ ~ il. *

• W T""~.' '

-;-~*.*,a.

l _. !

^

-e.,.

e-

. -, r,

+

t

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September 16, 1982 S

f/Vyg

%7 44E Mr. Earl Kent Q

9809 Spruce Court dy 90630 Cypress, California

Dear Mr. Kent:

Thank you for bringing your concerns relative to welding and nondestructive examination at San Onofre to our i

attention on September 7,1982.

To thoroughly investigate and address your concerns, special quality assurance audits and inspections wereIn addicipn f San organizations have ee6n consulted to evaluate compliance o performed.

Onofre with the ASME Code, ads 0.1.1 welding standard andFor eac SNT-TC-1A, where applicable.

determined that welding and nondestructive examinations, Sa Accordingly, our findings do not substantiate your condacted at standards.

claims.

~

Again, Mr. Kent,, we thank you for your interest.

Please be assured enat we will continue to audit these an Onofre areas to verify that the requisite quality of work at San is maintained.

Sincerely,

i J

M. CURRAN nager, Quality Assurance

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.,M AUDIT REPORT t mi.ct BPCS-13-82 1 Audit Datos __ 9 /8-9/82

2. Audit Report No.

.. Cniv ania a sias aveiven

.. mans ano aoems..or Conra=,avertue 10CFR50. Appendix B

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Bechtel Power Corporation Criterion III, I XVII SONGS 2 & 3 Jobsite AUDIT PURPOSE AND SCOPE This special audit was performed to address allegations brought to the attent Southern C'alifornia Edison Company on September 3 and September 7, 1982, re These concerns are the adequacy of welding performed at San Onofre Units 2 and 3.

documented in' Attachments 1 and 2.

A'UDIT HISTORY Previous recent audits of welding control are as follows:

CAR's Issued _

Audit Report Number None BPCS-6-81 None BPCS-66-80 SO23 F-724 and S023 F-725 BPCS-6-79 None BPCS-14-79 The Corrective Action Requests (CAR's) generated during BPCS-6-79 have s been closed.

AUDIT PLAN

(:.

Cee the att whed Audit Plan Items 1 through 3.

i AUDIT COMMENTS Mr. J. H. McCarty, Project QA/C Manager, San Onofre Units 2 and 3. Bechtel P His assistance ation, was notified on September 8,1982, of the scope of this audit.On September 13, was requested in order to resolve these issues in a timely manner.

1982, a formal request was made'to Mr. R. L. Patterson, Manager, Division Qu Assurancy, Bechtel Power Corporation to obtain the Bechtel Corp A e (Continued) g 9/....j s".

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l J. H. McCarty V. A. Gow J. W. Sheppard R. S. Ruiz

./j D. Martin B. O. Faber

!t omTS 8SSWED ASalasef Tn8B AW9IT REPORT d?

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.O. J. Ortega P. R. King l

J. W. Sheppard-Bechtel D. E. Nunn G. P. Vasios (i

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B. O. Faber-Bechtel J. M. Curran D. B. Schone/ Site QA File

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., g.E AUDIT REPORT NO.

AUDIT COMMENTS CONT _

/~ '4 The four issues identified during the meeting on September 7, 1982 (Attachment 2) were addressed in this audit:

The concern that'the velding r'equirements of AWS D.l.1 were not being followed A sample of Audit Plan Item No. 1 addresses this issue.

1.

' regarding end returns. drawings were reviewed, found to call out, end returns as req

. documents tion was performed to verify their actual installation.

10, 1982 to reverify the Bechtel Field Inspector's Report performed on September end returns had been applied in each case.

The details and sections in the sample were also verified as being on the draw-T ing revisions in effect during November and December 1980.

He was allegation worked in the field at San Onofre during November 1980 only.

assigned to office tasks during the other periods.

The concern that a spacer plate was missing on the inside door hinge of the U was reviewed. No spacer is required 2.

Drawing S023-205-5-369-4 A field surveillance was performed on both Units 2 and personnel hatch.

Unit 3 installation was in accordance for this installation.

3 which is documented in Attachment 5.

However the upper hinge with the drawing as was the lower Unit 2 hinge support.

support has an undersized fillet veld with a 3/16" gap in the fit-up.

Both Bechtel and Edison Engineering were consulted to determi the undersized fillet veld.

(.-

and 7) confirmed that the upper hinge support veld is structurally sound.

It should be noted that this subject had been brought to Bechtel attention on by the person making the allegation as documented in a Field f.

March 10, 1981 Inspector's Report and Telephone Notes (Attachments 8 and 9).

The opinion that Bechtel M&QS had misinterpreted the ASME

((

3.

implementing the requirements confirmed that Bechtel procedures comply w gagement length.

(

A review of a sample of WR-5 veld records verified ASME Code requirements.

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Bechtel implementation of the requirements.

The concern that since a Peabody Testing Report contained " numerous spelling errors" and another documented a dye penetrant examination where a magnetic 4.

particle examination was required, therefore, the quality of the inspections y,

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performed by Peabody Testing are suspect. firm allegation, however we y

l were adequate and Ii

,to assure the qualifications of Peabody Testing personneNotwithstand f

.h current.

.have been qualified in accordance with SNT-TC-1A.

7.:1

)y This specual audit of the Bechtel Control v~ Welding and Non6estruction Exam substantiates the effectiveness of the program in the areas audited.

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.4 :N AUDIT PLAN ITEM NO. 1 7

Verify that the welding requirements of AWS D.I.1 regarding "End Returns" hav

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.AWS 8.8.5 and 8.8.6 address requi ements for end returns as follows:

_ja followed.

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sPCS-13-82 p.g, E.

AUDIT REPORT NO.

C' AUDIT PLAN ITDi NO. 1 (CONT)

"8.8.5 Fillet velds deposited on opposite sides of a cot:: mon plane of contact between i two parts shall be interrupted at a corner common to both welds, 8.8.6 Boxing (End Returns) 8.'8'.6.1 Side or end fillet welds terminating at ends or sides, respectively, of part or members shall, whenever practicable, be returned cont This provision shall apply to side and top fillet welds connecting brackets, beam 2

ted.

seats, and similar connections on the plane about which bending moments are compu 8.8.6.2 End returns shall be indicated on the drawings."

l" Since the above code allows engineering preference on end returns "wheneve details speci-and since the physical conditions inspected were in accordance with the fied by the engineering drawings, no deficiency exists.

.~

DOCUMENTS AUDITED The following drawings were reviewed:

23624-Revision 4, Detail 4 23634-Revision 7, Detail 4 25219-Revision 7, Detail D 3

23213-Revision 20 Detail 1 Cont.

23213-Revision 20, Detail 1 23212-Revision 30, Section E

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23215-Revision 3, Detail 5 AUDIT FINDINC(S)

Each of the drawings reviewed contained examples of boxing or end return of fillet welds in accordance with the requirements of AWS D.l.l. presents the Bechtel Field Inspector's Report which documents ve of weld returns shown in drawings which are part of the attachment.

ITEM CLOSED _

No Deficiency Noted

~

AUDIT PLAN ITEM NO. 2 U-Verify the Unit 2 personnel hatch inside door hinge is installed in accordanc 5

S023-205-5-369-4, Drawing 152, Revision 4.

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DOCUMENTS AUDITED Chicago Bridge and Iron, Drawing 152, Revision 4.

Dra'w'ing S023-205-5-369-4, y

f.I AUDIT FINDINC(S)

The above referenced drawing was reviewed, and it was determined that no sp

• 1 3.1 called for in the installation of the hinge supports.

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Surveillance inspection of the upper hinge support on Unit 2 documented in Atta

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ment 5 revealed an undersized filled weld with a 3/16" gap in the fit-up.

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'c5 AUDIT REPORT NO.

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L AUDIT FINDING (S) (CONT)_

Bechtel and Edison Engineering were consulted to determine the adequacy of the under-These investigations / calculations are documented in Attachment 6 and 7, sized weld.

and su=marized in the audit coc=ents section.

ITEM CLOSED No Deficiencies Noted AUDIT PLAN ITEM NO. 3 Verify that Bechtel's interpretation of welding standards regarding socket veld ASME Section engagement length is in accordance with the ASME Code Section III.

length III, Paragraph NC 4427 addresses the requirements for socket weld engagement as follows:

"NC 4427 Shape and Size of Fillet and Socket Welds The size of the veld shall be deter-Fillet welds may vary from convex to concave.

mined in accordance with Figure NC 4427-1."

WELDING DET AILS FOR SOCKET WELDING FLANGES fg NOMtNAL PLPE WALL THICKNESS gg-h 8X 1/16 6n. APPROXIM ATELY N

5 BEFORE WELDING I

N t MIN = 1.09 t, SUT NOT i

ex LESS TH AN 1/8 in.

FIG. NC44271 FILLET AND SOCKET-WELD DIMENSIONS Wot permitted for socket weld connections over 24ach nominal pipe sue foe components) t

's DOCUMENTS AUDITED _

h' Wel* ding Gen. Welding Reference Standard _

Standard Dimension Drawing Weld No._

Dimension She 1 SJ 2 1/16"

! P-PS-T-Ag GWS-SN 2-2 1/8" S3-1201-ML-001,Sht 1 t.

P8-T-Ag GWS-SN 2-2 1/8" S3-1201-ML-001 SJ 2 1/16" P1-A-Lh GWS-FM Approx. 2 1/8" S3-1301-ML-001 Sht 2 SBK 2 1/16" P1-T (CVN)

GWS-FM Approx. 2 1/8" S3-1301-ML-001 Sht 2 SBH 2 1/16"

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GWS-FM Approx. 2 1/8" S3-1301-ML-001 She 3 SCK 2 1/16"

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AUDIT REPORT NO.

O AUDIT FINDING (S)_

The above sample of socket welds were reviewed and each was found to be in compliance with the ASME Code,Section III, Paragraph NC 4427.

The k'elding reports, procedures and standards referenced in this audit plan item com-

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prise Attachment 10.

ITEM CLOSED _

No Deficiencies Identified m

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SEP 071982 t'

MEMORANDUM FOR FILE _

S.0.N.G.S. 2 & 3

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1 September 3,1982 n'

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On Friday,' September 3,1982 Mr. Orlando drtega brought to my office

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j Mr. Kent had come to see Mr. Ortega and expressed some conc Mr. Ortega referred Mr. Kent to the Mr. Earl Kent.

'1 about the welding adequacy at San Onofre.

Mr. Kent stated the following:

4 undersigned.

That he was a Senior QA Engineer for the Bechtel Corporation wo

,j San Onofre on Units 1, 2 and 3 from the Fall of

'S 1.

Between 1978 and the Fall of 1980, Mr. Kent worked forSubs Engineer.

Austin Engineers in Irvine, California.

San Onofre Mr. Kent worked for some period of time at Midland Don Martin was Mr. Kent's boss at i

also for the Bechtel Corporation.Eechtel for at least some portion l*

Mr. Kent stated that he has concerns regarding l _,

2.

Mr. Kent indicated that He used as an example AWS 01.1.

tly, the Bechtel inspectors were reading the welding welding codes.

of inadequate welding could be stated.

He Mr. Kent stated that he felt there were gross 3.

ith would fail but merely that they were not constructed in accordance w He also mentioned potential structural problems wit the code.

his supervisor supposedly told him that the co containment air lock doors.

the air lock.

I indicated to Mr. Kent that we wanted to fully understand any

. g, ily problems that might exist at San Onofre so that they could b 4.

I told him that I wanted to have SCE personnel with experti the area of his concerns meet with him and fully explore all of h resolved.

I indicated that I would assemble the appropriate people and

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with him, would like to meet Tuesday, September 7.I advised

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be convenient.

• Mr. Kent's phone number is (714) 828-8064.

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' '.5.1 5.*' Attached to this memo is his business card that he gave M

,fyy Mr. Kent did not give me a

' t1 I obtained after uty dis &ssion with him.

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business card. I gave him one of my cards.

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Nemorandun For Fila Paga 2 h

Septemb:r 3,1982 ATTACHMENT 1 Page 2 of 2 Subsequent to my discussion with Mr. Kent. I talked with Dwight Don Schone.

meet with Mr. Kent.

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<g K. P. BASKIN KPS:jaj cc: Robert Dietch J. M. Curran D. E. Nunn D. B. Schone 8-j.

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ATTACHMENT 2 MCMORANDud FOR FILE Page 1 of 2 4

l Septemoer 7,198 2 l

i Meeting deld at SONGS 2 & 3 QC Of fice on Concerns of 1

S UdJ EC T:.

Mr. E. Earl Kent Regarding Jelding Adequa cy San Onofre Nuclear Generating Station, Units 2 & 3 4~

SELF cc AfrBNDSES :

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E. E. Kent jyh g.

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J. M. Curran j

P. R. Kin g D. C. Stonecipher 4

A dA CKGR0ddD On Friday September 3,1982, Mr. E. Earl Kent submitted an

'I Rosemead for a position with Edison.

employment application at Af ter a routine pre-employment screening interview with Mr.

Division, Mr. E. Kent entered the office

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d. AtKins of Cne Employment of Mr. O. J. Ortega and expressed nis concerns over welding adequacy

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at San Onoire.

Mr. Ortega referred dr. Kent to Mr. K. F. Bassin.

A summary of the discussion witn Mr. Bassin is outlined in a :4morandum for File

~

dated September 3,1982.

Based on tne ite:s presented during that discossion, tne Qdality Assurance Organization made arrangements to seet witn Mr. Kent on Tuesday, Septe=ber 7, 1982 in an effort to resolve Mr. Kent's concerns.

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DISSOSSION On Iuesday, September 7, Mr. Kent was called to San Onofre and a 1:30 p.m with parties in attendance as noted

=eeting was convened at

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dr. Curran stated the purpose of tne meeting was to docu=ent Mr. Kent's concerns regarding welding adequacy at 50dGS 2 & 3 and aoove.

take corrective action as appropriate.

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Mr. Kent oriefly outlined nis work experience during nis term of 1961) as a welding decntel e=ployment (dovember 1980 through AugustMr. Stonecipner tnen asned Mr. K l.

QC Inspector at SJdGS 2 & 3.

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describe nis concerns.

Mr. Kent stated tne following:

Item 1 - de was concerned enat the welding requirements of AJS D.1.1

/.i regarding "End deturns" were not ceing followed on pipe In

'.M nangers and electrical strut and structural steel.

addition, he stated these requirements were not snoen on

!}i design / detail drawings for Onits 1, 2 or 3.

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T' Kent was asked if ne had identified these conce.cos to Mr.

nis supervision wnen ne was employed oy decntel at SidGS.

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il de stated he nad verbally identified these concerns to dr.

c.'J J D. Martin, nis immediate supervisor, and itssrs. J. Lanr, Lli D. Woodward and H. de ssich (Associate delding Inspectors).

j'ai In addition, ne stated ne had written internal mezos to Mr.

Mr. Kent stated tnat Martin stating these same concerns.

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4 Mr. Martin's answer was always to " inspect to cae prf 't."

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'Hemorandum for File ATTACleiENT 2 "ady NOdchn-Mr. Stonecipher asked Mr. Kent if he had writte Mr. Kent formance Reports (dCRs) regarding this matter.

stated that he nad not written any NCRs, since the welding Mr. Kent's point was, was in accordance with the print.did not reflect the requirement for "End enat the print Kent was asked if ne ever identified nis Re turns".

Mr.

concerns to tne Becntel Quality Assurance depart =ent and ne

. stated he had not.

Mr. Kent further stated that' he had written NCds on other specific welding problems and believed the NC As were dispositioned properly to resolve the problems.

ltem 2 - Mr. Kent was concerned enat a spacer plate was He stated tnat he nad identified enis area of concern to Mr. Martin replied that it had i

his supervisor, Mr. Martin.

been supplied oy Cnicago Bridge and Iron Company (C3&I) and '

that Bechtel field QC was not responsible since it had Mr. Kent previously oeen receipt inspected and accepted.was j!

Mr. Kent replied enat ne nad not.

item.

Kent stated that, in nis opinion, ne felt enat tne Becntel Corporation nad misinterpreted tne ASME Section III Item 3 - Mr.

length welding standards regarding socket weld engagementinitiating witnout code relief.

Item 4 - Mr. Kent produced two. Peabody Testing reports, one of whica nad numerous spelling errors and the otner wnich documented tne performance of a dye penetrant inspection rather than Mr. Kent stated the required magnetic particle inspection.

that the quality of these inspections perforned oy Peabody Testing may oe questionaole due to cne calieer of individuals performing these inspection functions, i.e.

tne Peacody personnel could not spell correctly.

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CJ.iCLOS10d Mr. Curran tnanked Mr. Kent for his concerns and stated that a comprenensive investigation /audic would be conducted into tne areas j.')

and corrective action taken as appropriate.

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!.' t:4 Int meeting adjourned at 2:45 p.m.

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xooert Dierch J. d. Curran D. 6.

Scnone L. E. Pa pa y ak K. P. dasnin P. d. King D. C. Stonecipner f;

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Se ptember 13, 1982 Mr. R. L. Patterson, Manager Division Quality As surance l

Becntel Power Cbrporation P. O. Box 608860, Terminal Annex lo s Angeles, California 90000 De'ar Mr. Patterson:

Allegations Made by Mr. E. E. Kent on September 7,1982 San Chofre ?belear Generating Station, Units 2 & 3

Subject:

Memorandum for File, dated September 7,1982, de ference:

Same Subject Tne enclosed Memorandum for File documents the concernsKent relative to expressed by Mr.As you know, we are in the process of conducting an and 3.

audit addressing enese concerns and need to establish the de chtel position.

Please provide a response to eacn of the four allegations Tne formally expressing tne Becntel Corporation position.

response should address, at the very minis:m, the following in eacn instance:

Concern #1 "End Re turns" Tne AWS D.1.1 Code calls for end returns "wneneverdna e are the ground r a'

practicable."

Engineering to determine when to use end returns?

g 2 Personnel Hatch" Concern #2

" Spacer Plate Missing on Unit Our investigation, to date, nas determined that no spacer is called for in the installation.

However, the upper ninge support does nave a weld with a fit up enat leaves a 3/16" gap.

de will need formal calculations to verify adequacy of this 6

support to carry tne load.

y n:N Concern # 3

" Socket deld Engagement Lengen" 5

Mr. Xent. produced a Be chtel telephone note regarding this M

Does tne pnilosopony expresse d, enerein, represent dnat is the 8e chtel position on suoject.

... i Be cntel policy at San Onofre?

fi so::Aet weld engagement length?

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Mr. R. L. Pattercon ATTACHMENT 3 Page 2 of 2 Concern # 4_

Mr. Kent produced two Peabody testing reports, one with nu:nerous f a dye spelling errors, the othe r which docunented performance o i

penetrant inspection where a magnetic particle inspect on. was Mr. Kent state d enat the quality of inspections It performed by Peabody Testing were, therefore, questionaole.

require d. '

Howeve r, is our opinion that tnis is not a firm allegation.please b during the assure qualifications of Peabody testing personnel period and a position statement on this issue.

is requeste d IX2e to the sensitivity of tnis issue, your response by September 17, 1982.

Very truly yours, J

. CtJRRAN Manager, QJality Assurance GPVasio s En closure J. d. McCa rty - Be chtel e c:

bec:

J. M. Curran D. B. Senone P. A.

Kin g D. C. Stonecipher G. P. Vaslo s Site QA File 1272Q m

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a BECHTEL POWER CORPORATION SAN ONOFRE NUCLEAR GENERATING STATION UNITS 2 AND 3 FIELD INSPECTOR'S REPORT oghg 9-10-82 4

2 DISCI LINE bl ai r. e nienlity control SHIFT Day I

N/A

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_or WEATHER Weld Returns Verifications CENER AL COMMENTS:

The following re-verifications of weld returns per drawings, details and " sections were inspected and found to be acceptable as specified on the drawings:

DWG # 23634 Rev.7 Detail SEB 3 stl. framing below slab 9 8' el.

ITEMS SE-123, 124, 125, 126, & 127 BVG # 23213 Rev.20 Detail Cont. 3 Scl. framing below slab 9

'-0 El.

1Tei W8 I 35 (Typical)

DWG f 23212 Rev. 30 Section Cont. 3 Scl. framing below slab 8 30 ITEM W6 I 15.5 O Penetration 3 DWG f 25215 Rev.3 Detail g Stl. framing 9 50'-5" El. on step stairway 4

DWG f 23624 Rev.4 Detail SEB 3 9 21'-0\\" El.

on K-line wall. under El. 30'-6" slab.

DWG # 25219 Rev.7 detail Pent. 3 Scl. framing 9 bottom of El. 95' slab on S-line wall i

ITEM W24 I 68

/T\\ Scl. framing below

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DWG # 23213 Rev.20 Detail y E

slab 9 45'-o El. Cont. 3 2

ITDIW8 X 35 n;

Above details and sections were verified as being on x.

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the drawing revisions in effect during No(ccher & December,1980 P.il P.

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i ATTACHMENT 6 j,,*-. -

Page 1 of 9 -

Bechtel Power Corporation 4

Engineers - Constructors 12400 East imperial Highway Norwalk. California 9065o i

=

. ft8WeeAL ANNEX.LOS ANGELES CAJOsmeA sense 4

P O SOE$0B00 TELEPM0pt- (213) 0864011

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1

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September 17, 1982 i

l 1

i, Mr. J. M. Curran Manager, Quality Assurance i

Southern California Edison Company P.O. Box 800 2244 Walnut Grove Avenue

~

i Rosemead, California 91770 l

San Onofre Nuclear Generating Station, Units 1, 2 & 3

Subject:

Allegations Made by Mr. E. E. Kent on September 7,1982 i

4 j

Reference:

SCE-QA letter, Mr. J. M. Curran to Mr. R. L. Patterson, I

sare subject, dated September 11, 1982

[

Dear Mr. Curran:

I In response to your request for Bechtel's position on the four allegations made by Mr. Xent concerning welding adequacy at SONGS 1, 2 & 3, the position of the Los Angeles Power Division of Bechtel Power Corporation

j' j,

is as follows:

U Concern #1 "End Returns" Weld end returns are utilized in practice to enhance the redistribution of local stress concentrations in the design of selected welded connections.

Such redistribution of local stresses comes about only when the stresses reach the yield level.

In the case of the SONGS 2 & 3 Project and the

',7 modifications to Unit 1, the stresses are designed to remain at or below 90% of the yield level.

Weld end returns are recocinended by the AISC and AWS Codes, whenever practicable, u

i

• 'ven though tests, upon which code provisions are based, recognize that these y

n returns do "not necessari1s increase the strength of ther con. :ction" (AWS e

'l Commentary 8.8.6), when comparisons are made on an equivalent weld strength When end returns are specified by the design engineer, the AISC Code basis.

y

,firMM permits the engineer to utilize the additional nominal load carrying d

pacity increase in addition to the full capacity of the orthogonal weld.

N, / /7, 4;-

pv n..%cm.v.-7 9 r;=.gr.u/>

}.r =w v- -...

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7

Bechtel Power Corporation 9 2 l*r'ag,co77,,

ATTACHMENT 6

' September 17,.1982 Page 2 of 9 The tenn "whenever practicable" is interpreted by Engineering to'mean weld end returns are routinely specified as a matter of comon design

~

The practice, and such practice is followed by Bechtel Engi

~ requirements of a particular design condition.

are of insufficient length to develop the~ required lo a

In addition, increase the design capacity consistent with the AISC Code.

where the orthogonal weld produces a design capacity sufficiently in excess-of the required load capacity, the design engineer may omit the weld end return if the addition of the return results in excess conservatis meet both the provisions and intent of the AISC and sufficient margins exist to meet all SAR and FSAR comitments.

Concern #2

" Spacer Plate Missing on Unit 2 Personnel Hatch"_

We understand your investigation has revealed this concern to be a 3/16"S gap in a weld fit-up at the upper hinge support.

is critical, we also assumed this to be the case.

4 SONGS 2 & 3 Project Engineering has performed calculations (see A based on the Chicago Bridge and Iron stress report for the personnel hatc that prnvides verification that existing weld on the upper hinge supports d design loads.

t:vsn with the 3/16" gap is adequate to carry all impose Concern #3

" Socket Weld Engagement length" The philosophy expressed in the telephone note produced by Mr. Kent d Form 84 (Bechtel not represent Bechtel Policy at San Onofre Units 1, 2 & 3.

Drawing 90011) is the governing document for use of weld procedures on The procedures listed in Form 84 refer to various General Welding Standards (GWS) which conform to ASME Section III Code req SONGS 2 & 3.

For example, on SONGS 2 & 3 concerning socket weld engagement length.

GWS-SN Rev. 8 states:

The following steps should be followed for verification of the socket gap.

Scribe a line on the fitting 0.D. equal to the distance f

from the face of the fitting to the bottom of the socket, 3.1 4

Scribe a line on the pipe or tube that is 2 inches, or p

other predetermined distance (Y), from the end of the pipe 3.2 d

j p

or tube.

it

.i After fit up, tacking 'and welding, verify that the scribe

>f lines are greater than 2 inches but less than 2-1/8 inches 3.3 ljp apart or greater than Y but less than Y + 1/8, whichever is applicable il

~

WOar procedures are in effect for Unit 1.

J.'

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Bechtel Power Corporation,

- p g, 3 ATTACHMENT 6 Mr. J. M. Currcn September 17, 1982 Page 3 of 9 Concern #4

" Unqualified NDE Personnel" The qualifications of NDE subcontractor personnel are re The subcontractor's work is performed under the cognizance of a Results of the examination are reviewed by projects.

qualified Bechtel NDE person.a qualified Bechtel NDE person and, in the ca The results of the above activities are Authorized Nuclear Inspector.

documented and available for your review.

We hope this infonnation is of value to you in your investigation of If we can be of any further service in this Mr. Kent's allegations.

matter, please feel free to contact me or the Project Quality Assurance Manager, Mr. J. H. McCarty.

Very truly yours, BECHTEL POWER CORPORATION

.s. w c q R. L. Patterso Division Quality Assurance Manager RLP/JHM:drrb

3 Attachment D. B. Schone, SCE cc

H. F. McCluskey, BPC i

W. V. Horn, BPC J. H. McCarty, BPC F. B. Marsh, BPC R. J. Kosiba, BPC L. R. Brown, BPC

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ATTACHMENT 7 Page 1 of 3 AT10AE SONGS 2&3 ce N e GC M Kursch September 16, 1982

,s

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MR. D. B. SCHONE Personnel inck Weld Deficiency, Containment Unit 2 San Onofre Nuclear Generating Station, Units 2&3

SUBJECT:

SCE Field Surveillance Report No. W-79-82

References:

A.

S. Hoggan, dated Bechtel Calculation No. c-257-2-10, B.

September 10, 1982 Telephone Notes, J. W. Newbrough to R. Kane/H. Nazarian,

Attachment:

dated March 10, 1981 Re ference A will not impair the The alleged weld deficiency reported in not Personnel Lock and is, in fact, integrity or function of the structural deficient with respect to the cited codes.

deficiency was cited as an undersize weld at the upper hinge The undersize weld was the result of a fit-up gap of 0 inch to The weld The total length of the weld bracket.

3/16 inch over a 3 inch length (see attachment).

~

is 13 inches.

The as-built connection is adequate because:

.296 inch for the undersize weld is The required effective throat for this effective weld throat of The 1.

sufficient for the design loads.

weld based on strength requirements is.13 inch.

t The requirement for a 1/2 inch weld is based on the necessary weldin AISC input as required by the minimum weld size requirements of the 2.

Since this weld is Specification, 7th Edition, for 2 inch thick plates.

nsistent

f!

actually fabricated as a 1/2 inch veld, total heat input was co M

,, ith these requirements.

w Ev en if the undersize portion of weld is completply neglected, the fi B).

'! {!

3 remaining welds would be able to support the design loads (Reference

' !j A maximum gap of 3/16 inch is permissible in the assembly of two p a.;

4 7

i-be joined by fillet welds.

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ATTACHMENT 7 Page 2 of 3

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In conclusion, the upper hinge bracket connection is acceptable and does.not require repair.

Please call me if you require further clarification.

~w.

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h H. L. RICHTER TYee:npy Attachment cc:

R. L. Baker W. M. Schwab G. A. Chavez L. L. Seyler G. Vaslos J. K. Yann CDM Files l

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Sor heannec c'occ_of_ he-.perninel./ock in.u-2 Cca1cumd.

'T'u5 wdd ams examin.ec)_b.a aIdy 5m y

aukScand_h-have_c._% calchmms,m ofe29h.n. cccc.. -

len9 Ne. ncmina.I Arcaldamensa fec.

k

_a -. cee in.

%s cmdde.1_.

- s X2 '..' fdJetweld. shedd.1x U.350 n.

- ts.abkdecLk a_9y_heken_.&o ka.weidehalak5 aopox. %". 3ee_sMe hek.--.....

- d.Aalph a.vd 5ck. >.nvesbaM 4hs ccrw% d.

dekcenaed 1haf inedced.ikccai_cw_cuamaILl+yjiL__

s Ae._ weld as_xelL.wk b Mawces. cf.desp.

ac.curc9.. kyhk felLkt.haId.can be. teGas a..

.wd no. dekmedaLdlecten.#.e s%1ure.

.0$e.: %S..asseabl.q.u).g%cusG.mspeled.ad accspli y

pr1 A.h fe.'armel

.. l2L..._

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t Materials and Quality BECHTEL POWER CORPORATION WELDING STANDARD Services # / g/ m g[ I,

Prepared Welding Procedure Specification Revie ed g.

Authorized f use w

O

,V March 22, 1978 Approved

j. _

PI-T (CVN)(Wash)

W.R. Smith, Sr.

Revision 0 Date By Manager of En ineering TPO d in conjunction with the General is welding procedure specification must be use tested or non-impact

~ Thlding Standard (s) GKS-FM Gas tungsten-arc welding of P1 - Subgroups I and 2 impactld heat treatment We tested carbon steels which receive subsequent postwe Scopa wash pass technique to improve surface contour.

Typical Joint Design J

ase Metals _ Carbon Steel. P1 Group 1 B

or P1 Group 2 Itself and each other 1 (G-1 or 2)_

Welded to PW l (G-lor 2_)to PN Cas Tungsten-Arc Welding (GTAW)

ASME Sect. IX:

. Note 3 Welding Process:

Approx.

Filler Material E705-2 or E70S-3~ WS AS.18/SFA 5.18 (Note 1) 3/4

.J A

l-f A#

1

/

ASME Sect. IX: F#

6 All (Note 2)_

Position (s) Qualified _

(in inches)

Thickness Range Qualified 1

a

.As-welded:

min. --

_ max. ---

RECElVED (Note 4)

C Postweld Heat Treated:

min. 3/16 max.__6.0 _

MAY 0 51978' l

Ba king Material P1(G1),P1(C2)* or Al weld meta EDM S!TE Min. Preheat Temp._ in accordance with GWS-FM but not less than 51 F.1100 - 1250 F 612. 614 Postweld Heat Treat Applicatie Procedure cualification Record (s) Sections III and IX I

l ASME Code.

(

Procedure Qualified to:

l J GTAW Welding Process Wash E

fi' I f f" s 4 rt r s

__ Layer Nar.ber 1.5-6.7

[.

_ Travel Speed (in./ min.)

[E S Q h

' @_3 V

135-300 Qgi F. b.

5_

l Amperage Range DCSP r

AC/DC Polarity 9-10.5

1. 7

}

Voltage Torch. Gas - cfh.

18-25 MAY 5 ISK

.?

Backing Gas - cfh.

None

),

,?RAWINQ-(inch) 1/8 r

Electrode Diameter EWTh-2 CONTITQL i

Tungsten T/pe riller Wire Diameter (inch),3/32 or 1/8

/)

Other Al analysis weld metal may be consumed as necessary.

yfrom0to1/2-inci Additional Instrucdons d

Both vertical up and/or vertical down welding m

~.

Note 1:

Note 2:

Dwell may vary from 0 to 1.seco.d and oscillation from 0 toidth is indeterm Note 3:

not, apply to non-impact testeu.uterials. Final weld wWash pa d

varying puddle size. (Note 4):

Page 1 of'.,l r:

J, L -...,.. fusion lines.

3,..

_._, y.... _._....g p : m,.;.g.;,Q,,

, -;n ;. %,4

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' y,,, g og 35 Bechtel Fover Corporatica An 10 C'ds-FM 1.ECENp Page 2 of L2

}

Neueent No.

T = No inal pipe wall thickness.

m 1 Min = 1.4T or thickness of hub, whichev I

h I

I Cx Min = 1.09T, but not less than 1/8 inc I

y (j

fm 7

.w

.=.m.

3

.w m.

A = Engagement T

{4 _i

( -4 a f - (

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f l

7:

7 o,.

c J i

'1

.J_

i3 t

W r

e sf

, ' i

-9 F-- a i

'socat1 wti.n astaAs over 1 inch nominal a-,

b A minimum of two weld layers is required for pipe or tu eEit ss may be 1.

pipe sise.

used.

the Cas Tungsten Arc i

The Shielded Metal For pipe or tube 1 inch and less in nom'inal pipe a re, is permitted.

ld layers is deposited.

~

process should be used and a single veld layer 2.

When gap verification systems are Socket velds shall be fit up with a gap.

k d once, either prior to welding, shall approxicate 1/8 inch prior to Velding. required and u 3.

or af ter velding using the method below.

disengagement k

The f ollowing steps are reco=aended to obtain soc etOth l

3.1 i

en! are approved by the Lead Field Velding Eng neer.h that the line v (minimu= gap).

Scribe a line on the fitting CD far enough back suc 4

not be eltainated by velding or grinding.-

,g 32 h fitting socket When feasible, insert the pipe or tube fully into t e l

(bottomed, maxitum engagement "A").

free the fitting 3.3 Scribe a line on the pipe or tube that is 2 inches If the 2 inch dimension cannot be obtained, use ano 1

" for the scribed dimension.

3.4 predetermined and docunented distance "YDocum "T" distance abould be placed on t e scribe line.

h WR-4, VR-5 or distance of approxi-After scribing, withdraw the pipe or tube for ama fit, tack and weld.

WR-5A form.

k 3.5 r "Y" inches apart, which-After welding is complete, the gap may bethe scri d gap verification is 3.6 ever is applicable.

When the use of scribe lines is not practical an lding.

required, the gap should be verified prior to wel ted welds and 3.7 When scribe lines are damaged or missing on comp ebe used to de verification is required, radiography mayRadiography is not required, 3.8 table. The a gap was present prior to welding.if used, shall show the has no minimun or muisua dimension. RT shall be for gap 5a*

of interest and may be masked off. k t veld acceptability.

3 s,a

.a12ation only and not applied to soc e ar.

dr

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QUALITY CONTROLVERIFICATION 3

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j' Points Designated in Appropriate Colymn Withs' II(lloid) W (Witness) R (Review)

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--.4---,..._-._m, ATTACidtENT 10 Page 6 of 12 e

a

..f Materials and Quality e

BECHTE1 POWER CORPORATION Services WE1. DING STA!!DARD Prepared N [ g vejf, b Authorired for use tielding Procedure Specification Reviewed} g} T G g y i

P8-T-Ag Approved

,g ef Revision 2 Date Dec. 2,1976 By

.h.

Snith, Sr.

Manager of Engineering TPO

~

h the General Tnis welding procedure speelfication rnust be used in con) unction wit CWS-SN

'deldine Standard (s)

tanual gas tungsten-are welding of austenitic stainless-steel piping with Scope:

1)TCHTgt

/

internal argon purge.

A Typical %7oioggDe sign '

Austenatic stainless steel es w Base Metal:

Austenitte stainless steel i

Weldeu to

>i 6

ASSC Sect. IX: P4 8

to P8 D 8 Ca s Tuna sten-Arc lCTA)

Welding Process:

hY8 ein tiller Material Refer to GWS-SN THICX'4ESS 3/16 THROUGH 3/3

-- # ' 8'--- /

e--

J A8 8

AS:2 Sect. IX:

T*

6 Position (s) QJalified:

All positions T

Thich ess Ra.ce QJalified (in inches) 3/327"

-q 4

I

/

As.elded:

min.1/16 max. 0.864 M

l

\\

.)._

f gg "en Postsold Heat Treated:

t min. _ --

max._ ---

- ^.r.irn..

None Backing Material THICKNESS GREATER THAN 3/_8_

600r Min. Preheat Temp.

Interpass Terperature shall be 3500r as-welded condition only)

S'a x.

(procedere cualified in the l Postseld Feat Treat: ; ten e PQR 53 and 54 iAtelies'cle Procedure QJalification Recordis)

ASME Secticn IX I Procedure QJalified to:

'GTA

'GTA GTA 3 t. Rem.

F.S A..

I Weldia.q Process 2

' ayer Nu-cer 2-10 2-10 ff ff. l. (*

1 Travel Speed fin./nin.)

2-10 40-140 A 40-140A i

t et s40-140 A Anperace Range DCSP DCSP

+

DCSP 1

fl A f AC/DC Polarity 6-13 8-13 8-13 I

'loi tse e Argon Argon *

./,

' Torch Gas - c'h.

Argon 18-25 rgp'

• 18-25 18-25

.i CONI 10!'

'I zacking Gas - cfh.

Argon Argon r

's -

ic.15 10-15

.lectrode Dia. meter (inch) 1/16, 3/32 or 1/8-1 or 2%

I T*Jnc s en Ty >e (Thor.)

1 or 2%

l1 or 24 i

1/16, 3/32 or 1/6-i IPaller Wire Diameter (inch) 7 RECEIVED CoHTN Additional Instructicns JUL181977 t,

EDM SONGS 2 b 3 U i um 4

Pace 1 of 1

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ATTAC&fENT 10 B2chtel power Corporation pan 7o 12 7

Rev. 7 Fage af

,.spee./ Doc. No. GwS-SN SOCKET WE1.D DETAll.S

\\

C)

Before Welding 42.1/18 mis.>

i scribe 04te41 scrike 4- --- 2

!.ine 1.Lae I Mis.

d fV

, r-T r ~~

11 X

[I I &

M/I I

M f

't

' e--i 1---

m

- G G

o.

T = Nominal pipe wall thickness.

I Min = 1.4T or thickness of hub, whi hever is saa!!er, but not less than 1/8 inch.

Cx Kin = 1.09T, but not less than 1/8 inch.

G = 1/16 inch approxi:tately before welding.

of.two weld layers is required for pipe or tube over 2 inches nominsi 1.

A minimu::

Either Cas Tungsten-Arc or manual Shielded Metal-Arc process may pipe site.

-}

be used.

For pipe or tube 2 inches and less in nontual pipe size, the Gas Tungsten-Arc 2.

The Shielded process should be used and a single weld layer is permitted. Meta The following steps should be followed for verification of the socket gap.

• 3.

Scribe a line on the fitting 0.D. equal to the distance froe the face 3.1 of the fitting to the bottom of the socket.

Scribe a line on the pipe or tube that is 2 inches, or other predetermined 3.2 distance (Y), from the end of the pipe or tube.

7 After fit trp, tacking and welding, verify that the scribe lines are 3.3 greater than 2 inches but less than 2-1/8 inches apart or greater than Y but less than Y + 1/8, whichever is applicable.

1 i.

t l

FIGURE NO.

KEY.

DATE I

CWS SN-8 3

01/02/80 mqs-004 Rev. O, 9/79

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IiLLD DLIJ.,G Ci tCK LI5E Page Of _

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FOR 2 INCil AND LFx. SOCKET UELDLD !OINTS

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FILLET WI.:.DS 1007a UNIT NO.

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BECHTEL POWER CORPOllATION Quality Control Services W ELDING ST ANDARD P repa red QJJ Welding Procedure Specification Reviewed 4kg g

/N Revision 1 Date 11/8/74 V. R. SMeh. St.

P1-A-J.h Approved hTC, D

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This welding procedure specification must be used in con un

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CWS-FM.

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NUCLEAR HEGULATORY COMMISSION 1

y REGION V 0,

4 1450 MARIA LANE.SulTE 210

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WA LNUT CRE E K, CALIFORNIA 94596 OCT 2 01982 I

MEMORANDUM FOR: Darrell G. Eisenhut, Director, Division of Licensing, NRR FROM:

Jesse L. Crews, Director, Division of Resident, Reactor Projects and Engineering Programs

)

SUBJECT:

REQUEST FOR TECHNICAL ASSISTANCE ALLEGATIONS BY E. EARL KENT (SAN ON0FRE)

This memorandum is to confirm discussions on the above subject between R. H. Engelken and H. R. Denton and members of my staff (T. W. Bishop /

D. F. Kirsch) and the NRR staff (H. Rood /D. Smith).

In the course of RV's special inspection (currently in progress) into allegations by Mr. Kent, we recognized that some could potentially impact upon license issuance for San Onofre Unit 3, and that the resolution of some issues may require technical assistance from NRR.

Attached is a copy of a statement obtained from Mr. Kent which relates his principal allegations.

Harry Rood has been of great help in coordinating NRR assistance in this matter, and has arranged the participation of David Smith.

To date, discussions i

have been held by telephone between my staff and Harry and David to keep them abreast of technical issues as they have developed. An early draft copy of the attached statement was provided to Mr. Road, and Dennis Kirsch has i

had numerous telephone discussions with Mr. Smith on these issues.

At the present time, we anticipate the need for NRR technicai assistance in the resolution of items (2), (Sh (6) and (8) of Mr. Kent's statement.

It is our intention to have a satisfactory resolution on all-of the allegations by Mr. Kent prior to license issuance for San Onofre Ur.it 3, tentatively estimated by Region V as November 15, 1982. Your assistance in this time frame would be appreciated.

We have discussed with Messers. Rood and Smith the prospect of Mr. Smith accompanying NRR personnel on a planned visit to the San Onofre site on November 3, 1982. At that time, Mr. Kirsch will be in a position to provide a substantial amount of technical information related to the issues for which NRR assistance is requested.

This visit will also provide an opportunity for additional discussion with SCE and Bechtel personnel relative to these issues, shcild that be necessary.

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e Darrell G. Eisenhut OCT 2 31982 Your cooperation in this matter on relatively short notice is appreciated.

Should you have questions, please give me a call.

W.

!aO P Jesse L. Crew 1, Director Division of Resident, Reactor Projects and Engineering Programs Attachment a/s cc:w/ enc H. R. Denton, NRR T. A. Ippolito, NRR H. Rood, NRR R. L. Baer, IE 4

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UNITED STATES y'

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g NUCLEAR REGULATORY COMMISSION l

REGION V g,

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,@,p 1450 MARIA LANE.SulTE 210 WALNUT CREEK CALIFOHNIA 94596 J),

b s-J Docket Nos. 50-361 007 2 9 1982

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f @y Southern California Edison Company P. O. Box 800 s.c 4

2244 Walnut Grove Avenue l'

(v Rosemead, California 91770 gb S

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Attention:

Dr. L. T. Papay l

Vice President

[

Gentlemen:

This letter relates to an on-going special inspection by this office into allegations regarding construction quality at the San Onofre Nuclear Power Plants.

During the course of our special inspection, quastions have been identified i

regarding how certain requirements of the AWS D.1.1 Structural Welding l

Code, and ASME Section III Boiler and Pressure Vessel Code were met for the San Onofre Units 2 and 3.

i i

Based on discussions between Messrs. J. L. Crews and members of his staff and D. E. Nunn of your staff on October 28, 1982, it is our understanding that you will provide to this office in writing by November 3,1982 a discussion of your practices, including how you fulfilled code requirements, in the following areas:

l a.

Weld end returns on structural steel and supports as addressed i

in AWS D.1.1.

f b.

ASME Section III, NF, pipe support weld visual inspection acceptance criteria in the areas of porosity, slag, arc strikes, and filling i

, of weld craters.

c.

AWS D.1.1 structural steel and s'apport weld visual inspection l

acceptance criteria in the area of weld crater fill.

Should my understanding as stated above not be correct, you should notify j

this office promptly in writing.

Sincerely, i

k di R. H. Cngelken l

Regional Administrator cc:

J. G. Haynes R. Dietch J. M. Curran e

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i Southern Calibrnia Edison Company h5 seOBox800 32e4 WALNUT GROvt AvtNUE ROSEMEAD. CALWO8tNIA 94770 tbvember 3,198 2

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Region V 1

1450 Maria Lane, Suite #210

{i Walnut Creek, C A 94596 1,

At ten tion:

Mr. R. H. En ge lk en Regional Administrator i-i j

Dear Sir:

S UBJECT:

Response to NRC letter dated October 29, 1982, on allegations regarding construction quality at San Onofre Nuclear Generating Station, Units 2 and 3 j

Ibcket tb s. 50-361 and 50-36 2 i

R EFERENC ES :

1) Sub ject NRC Re quest Le tter, Mr. R. d. Engelken to Dr. L. T.

Papay, dated October 29, 1982

2) NRC Re gion V. Inspection Reoort 50-361/82-27, dated Octaber i,198 2, Page 13, Item 6

3) SC E Audi* Re oort No. BPC S-13-82, dated Sep tembe r 20, 1982, Attachment 6, Pages 1 and 2,

" Concern # 1 -End Re turns." (Transmitted October 7,198 2, J. M. Curran to D. F. Kirsch, NRC. )

I ENC LOSURES :

I Weld End Re turn Requirements 11 ASME Cod e,Section III, Subsection NF:

Pipe l

Sucooets:

Visual Acceptance Criteria for Weld Porosity /Sla g, Arc Strikes, and Crate r Fill III AWS D.1.1 ; Veld Crater Fill Criteria

's 1his letter provides the information requested in Reference 1.

j The design and construction oractices employed at San 01ofre Uhits 2 and 3 were governed by the appropriate code as defined in reguistory doctratuts or as generally accepted as 3

industry practice, t

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n Mr. R. H. En gelken November 3, 1982 The applicable national standard that deals with welding of safety-related pipe supports in nuclear power plants is the American Society o f Mechanical Engineer s Boiler and Pressure Vessel Code,Section III, Subsection NF (ASME CODE).

Only the ASME Code provides definitions for acceptance of pipe suoport welds by visual examination.

The Nuclear Regulatory Commission (NRC) in their Code of Federal Regulations,10CFR50 (Domestic Licensing of Production and Utilization Facilities) and Re gulatory Guide 1.26 (Quality Group Classifications and Standards for Water, Steam, and Radioactive Waste Containing Components of bbelear Power Plants), specifically approves the use of ASME Ill for nuclear safety-related elements of the

~

plan t.

The portion of the ASME Code governing pipe supports is i

Subsection NF.

For San Onofre Units 2 and 3 the 1974 Edition Sumner 1974 Addendum is the applicable code.

Specifically, San Onofre Units 2 and 3 construction specifications for pipe supports provide detailed acceptance criteria for welding which

~

comply with the ASME Code and interpretations o f the Code written by the ASME.

Outside the NF boundarv the American Institute of Steel Construction (AISC) specification and the American Welding Society's (AWS) Structural Welding Code are utilized.

It is importan t tha t the detaile d wording o f oarticular paragraphs o f the engineering orepared construction specification be evaluated in the context of the overall quality program.

The quality program used for design and construction is comprised of documented criteria and guidelines that ensure the adequacy o f the end product.

These include design guides, National Standards and Codes, developmental work by contractors and consultants, the qualification of welds and materials, construction welding procedures, qualification o f welders, and qualification o f weld inspectors.

To develop the criteria a welding inspector uses to inspect a wald, the following procedure is employed:

1) The code applicable boundaries are delineated on engineering drawings;

2) There are Work Plan Procedures at the jobsite which precisely define what to do;

3) Engineering docunents such as construction specifications and veld forms orovide inspection criteria.

Based on these documents, NF 4elding ( ASME III) would be visually inspected by Pipe Sucoort quality Control Engineers (QC E) in accordance with acceptance crite:La specified in construction specification C S-P237 Attachments to pressure I

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Mr. R. H. En gelken November 3,1982 i

boundaries would be inspected by welding QCE's using visual and NDE procedures prescribed by engineering documents specified on the applicable welding forms.

Structural stee l, where AWS welding is appropriate, would be inspected by QCE's to the requirements o f Construction Specification CS-C16.

All cognizant QC E's are certified in accordance with ANSI N45.2.6, SNT-TC-1 A, a s applicable.

Specific responses to areas addressed in your letter of Octobe r 29, 1982 are a s follows:

a. Weld end returns on structural steel and supports as 4

addressed in AWS D.1.1.

j As stated in Enclosure I, the design of all welded

.i connections for San Onofre Units 2 and 3 is i

established in accordance with the applicable code for which the structure or component is classified.

Enclosure I describes the methods and practices for assuring the fulfillment o f code requirements,

b. ASME SECTION III, NF, pipe support weld visual i

acceptance criteria in the areas of porosity, slag, are s trikes, and filling o f weld craters.

2 This matter is addressed in Ehclosure II.

]

c. AWS D.1.1 structural s teel and support weld visual insoection acceptance criteria in the area of weld crater fill.

1 This matter is addressed in Enclosure III.

In s ummary, Southern California Edison design and construction practices as implemented at San Onofre Units 2 and 3 are consistent with applicable regulatory requirements, codes j

and normally accepted industrial practices.

)

Sincere ly,

'I j

77 i

Enclosure s 7

4

.s ENCLOSURE I Page I t

WELD END RETURN REQUIREMENTS, SAN ONOFRE UNITS 2 AND 3 Design Basis The design of all welded connections utilized on the SONGS 2 and 3 project is established in accordance with the applicable code for which the s tructure or component is classified, consistent with the design criteria and FSAR requirements.

The AWS Code in its " Foreword" specifies the following:

"This Code does not concern itself with such design considerations as arrangement of parts, loading and the computation o f stresses for proportioning the load-carrying members o f a s tructure and their connection.

Such considerations, it is assumed, are covered elsewhere in a general code or specification such as a Building Code, AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings,

., or other specifications prescribed by the owner."

The AWS Code excludes from its jurisdiction the design responsibliity for the weld details, and further directs the design function to the designing professional engineer who is required to adopt and interpret other appropriate design soecifications including AISC Specification for the Design, Fabrication and Erection o f Structural Steel For Buildings (AISC).

In this regard, AISC 1.17.10 is considered in the design and utilized accordingly.

This AISC provision states as follows:

" Side or end fillet welds terminating at ends or sides, respectively, o f parts or members shall, whenever practicable, be returned continuously around the corners for a distance not less than twice the nominal size of the weld.

This provision shall apply to side and top fillet welds connecting brackets, beam seats and similar connections, on the plane about which bending moments are co mpute d.

End returns shall be indicated on the design and detail drawings."

The provisions of this requirement are clearly specified to apply to structural components subject to bending where high stress concentrations due to high local weld stresses may exist in extreme edges o f weld details.

These include selected connection details subject to high stresses which warrant such con side rat io n.

The purpose o f this provision is elaborated upon and discussed in considerable detail in technical references used by practicing professional engineers internationally.

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i ENCLOSURE I Page 2 l

purpose of weld end returns are to assist in the redistribution

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of high local s tresses when the following conditions apply:

i 1.

Where vertical welds are subject to high stresses which are calculated to exist at extreme tips of a weld group, generally from large bending moments which have a tendency 3

to " pry" the weld apart.

2.

Where the weld stress is required to perform to its maximum allowable stress value, and further, where maximum loading conditions can readily carry the local weld stress intensity 4

into yield conditions.

3.

In applications for which the local tensile stress from extreme bending effects are required to be resisted by small, narrow weld details.

In the design of all structures and components in San Onofre Units 2 and 3 A-ISC 1.7.10 has been considered.

Where the i

provisions of this section are appropriate, San Onofre Units 2 and 3 construction drawings and specifications provided weld details, including weld end returns, which meet the provisions and intent o f the AISC Specifications.

As a whole, weld end 4

returns have been specified for appropriate design applications when calculated weld stresses approach code allowable values.

, These weld end returns have been provided conservatively even though the San Onofre Units 2 and 3 design criteria limits the l

Design Basis Earthquake (DBE) combined stresses to 90% yield.

Tyoical tyoes o f details where weld ends have been specified to j

enhance local stress conditions include:

l 1.

Welded double angle structural connections with high weld stresses (e.g. weld stresses near code allowables) which are i

field welded to intersecting beams and columns and for which i

" prying" is a credible failure mechanism.

2.

Special beam connections where beam brackets or seats are required designed for high stresses (e.g. weld stresses near 4

f code allowables) whose behavior has a tendency to " pry" the weld detail.

3.

Special highly stressed design connections which are not l

resisted in tension by a large weld segment whose behavior could result in " prying" action.

As such, the San Onofre Units 2 and 3 structural design appropriately accounts for the provisions of AISC 1.7.10 and utilizes this provision for those specific conditions for which 4

it is intended to apply.

.2 ENCLOSURE 1 Page 3 It is important to recognize the clarification specified in the second sentence of AISC 1.7.10 which states.

."This provision shall apply to side and top fillet welds connecting brackets, beam seats, and similar connections, on the plane upon which hending moment s are compute d."

The referenced allegations extend not only to Bechtel's interpretation of the provision, but also to the AISC.

The allegations contend that full welding all-around is "optimu2" and should be adopted for all details which are subject to seismic considerations.

The contention obviously extends the interpretation of weld end returns to conditions for which it is neither recommended by the code, nor required by the specific structural design conditions by the designing professional enginee r.

It was contended that weld end returns should be specified for Type A and B connection details.

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TYPE "A" TYPE "B" 1.

The details are not appropriate for the types of connections for which AISC 1.7.10 is intended to apply.

2.

The too and bottom welds (for Details A & B) are designe.

to take the tension and compression loading components f rom bending with a weld sized to take the full load accordingly.

The vertical welds are designed to take the full shear load.

In essence, the top and bottom welds behave in a tension and compression mode, not one of "pryin g. "

If the weld is cized to withstand the full design load at allowable stress levels, the weld end return would be located below the extreme weld fiber and would have limited value.

The weld end return, if provided according to the interpretations included in the allegations, would remain below the stresses at the top fiber until the section reached yield levels.

Since this design condition is prohibited by the DBE criteria, the weld end return, if installed, would have no meaning provided that the top weld is sized to resist the full design force.

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ENOLOSURE I Page 4 3.

The full "2t" weld may not be constructible orthogonal to the top weld since the curvature o f the weld at the tip of the structural member may prohibit its installation.

This condition is prevalent for angle member extreme ends and certain structural shapes.

In addition, the high stress concentration caused by the nonorthogonal weld end return may increase stres s concentrations.

4.

The entire weld detail must be proportioned in such a manner that adequate weld exists to withstand the loads.

Beam sizing is often made utilizing stock size member selection which provides some uniformity in ordering steel and some consistency in field erection.

It is, therefore, not unusual to see a member with oversize beam section properties connected by a weld detail which does not develop its full section.

The important and relevant design consideration 'is that the weld detail should be sized to withstand all design loads imposed upon it.

The arbitrary selection of weld details which develop all beam sections would lead to excessive construction delays for the olant, while adding nothing to the structural integrity o f the design.

5.

The detail utilized for tension and compression members (e.g. axial struts) do not require the same attention to weld end returns since " prying" is not, in general, a credible failure mechanism.

11-2-82 I

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ENCLOSURE II Page 1 ASME CODE SECTION III, SUBSECTION NF PIPE SUPPORTS:

VISUA L AGGEPTANG E CRITERI A FOR WELD POROSITY / SLAG, ARC STRIKES, AND CRATER FILL Porosity and Slag In addressing porosity and slag inclusions in pipe support welds, Paragraph 5.6.1.3 o f San Onofre Units 2 and 3 Construction specification CS-P207 states:

" Porosity and slag shall not be cause for rejection."

From ASME NF-5360, porosity and slag are not cited as bases for rejection of pipe support welds by visual examination.

The ability to visually examine a pipe support weld is a function of the surface condition o f the weld.

This surface condition of the weld may be minimally obscured by overlying slag.

Surface

~

slag is not of itself a cause for rejection of the weld and does not limit the weld inspector's requirement to accept the weld.

Removal of the surface slag then allows the inspector to judge the visual acceptability o f the weld surface.

Surface porosity also is not a cause for rejection of the weld.

Minimal amount o f surface porosity may result due to the metallurgical nature o f the base metal and welding filler material and methods required by the ASME Code, and as used with qualified welding procedures and welders.

This resulting surface porosity is compensated for by the conservative weld metal allowable stresse s required by the ASME Code.

Welding processes properly qualified and used in fabrication under a controlled quality program as have been implemented at San Onofre Units 2 and 3 will result in minimal porosity and slag in the weld metal.

The construction specification acceptance criteria on porosity and slag should be considered in the context of the overall quality program.

Arc Strikes Paragraoh 5.6.1.11 o f C S-P207 states:

" Arc strikes are acceptable, provided that the craters,

1) do not contain cracks (as determined by visual examination),

and 2) maximum size does not exceed 3/8-inch plan nor 1/16-inch profile.

Arc strikes shall be free of any foreign deposits which might interfere with the performance o f visual e xamina tion. "

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1 ENCLOSURE 11 Page 2 1

Even though the ASME Code, Subsection NF does not explicitly discuss are strikes, the ASME Interpretation in 111-80-109, Question (3), states that weldment surface defects are removed without regard to the cause of the surface defect.

Arc strikes are of concern only if a crack is produced or the section size is reduced beyond required design section thickness.

Arc strikes are not likely to cause cracks in plain carbon steels i

used for pipe supports.

Plain carbon steels are essentially i

nonhardenable steels.

Furthe r, Paragraph 5.6.1.11 o f the specification excludes, in particular, crater cracks from acceptability.

Minor hardening that might result from arc l

l strikes in plain carbon steel is easily accounted for in the massive surrounding matrix of the ductile material.

Arc strikes 4

might be of concern in alloyed steel materials.

However, these 4

types of materials are not used in pipe hangers, cable trays supoorts, or similar items.

1, Most codes and standards including many AWS standards do not treat arch strikes because o f the essentially cosmetic nature o f these discontinuities.

These codes and standards include:

" Specification for W lding Industrial and Mill 4WS D14.1 e

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" Specification for Metal Cutting Tool Weldments" l

AWS D14.2 -

Ekport, " Welding Ferrous bhterials for !belear i

AWS D10.5

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AWS D3.5

" Hull W' ldin g Manual" e

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ANS1 B31.1 =

" Power Piping" i

ANS I B31.3 =

"Petrole um Refinery Piping"

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Grinding of arc strikes is permitted but does not require such j

grinding provided no crater cracks are present and a gentle or

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rounded profile exists which does not encroach on the minimum design thickness.

Because the significance of are strikes in the carbon structural and oiping steels is minimal, a "Bbndestructive Examination" method which is likely to create are strikes is widely accepted e

l and in common use throughout manufacturing and construction industries.

The " prod method" of magnetic particle examination may also cause are strikes on the component surface being examined.

The f act is, that on carbon steels are strikes are so insignificant, that an "NDE" method which induces them is widely used.

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ENCLOSURE II Page 3 Weld Crater Fill Criteria, ASME Paragraph 5.6.1.9 of specification CS-P207 addresses underfilled groove weld crate r.

It state s:

" Underfilled groove weld craters shall be accepted provided the depth o f underfill is 1/16-inch or less.

Underfilled single-pass fillet weld craters shall be accepted provided the crater length is less than 10 percent of the weld length.

On multicass fillet welds, crater depth 1/16-inch or les s shall be accepted."

ASME Section III, Subsection NF does not specifically address acceptance criteria for underfilled groove craters.

In response to a specific inquiry on underfill, the ASME issued In terpre tation 111-80-109, Question (4).

The interpretation states that the ASME Code, NF-5360, addresses weld metal indications only, and is not concerned with underrun on fillet weld size or length.

The margins inherent in the engineering design o f welds accoun t for underrun on fillet size or length de fined by the visual insoection criteria.

The size of welds shown on engineering drawings accommodate the underfill to the extent specified in the Paragraoh 5.6.1.9, and this will not affect the structural integrity of the weld.

11-2-82 I

s l

I l-

El4 CLOSURE III Pa ge 1 AWS D.1.1, WELD CRATER FILL CRITERIA Reconciliation between San Onofre Ubits 2 and 3 Construction Specification CS-C16 Paragraph 3.3.3 and AWS DI.1 -72 Paragraphs 5.12.1.5(2)(b) and 8.15.1.3 regarding the filling o f weld craters is as follows, namely:

AWS 5.12.1.5(2) (b)

"All craters filled to the full cross section o f the weld."

AWS 8.15.1.3 "All craters are filled to the full cross section i

o f the weld."

C S-C 16, 3.3.3

" Underfilled groove weld craters shall be accepted provided the depth o f underfill is 1/16 inch less.

Underfilled single-pass fille t welo craters shall be accepted provided the crater length is less than ten percent of the weld length.

On culti-pas s fille t welds crater death 1/16 inch or less shall be accepted."

This Section 3.3.3 applies to miscellaneous steel only and not to the main building members.

The criteria for acceptance of welds in main building members is addressed in:

C S-C16, 3.1.5 "ISe weld may have an underfilled crater orovided that the underfilled depth does not exceed 1/32", and the crater has a smooth contour blending gradually with the adjacent weld and base metal without acute notches.

Consideration o f underfilled craters, grooves, subsize, and concave fillet welds has been based upon conservative evaluation o f decreased load carrying e ffective throat area.

The weld

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metal has substan-lally higher minimum specified yield strength than does base metal, that is, 50,000 psi versus 36,000 psi.

CS-C16 is included in its entirety in the San onofre 2 and 3 FSAR as Appendix 3.84.

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November 3, 1982 Mr. D. F. Kirsch U.S. Nuclear Regulatory Commission Region V 1450 Maria Lane, Suite #210 Walnut Creek, CA 94596

SUBJECT:

Response to NRC Letter Dated October 29, 1982, on Allegations Regarding Construction Quality at San Onofre Nuclear Generating Station, Units 2 & 3 Per your request at the November 3, 1982 site neeting, enclosed herein is Bechtel's response of October 29, 1982 from R. L.

Patterson to J. M. Curran.

Please consider this as reference to our response of November 3, 1982 from Dr. L. T.

Papay to Mr. R. H. Engelton.

j Very truly yours, L.

J. M. Curran Manager, Quality Assurance Enclosure 4

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Bechtel Power Corporatio_n Engineers - Constructors 12400 East Impenal Highway Norwalk, Cahfornia 90650 j

MA4 ADDRESS P o sou eoneo.1(massent aWx to5 ANG(L[$ CALF Q%4 9mmo TELEPHONE (2th 06a e011 October 29, 1982 Mr. J. M. Curran Manager, Quality Assurance Southern California Edison Company 2244 Walnut Grove Avenue Rosemead, California 91770 San Onofre Nuclear Generating Station, Units 2 & 3

Subject:

Bechtel Job 10079 Allegations Made by Mr. E. E. Kent

References:

(A) SCE QA Letter, Mr. J. M. Curran to Mr. R. L.

Patterson, dated September 11, 1982,

Subject:

Same as above (B) BPC Letter, R. L. Patterson to J. M. Curran, dated September 17, 1982,

Subject:

Same as above (C) SCE QA Letter, Mr. J. M. Curran to Mr. R. L.

Patterson, dated October 15, 1982 Sabject:

Same as above (D)

E. C. Rodabaugh, et. al., " Review and Assess-ment of Research Relevant to Design Aspects of Nuclear Power Plant Piping Systems" NUREG-0307, published July 1977, pp. 2-147

Enclosures:

(1) Response to Specific Allegations (2) ASME Section III, Subsection NF,1974 Edition, Summer 1974 Addendum, NF-5360 (3) ASME Section III, Subsection NF,1974 Edition.

Summer 1974 Addendum, NF-4427 and Figure NF-4 tI27-1 (4) ASME Boiler and Pressure \\essels, Interpretation.

No. 7, III-80-109 (5) ASME Boiler and Pressure Vessels. Interpretation.

No. 6 III-1-79-176 (6) Photomicrographs of Vibro-Graved and Scribed Marks

Bechtel Power Corporation f

a Southern California Edison Company October 29, 1982 Mr. J. M. Curran, Manager Quality Assurance i_

- Page Two i

Enclosures:

(cont.)

i (7) ASME Section III Subsection NB,1974 Edition, Summer 1974 Addendum, NB-4232.1, Figure NB-4233-1 (8)

/.SME Section III, Division I-Subsection NC, 1974 Edition, Summer 1974 Addendum, NC 4711, NC-4720 4

(9) Supplementary Data - Structural Welding 1

4 Design and Construction Adequacy

Dear Mr. Curran:

This letter responds to twenty one allegations made by Mr. E. E. Kent 1

pertaining to various aspects of welding, welder qualification and in-spection procedures used by Bechtel Power Corporation in the design and Additional allegations construction of the San Onofre Units 2 and 3 made pertaining to a hydrogen line wall thinning and the use of ASTM A-7 steel on Unit 1 will be addressed separately, t

'he first four allegations were transmitted in Reference ( A) and were l

responded to in Reference (B). The NRC has reviewed this information Additional information l

in NRC-Report 82-27 and has closed these items.

on one of these allegations developed as a result of the October 25, 1982 j.

meeting with Mr. Kent is provided as Enclosure (9).

1 I

The remaining 17 allegations can be segregated into six categories:

1 Five allegations were made regarding the adequacy of visual accep-A.

tance criteria employed in Bechtel's Construction Specification CS-P207 for American Society of Mechanical Engineer Boiler and Pres-i sure Vessel Code ( ASME)'Section III, Subsection NF, component sup-and one allegation was made in. relation to B31.1 (non-safety porti related piping).

(Note, although not an allegation. Reference (C) requested that Bechtel review the remaining paragraphs of Section 5.6 iI of CS-P207 to show conformance with the ASME Code.)

Two allegations were'made comparing the American Welding Society's B.

(AWS) D.1.1 Structural helding Code versus CS-C16. " Visual Inspection Criteria for Structural Steel and Miscellaneous Metal Welding to Meet i

Design Criteria."

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Bechtel Power Corporation

.- a Southern California Edison Company Mr. J. M. Curran, Manager, Quality Assurance October 29, 1982 c

Page Three These were C.

Three allegations were made relating to field operations.

pipe damage due to pipe cutter scribe marks, inadequate flare bevel weld details, and inadequate welder qualification requirenents.

D.

Three allegations were made which question the structural adequacy of welded joints.

These were the lack of prototype testing, the lack of precise knowledge of actual weld strengths, and the lack of fillet welds that completely surround the attached member.

E.

One allegation related to the question of runoff plates for groove welding not being required either by BPC design or by our suppliers.

The final two allegations on Units 2 and 3 were expressed by Mr. Kent F.

after the site tour on October 25, 1982.

The first related to the slope requirements at either a valve to pipe joint or pipe to pipe The joint where the schedules of the two components are different.

second related to thread engagement requirements on the bonnet of a check valve.

Before addressir.6 each item in particular Enclosure (1), we wish to state that the oesign and construction practices employed by BPC were governed by the appropriate code as defined in regulatory documents or as generally accepted as industry practice.

The applicable national standard that deals with welding of safety related pipe supports in nuclear power plants is the American Society of Mechanical Engineers Boiler and Pressure Vessel Code ( ASME Code). Only the ASME Code provides definitions for acceptance of pipe support welds by visual exam-ination. The Nuclear Regulatory Commission (NRC) in their Code of Federal Regulations,10CFR50 (Domestic Licensing of Production and Utilization Facilities) and Regulatory Guide 1.26 (Quality Group Classifications and Standards for Water, Steam, and Radioactive Waste Containing Components of Nuclear Power Plants), specifically approves the use of ASME III for nuclear safety related elements of the plant. The portion of the ASME Code govern-ing pipe supports is Subsection NF.

For the San Onofre Units 2 and 3 the 1974 Edition Summer 1974 Addendum is the applicable code.

Spe cifically,

San Onofre 2 and 3 construction specifications for pipe supports provide detailed acceptance criteria for welding which comply with the ASME Code and interpretations of the Code written by the ASME.

Outside the NF boundary the American Institute of Steel Construction ( AISC) specification and the American Welding Society's ( AWS) Structural Welding Code are utilized.

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Southern California Edison Company Mr. J. M. Curran, Manager, Quality Assurance October 29, 1982 Page Four It is important that the detailed wording of particular paragraphs of the construction specification be evaluated in the context of the overall BPC The quality program used for the design and construction quality program.

is comprised of documented criteria and guidelines that ensure the ade-quacy of the end product. These include design guides, National Standards and Codes, developmental work by our Materials and Quality Service (M and QS) Group, qualification of welds and materials, construction welding pro-cedures, qualification of welders, and qualification of weld inspectors.

For example, to respond to an NRC request relating to the criteria a weld-ing inspector uses to inspect a weld, the following procedure is employed:

(1) The code applicable boundaries are delineated on engineering drawings; (2) there are work plan procedures at the jobsite which precisely define (3) engineering documents such as construction specifications what to do:

and Form 84 provide inspection criteria.

Based on these documents NF weld-ing (ASME III) would be visually inspected by Pipe Support QCE's in accor-Attachments to dance with the acceptance criteria specified in CS-P207.

pressure boundaries would be inspected by Welding QCE's using visual and NDE procedures prescribed by engineering documents specified on FORM 84 Structural steel, where AWS welding is appropriate, would be inspected by QCE's to the requirements of CS-C16.

All cognizant QCE's are certified in accordance with ANSI N45.2.6 or SNT-TC-1 A, as applicable.

In general, any statenents extracted from the BPC construction specification must be examined in the context of the overall quality program.

Bechtel Power Corporation has reviewed the allegations made by Mr. E. E. Kent and found them to be without su'. stance. The design and construction prac-tices employed by BPC are consistent with normally accepted practices, codes, and regulatory requirements.

Very truly yours.

BECHTEL POWER CORPORATION 1/

tt' R. L. Patterson Division Quality Assurance Manager SHF:Jv cc: Mr. D. B. Schone, SCE (Jobsite)

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Enclosuro (1)

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Pcgo 1 Response to Specific Allegations The first six allegations were that specific sections of CS-P207 are A.

not in accordance with the AWS Code.

As previously stated, the appli-cable code covering inspection of safety related pipe supports is ASME Section III, Subsection NF, not the AWS Code.

The following discussion compares specific sections of CS-P207 versus the criteria of the ASME Code [ite=s 1 through 6 and item 11 of Reference (C)).

In addressing porosity and slag inclusions in pipe support welds, 1.

Paragraph 5.6.1.3 of the specification states:

" Porosity and slag shall not be cause for rejecc. ion."

From Enclosure (2), ASME Code,Section III, Subarticle NF-5360, porosity and slag are not cited as bases for rejection of pipe support welds by visual examination. The ability to visually examine a pipe support weld is a function of the surface condition of the weld. This surface condition of the weld may be minimally obscured by overlying slag.

Surface slag is not of itself a cause for rejection of the weld and does not limit the weld inspector's requirement to accept the weld.

Removal of the surface slag then allows the inspector to judge the visual acceptability of the weld surface.

Surface porcsity also is not a cause for rejection of the weld.

Minimal amount of surf ace porosity may result due to the metal-lurgical nature of the base metal and weldin[ filler material and methods required by the ASME III Code, and as used with qualified welding procedures and welders. This result ing surface porosity is compensated for by the conservative weld metal allowable stresses required by the ASME III Code. Welding processes prop-erly qualified and used in fabrication under a controlled quality program as have been implemented at San Onofre 2 and 3 will result in minimal porosity and slag in the weld metal.

As stated previously, to take the construction specification ac-ceptance criteria on porosity and slag out of context of the over-all quality program is inappropriate.

Paragraph 5.6.1.4 of the construction specificatio'n for pipe sup-2.

It states:

ports discusses weld convexity height acceptance.

" Convexity height may be accepted without limit.

Rollover (overlap) not exceeding 1/8 inch is acceptable provided the toe or fusion line of the weld remains visible for examina-t ion."

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This paragraph from the specification deals only with fillet welds Paragraph for pipe supports and not with piping pressure boundary.

5.6.1.4 is consistent with the requirements of Subarticle NF 4427 of the ASME III Code, which is shown in Enclosure (3), and states that a weld may vary from concave to convex. Convexity of a fillet weld deals with additional weld metal deposited over what is re-quired by the drawing and may enhance the ability of a weld to Additionally, convexity is self-sustain greater design loads.

limiting by the nature and type of weld process used and will not cause significant stress concentration in the pipe support welds.

In addition, Code Interpretation III-80-109, Question (1) (Enclo-sure (4)] confirms that convexity criteria are not addressed by the ASME III Code.

Paragraph 5.6.1.9 of the specification addresses underfilled 3

groove weld craters.

It states:

" Underfilled groove weld craters shall be accepted provided Underfilled the depth of underfill is 1/16 inch or less.

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single-pass fillet weld craters shall be accepted provided

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the crater length is less than 10 percent of the weld length.

On multipass fillet welds, crater depth 1/16 inch or less shall be accepted."

ASME Section III Subsection NF does not specifically address In response acceptance criteria for underfilled groove craters.

to a specific inquiry on underfill, the ASME issued Interpretation III-80-109, Question (4) [ Enclosure (4)]. The Interpretation states that the Code, NF-5360, addresses weld metal indications only and is not concerned with underrun on fillet weld size or The margins inherent in the engineering design of welds length.

account for underrun on fillet size or length defined by the visual inspection criteria. The size of welds shown on engineering draw-ings accommodate the underfill to the extent specified in the paragraph 5.6.1.9 and this will not affect the structural inte-grity of the weld.

Paragraph 5.6.1.10 of the specification addresses adherent weld 4

spatter. It states:

" Adherent weld spatter, not removable by wire brushing, is acceptable unless its complete removal is required for further processing such as coating."

Weld spatter on the surfaces of pipe support welds or base metal has no effect on the structural function or integrity of the sup-The ASME III Code, Subsection NF, does not require weld port.

spatter removal. The specific question of weld spatter removal has previously been asked of the ASME.

Their written response to shown in the inquiry is contained in Interpretation III-1-79-176 Enclosure (5), and is consistent wIth the specification.

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Paragraph 5.6.1.11 of CS-P207 states:

" Arc strikes are acceptable, provided that the craters, (1) do not contain cracks (as determined by visual examination), and (2) maximum size does not exceed 3/8 inch plan nor 1/16 inch profile. Arc strikes shall be free of any foreign deposits which might interfere with the performance of visual examina-tion."

Ev'en though the ASME III Code, Subsection NF does not explicitly discuss are strikes, the ASME Interpretation in III-80-109, Ques-tion (3) (Enclosure (4)] states that weldment surface defects are removed without regard to the cause of the surface defect. Arc strikes are of concern only if a crack is produced or the section size is reduced beyond that required design section thickness, Arc strikes are not likely to cause cracks in plain carbon steels 4

3 used for pipe supports.

Plain carbon steels are essentially non-i hardenable steels. Further, paragraph 5.6.1.11 of the specifica-tion excludes, in particular, crater cracks from acceptability.

Minor hardening that might result from are strikes in plain carbon

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steel is easily accounted for in the massive surrounding matrix of the ductile material. Arc strikes might be of concern in alloyed steel materials. However, these types of materials are not used' in pipe hangers, cable trays supports, or similar items.

Most codes and standards including many AWS standards do not treat are strikes because of the essentially cosmetic nature of these discontinuities. These codes and standards include:

" Specification for Welding Industrial and Hill AWS D14.1 =

Cranes."

" Specification for Metal Cutting Tool Weldments."

AWS D14.2 =

Report, " Welding Ferrous Materials for Nuclear AWS D10.5 =

Power Piping."

" Hull Welding Manual" AWS D3.5

=

ANSI B31.1 =

Power Piping ANSI E31.3 =

Petroleum Refinery Piping The Bechtel position on arc strikes permits grinding of arc strikes but does not require such grinding provided no crater cracks are present and a gentle or rounded profile exists which does not en-croach on_the minimum design thickness.

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fillet welds for a weldment combining a full penetration groove weld with a fillet weld cover.

Paragraph 5.7.2 of the specifica-tion states:

" Pipe support drawings for B31.1 piping that indicate full-penetration groove welds with fillet covers may be welded as just fillet welds.

The minimum fillet weld size for B31.1 pipe integral attachments shall be as follows:

Fillet weld size = (0.7) x (the wall thickness of the a.

thinner of the pipe wall or the dummy stub wall).

If the attachment is tension loaded due to a snubber or b.

variable spring hanger, engineering calculations must be performed to justify the strength of the weld."

Since the reference is to B31.1 piping, the scope of this paragraph in the specification is limited to non-safety related piping sys-

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These non-safety related areas of the power plant do not t ems.

affect the safe operation of the nuclear safety related systems or The the ability of the nuclear systems to be safely shut down.

original design using all full penetration groove welds with fillet cover welds was found to be very conservative.

Therefore, an al-ternate design using fillet welds was developed.

Engineering eval-uation has determined that the minimum fillet weld size of (0.7) x (the wall thickness of the thinner of the pipe wall or the dummy Para-stub wall) is adequate for bearing type loads (5.7.2.a).

graph 5 7.2.b requires a substantiating calculation to assure the adequacy of the design when tension loads are applied.

In addition, field procedures require the preparation of an FCR No FCR's for any modification of the dummy stub to pipe welds.

were found in a search at the site for cases where this alternate procedure has been applied.

It is therefore concluded that all dummy stubs installed with fillet welds have been authorized by engineering and properly sized to carry the imposed loads.

Reference (C), item 11, requested that BPC also review the remaining paragraphs of Section 5.6 for compliance with the ASME Code.

5.6.1.1 "The weld meets or exceeds specified size requirements.

Either or both fillet weld legs may exceed design size by 3/16 inch for welds up to and including 5/16 inch fillet, and 1/4 inch for welds larger than 5/16 inch fillet. Welds may be longer than specified. Continuous welds may be accepted in place of intermittent welds."

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Subsection NF of the Code is silent on this question. This criteria precludes weld rejection when the welder has provided oversized fillet welds within the bounds stated.

It also permits acceptance of fillet welds which are longer than the drawing indicates. Both of these vari-ances result in increased weld material deposition which can not reduce the strength of the weld but may increase its load carrying capability.

5.6.1.2 "The fillet leg dimension may not underrun the nominal fillet size by more than 1/16 inch for more than 10 percent of the weld length. For flange to web joints the undersize may not be wi, thin two flange thicknesses of the weld end."

Subsection NF of the Code is silent on this point. However, ASME Inter-pretation III-80-109 (Enclosure (4)3 issued May 12, 1980 is as follows:

Are undersized dimensions greater than 1/16 inch of a weld Question:

considered as relevant indications when detected by visual examination in accordance with NF-5360(a)?

Reply:

NF-5360 addresses weld metal indications only.

It does not address underrun on fillet size or length.

Engineering justification for allowing the fillet leg dimension to under-run the nominal fillet size is based upon the inherent margin in the de-For example, calculations on file demonstrate that when a 3/16 sign.

inch fillet weld (the smallest weld specified for use in construction of pipe supports) is undersized by 1/16 inch for 10 percent of its length, it has a usable strength of about 160 percent of the design limit load.

5.6.1.5 "The height of reinforcement of butt welds on each face of the weld shall not exceed the following:"

Nominal Thickness Maximum Reinforcement (inch)

(inch)

Up to 1 incl.

3/32 Over 1 to 2 incl.

1/8 Over 2 to 3. incl.

5/32 ~

Over 3 to 4 incl.

7/32 Over 4 to 5, incl.

1/4 Over 5 5/,16 This criteria is identical with the ASME III Code NF 4426.

5.6.1.6 "There are no cracks or linear indications in the weld exceed-ing 1/16 inch."

This criteria is in accordance with the ASME III Code Subsection NF, Subarti-Subarticle 5360(a) which permits indications up to 1/16 inch.

cle 5360(b) precludes the acceptance o'r any cracks.

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" Thorough fusion exists between the weld metal and base metal'.

5.6.1.7 except as permitted as rollover in paragraph 5.6.1.4."

Fusion is not specifically addressed by the Code.

This paragraph gives additional criteria for inspection.

" Undercut (underfill) not exceeding 1/16 inch may be accepted 5.6.1.8 for the full length of the weld provided it does not encroach For members welded from both i

on minimum design thickness.

sides, the criteria shall be applied independently except that the cumulative depth shall not encroach on the minimum design thickness."

,i The This criteria is more stringent than the requirements of NF 4424 e

latter permits undercutting up to the minimum design thickness of the base metal while this criteria limits undercutting to 1/16 inch or up 4

to the minimum design thickness of the base metal.

The next two allegations made concerned specific differences between B.

the AWS D1.1 Code and BPC Construction Specification CS-C16.

" Reconcile the apparent The first question was given in Reference (C):

differences between AWS D1.1 1972 paragraph 4.4 and CS-C16 paragraph This allegation is identical to that d

3.3 7. regarding arc strikes."

responded to previously in our discussion of paragraph 5 6.11 of CS-P207 The major. difference is that AWS D1.1-74 paragraph 4.4 refers to arc strikes outside the area of pe rmanent welds.

(1) do

" Arc strikes are acceptable provided that the craters.

337 not contain cracks (as determined by visual examination), and (2) maximum size does not exceed 3/8 inch plan nor 1/16 inch Arc strikes shall be free of any foreign deposits profile.

which might interfere with the performance of proper visual i ns pect ion."

It should be noted that the application of Section 3 3.7 is confined Arc only to miscellaneous steel and not the main building members.

strikes are harmful e91y if they produce a crack or diminish the re-i l

For steels used in the construction of a quired design thicknr.is.

nuclear power plant, are strikes are not likely to produce a crack because these mild carbon and austentitic stainless ste,els are not I

appreciably hardenable.

In addition, the steels used in the building structural framework and the piping system and electrical system sup-ports are not susceptible to cracking resulting from arc strikes.

i Because the significance of are strikes in the carbon structural and l

piping steels is minimal, a " Nondestructive Examination" method which arc strikes is widely accepted and in common use is likely to throughou manufacturing and construe, tion industries.

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The second allegation was presented by Mr. Dennis Kirsch in the Octo-b er.19, 1982 meeting. He requested a reconciliation between CS-C16 and AWS D1.1-72 paragraphs 5 12.1.5(2)(b) and 8.15.1.3 Both of these sections refer to filling of craters.

5.12.1.5(2)(b). "All craters filled to the full cross section of the weld."

8.15.1.3 "All craters are filled to the full cross section of the weld."

333

" Underfilled groove weld craters shall de accepted provided the depth of underfill is 1/16 inch or less. Underfilled 4

single-pass fillet weld craters shall be accepted provided the crater length is less than ten percent of the weld length.

On multi-pass fillet welds crater depth 1/16 inch or less shall be accepted."

This Section 3 3 3 applies to miscellaneous steel only and not to the main building members.

Consideration of underfilled craters, grooves, subsize and concave fillet welds has been based upon conservative evaluation of decreased load carrying effective throat area. The weld metal has substantially higher minimum specified yield strength than does base metal, that is, 50,000 psi versus 36,000 psi.

Mr. Kirsch also requested SAR references for these and any other excep-tions. CS-C16 in its entirety is in the San Onofre 2 and 3 FSAR as Appendix 3 8A.

C.

The next three allegations related to field operations:

The first of these allegations was that pipe fitters used a pipe 1.

cutter to make scribe marks for socket weld fit-up, and these marks would cause stress concentrations. While perhaps, not a particularly t

desirable method to use for scribe marks, any " mechanical damage" would be controlled under our overall quality program.

Inspection and acceptance criteria are specified in Work Plan Pro-cedure/ Quality Control Instruction 400 (WPP/QCI-400). By proce-dure, minor surface defects not requiring corrective action are defined as, " Defects in pipe having a depth not exceeding 5% of It the nominal pipe wall thickness., or 1/16", whichever is less."

should be noted that the 55 limitation is a more stringent re-quirement for small piping (2 inch #and under) than the 1/16 inch requirement.

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" Mechanical damage" is defined as scoring, gouges, pits, suspect lap, seams, and similar types of surface damage or defects that may exceed the " minor surface defects" above.

Visual inspections for physical damage on piping material are per-formed by certified QCE's and include the use of pit gauges to verify the depth of scribe marks.

All scribe marks, including those made by a pipe cutter on socket welded pipe are inspected to these criteria. Remedial action of non-conformsnces are dispositioned in NCR's.

As a design analogy to the effect of the groove on the integrity of the pipe, reference is made to the misalignment conditions per-NUREG-0307 (Reference (D)].

mitted in Section III of the ASME Code.

paragraph 2.9 2.2, " Girth Butt Welds" states in part.

"It is recognized that thin wall pipe can have relatively high weld reinforcements; producing a significant " notch" at the It is also recognized that misalignment can signifi-weld.

Both of cantly increase the local stresses in the welds.

these aspects were considered in assigning the relatively high C and K indices of 1.4 and 2.5, respectively."

2 2

x K )/2 Therefore, the Stress Intensification Factor (SIF) of (C,1gniricant p

= (1.4 x 2.5)/2 = 1.8 is considered acceptable for this 3 notch effect and misalignment. Furthermore, Figure NC-3673 2(b)-1 of ASME Section III requires use of 1.8 SIF for girth butt weld (as l

welded). This 1.8 SIF requirement is also referenced in NUREG-0307

[ Reference (D)). The applicab,le SIF for the type of scribe marks under consideration and as shown in photographs of Figures 1 through 4 of Enclosure (6) are judged to be less severe than the misalign-ment and reinforcement covered in the referenced document and less than 1.8, In accordance with Figure NC-3673 2(b)-1 of ASME Section III, SIF of 1.8 is applicable for girth butt welds with misalignment greater Therefore, for the than 10 percent of the nominal wall thickness.

scribe mark depth limitation of 5 percent of the pipe wall thick-ness, use of SIF of 1.8 is conservative.

The SIF used for socket welded connections is 2.1 (per Figure NC-3673 2(b)-1 of ASME Sec-tion III) which also includes the notch effect. The SIF of 2.1 is For the San Onofre 2 greater than the SIF of 1.8 developed above.

and 3 project, a SIF of 2.1 is used in design for all socket welds and therefore the socket weld is the governing design factor and not the scribe mark.

The moment loadings at the socket weld and the scribe mark (approximately 2 inches away) are essentially identic al.

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ing for the 12.5 percent manufacturing tolerance, the nominal wall thickness provided exceeds the calculated wall thickness by at least 40 percent.

'Therefore the 5 percent depth limitation is adequate for pressure design as well.

The second allegation in this series related to flare bevel welds.

2.

The allegation was unspecific.

An apparent nonconforming condition was identified during a normal The nonconfor-QC inspection of cable tray support installations.

mance related to the underfill of a flare bevel weld associated No acceptance criteria existed with a particular support detail.

to disposition a partial penetration flare bevel weld as specified on the engineering design drawings. The problem was determined to be programatical in nature and a Deficiency Evaluation Report was

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generated (DER No. 69, dated November 4, 1980).

The following is a summary of the course of action which transpired to close out the referenced DER:

The associated design disclosure documents (Construction a.

Specification and SAR) were revised to incorporate the appli-cable acceptance criteria.

i All partial penetration, flare bevel welds were reinspected to b.

the revised criteria.

Engineering performed a review of the original design and c.

identified the minimum acceptable dimension for the partial penetration flare bevel weld, All nonconforming conditions were corrected and no further d.

applications of this type of detail were identified.

The third allegation in this series related to welder qualification.

3 Mr. Kent stated that sheet 20, note 1 of Welding Qualification docu-ment WQ-2 permits weld reinforcement of 1/3 inch contrary to para-graph 3.6.2 of AWS D1.1.

Sheet 20 is not part of,the welder qual-Review of the ification program used on San Onofre Units 2 and 3 document, however, concluded that the 1/3 inch was in fact a typo-This is consistent graphical error and should have been 1/8 inch.

with detail E also contained on sheet 20.

The additional allegations were made concerning the structural adequacy D.

the need

_ These allegations in particular were:

of structural joints.

for fully welded connection details., prototype testing of weld details, and methods utilized in the selection of actual weld strength, e

e y

- - ~ -

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Need for Fully Welded Connections There are no provisions in any structural design code, nor is it standard design practice, to require fully welded details for use in all structural, pipe support, or cable tray support designs.

All structural design texts, specifications, codes, and technical references permit a broad variety of acceptable design details which have been shown to provide required structural integrity to meet the intended function of the supports. For example, the American Institute of Steel Construction (AISC) Specification is the national specification and design guide utilized by structural In Sec-engineers for the design of structural steel components.

tion 1.2 of the AISC Specification three basic types of construc-tion and associated design assumptions are permissible, utilizing design details which dictate the member sizes and corresponding strengths. These three types include:

0 Type 1 - " Rigid-frame" (continuous frame) details which possess sufficient rigidity to minimize angular movement between intersecting members.

A fully welded or heavily bolted mo4Whent resistant connection is representative of this design type.

Type 2 - " Simple" frame details which permit unrestrained, free-ended rotation for specified loading conditions, neces-sitating the design of the connections to resist shear loads only.

A lightly welded or lightly bolted connec-tion, or more heavily welded or bolted connection with details which have flexible rotational capability (e.g.

double angle connections) are representative of this de-sign type.

' Type 3 - " Semi-rigid framing" which permits partial rigidity (par-tially restrained) for connections of structural compo-nents providing the moment resistant capacity can be technically supported through accepted procedural analy-sis to confirm the degree of restraint. This design type f alls between Types 1 and 2.

The selection of the connection type from these three approved types has been made by Bechtel engineering based upon consideration including intended function, required design integrity, types of steel available, constructibility preferences, applicable codes, The selection regulatory requirements, and other relevant aspects.

of a particular connection detail is made to assure structural con-sistency and technical compatibility with the analysis and design of the structural system. Any arbitrary alteration of the connec-tion detail outside the bounds specified in the design drawings or construction specification could nyalidate the basic design I

=

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Pcge 11 assumptions.

It could also result in the overstress of structural components in excess of specified code allowables.

The connections utilized for the San Onofre Units 2 and 3 project have been de-signed, reviewed and checked by qualified engineers consistent with NRC quality requirements.

As such, complete technical consistency and design compatibility have been provided in the San Onofre 2 and 3 design throughout. See Enclosure (9) for additional information.

2.

Prototype Testinr, of Weld Details The design.of weld details and welded connection details are based upon nationally recognized design procedures which are referenced in the project design criteria are specified in the SAR, FSAR and other regulatory documents.

Such details utilize recognized anal-ytical techniques which appear in standard textbooks as well as referenced codes.

These designs are based upon accepted procedures which have evolved since the founding of the American Institute of Steel Construction in 1921.

This organization establishes, through close interaction between industry and university development, ex-tensive research and engineering studies programs to establish

~

acceptable design procedures, economical and efficient design re-commendations, and methods to improve and control the quality of structural steel.

The use of the AISC Specification and AWS Code in the selection of relevant weld details precludes the need for prototype testing, providing the material, weld red and welding procedures conform to the stated code requirements, utilizing basic engineering mechanics principles. M and QS has performed over 800 welding qualification tests to substantiate various welding configurations, materials, and essential welding variables.

The AISC Manual states, "The AISC Specification and the Structural Welding Code of the American Weld-ing Society exempt from tests and qualification most of the common welded joints used in steel structures.

Such exempt joints are designated as prequalified." The use of prototype testing for weld details is necessary only when unusual non-code weld rod or plate materials are selected, and prior research and testing. utilized in code recommendations cannot be directly applied. Such prototype testing can be utilized to justify the use of the proposed design.

In the San Onofre 2 and 3 design, no unusual materials or details are utilized. The San Onofre 2 and 3 design utilizes common indus-try and code accepted structural plate materials, and standard weld rod materials. As such, no prototype testing is required. All materials, procedures, and code applications are described in de-tail in the project design criteria and the San Onofre 2 and 3 SAR and FSAR.

3 Actual Strength of Welding Materials The actual strength of welding materials is based specifically upon code allowables for the particular component and its function.

The allowable stresses of weld rod material is based upon the spe-cific electrode type (e.g. AWS AS.1 or ASME SA 5.1. E70XX) and i

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Page 12

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i the matching base metal comprising the joint detail (e.g. ASTM A-36 or A570). The strength calculations are based upon these allowable stresses, which are a percentage of the minimum specified material properties, and engineering mechanics behavior assumptions speci-fied in code and textbook references.

This approach results in To significant tensile strength margins over allowable values.

assure that appropriate weld rod and connecting materials are util-ized, the design specifications include provisions for material l

verification, material identification and control, and testing j

The allowable requirements to the minimum specified properties.

stresses specified in the codes are based upon extensive university and industry testing and research, and years of shop and field experience. The selection of AISC and AWS welding materials and I

prequalified welding details results in a highly conservative welding design basis for the San Onofre 2 and 3 project.

The final allegation relates to the use or non-use by BPC and their E.

suppliers of runrf f plates for groove welding described in AWS D1.1, paragraph 4.6.1.

The use of runoff tabs or extended backing bars are referred to in the Structural Welding Code, AWS D1.1-74, Article 4.6.1 as follows:

" Groove welds shall be terminated at the ends of a joint in a manner that will ensure sound welds.

Where possible this shall be done by use of extension bars or runof f plates."

l adhere to The allegation claims that Bechtel and its suppliers do not this portion of the Code.

j The use of rur.off tabs is usually restricted to high current density automated welding processes such as submerged are and gas metal are machine welding processes where the control of weld end fill is not possible. Since the bulk of the welding at power plant sites is shielded metal arc welding, the control of the weld end fill is of no concern because the process is one of low current density and can be i

readily controlled by the welder to ensure sound welding including complete filling of the groove weld ends.

As to weldments produced by suppliers of structural steel (fabricated beams, etc.) the same circumstances would control. Wher,e the high cur-rent density processes are utilized, extension bars are generally used.

Where extension bars are not used, the beam or structural material is cut off at a point where the weld is full section and meets the length i

1.

requirements of the Purchase Order.

The Structural Welding Code AWS D1.1-77, Revision 2 recognized the fact that the article on groove weld termination should not be inclusive of For this reason Article 4.6.1 has been changed all welding processes.

in the 1977 edition and reads as follows: 4

[

- ~. - -

P:ge 13

" Welds shall be terminated at the end of a joint in a manner that will ensure sound welds.

Whenever necessary, this shall be done by use of extension bars and runoff plates."

This same wording continues through the latest edition of the AWS Code (D.1.1-82).

Mr. Kent alleged in the meeting between SCE, BPC and the NRC af ter his F.

site tour that there existed cases where BPC did not meet the ASME Code requirements on a 3: 1 slope in the body of several Kerotest valves at the valve to pipe joint. He also stated that this was true at the union of two different sized pipes.

He stated that NB, NC, and ND-4232 re-quires this : elope and that on the tour they had observed many cases Our where this slope was obviously steeper, approximately 1:1 or 45.

review of this allegation indicates again his superficial knowledge of the ASME III Code.

Enclosure (7) extracted from Subsection NB of the ASME III Code specifically states that the 3: 1 slope requirements is in the weld prep area and extends only for a distance of 1.5 times the fhereafterthevalvebodyorhigherschedule thinner wall thickness.

angle.

Enclosure (7), page 3, is a copy of pipe is flared up to a 45 a San Onofre Units 2 and 3 drawing showing the required slope details consistent with the ASME Code. Observation of two valves taken from spares and the valves and piping observed during the tour verified that all code requirements were met.

The last allegtion made by Mr. Kent on Units 2 and 3 concerned thread engagement en one of sixteen bonnet to body studs for swing check valve The stud was recessed slightly into the upper nut.

53-1204-MU-087 His allegation was that this indicated short studs were in use and the thread engagement did not meet the ASME Code.

The valve in question was supplied by the manufacturer, Anchor Darling, in the same condition as installed. The bonnet has not been removed since the valve was re-ceived at the San Onofre site.

Requirements for installation or fabrication of mechanical joints are described in Subarticles NB/NC/ND-4700 (Enclosure (8), page 1) (since NB/NC/ND-4700 are identical, only NC-4700 is shown in the enclosure).

Subarticle NC-4711 " Thread Engagement", required all bolts or studs to However, only Code Class 2 be engaged in accordance with the design.

and 3 F ping flanged joints are required to have bolts extend completely i

through the nuts, Subarticle NC-3647.6(a) [ Enclosure (8), page 2).

In all other bolted connections used for pumps, valves, tanks and vessels, thread engagement is a matter of design.

It is our conclusion that Mr. Kent's allegation is without basis since the Code does not require bolts to be flush with the top of the nut (except for Code Class 2 and 3 piping flar.ged joints), the vendor did not require it in his maintenance manual, and the valve was designed to be used with the studs and nuts provided.

4 S

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Sh ut 1 of 1 SECTION 111,I'lVISION 1-StJBSECTION NF N F.5 351-N F.55 30 3 times the width. Rounded indications are it:-

nondestructive examination operations under this

(,

dications which are circular or elliptical with the Subsection are competent and knowledgeable of the A

applicable examination requirements to the degree length less than 3 times the width.

specified in NF-5520. All nondestructive e x-NF 5352 Acceptance Standards aminations required by this Subsection shall be performed and the results evaluated by quahfied (a) Only indications with major dimensions greater nondestructive examination personnel. He as-than bin. shall be considered relevant.

signment of responsibilities to individual personnel (b) Unless otherwise specified in this Subsection, will be at the discretion of the Manufacturer or the fellowing relevant indications are unacceptable:

Installer.

(/) Any cracksorlinearindications, (2) Rounded indications with dimensions great-er than bin.

NF-5520 PERSONNEL QUALIFICATION (3) Four or more rounded indications whose major dimensions are greater than % in, when the in.or indications are in a line and are spearated by NF 5521 Qualification Procedure less edge to edge.

(4) Ten or more rounded indications whose (a) Personnel performing nondestructive ex-

m. when the amination under this Section shall be qualified in major dimensions are greater than mdications are in any 6 sq m. of surface with the accordance with SNT-TC-l A,1 Supplements and -

major dimensions of this area not to exceed 6 m.,with Appendices as applicable for the technique and the area taken in the most unfavorable location methods used. For nondestructive examination me-relative to the mdications bemg evaluated.

thods not covered by Sb7-TC-1 A documents, per-sonnel shall be qualified by the Manufacturer or NF-5360 ACCEPTANCE STANDARDS FOR Installer to comparable levels of competency by VISUAL EXAMINATION OF subjection to comparable examinations on the par-WELDS ticular method involved. De practical portion of the

[

(a) Only indications with major dimensions greater qualification shall be performed using the Man-than in. shall be considered relevant.

ufacturer's or Installer's procedure or part rep-(b) Unless otherwise specified in this Subsection, resentative of the Manufacturer's products.

cracks or other linear indications are unacceptable.

(b) The emphasis shall be on the individual's ability Perform the nondestructiu examination in ac-t NF-5400 EXAMINATION OF SPRINGS C rdance *ith the *Pplicable procedure for the FOR CLASS 1 COMPONENT intended 8PP cation.

li STANDARD SUPPORTS (c) For nondestructive examination methods that c nsist of more than one aperation or type, it is NF-5410 REQUIRED EXAMINATION AND Permissible to use personnel qualified to perform one ACCEPTANCE STANDARDS or more operations. As an example, one person may Springs for Class I component standard supports be used who is qualified to conduct the examination shall be examined after coilingby either the magnetic and another may be used who is qualified to interpret

[1

'W and evaluate the results.

particle or liquid pentetrant method. Springs with seams, slits, or quench cracks longer than 3% of the bar diameter shall be rejected.

NF 5530 RECORDS NF-5500 QUALIFICATIONS OF Personnel qualification records shall be retained in NONDESTRUCTIVE accordance with NA-4900.

EXAMINATION PERSONNEL NF 5510 GENERAL REQUIREMESTS isNT.Tc. A and suppteinents is a Jt,comm,w,d rr ct.ce fa, Nondestructuve Testsng Persmn,t Qwhpcarson and Cerrupcanon it shall be the responsibility of the Manufacturer or petished y & Aniencan sociciy ro, Noodesmvc Testing.

Installer to ' assure that all personnel performing 914 Qucago Avenue. Evanston. Ithnois 60202.

68 i

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Enclosure (3)

Sheet 1 of 2 SECTION !!!, DIVISION 1-SUBSECTION NF NF 4400-NF.4440 NF-4400 RIJLES GOVERNING MAKING, ripples, grooves, overlaps. abrupt ridges. and sallep

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to meet the requirements of (a) through (d) below.

EXAMINING, REPAIRING, AND HEAT TREATING WELDS (a) ne surface condition of the finished weld shall be suitable for the proper interpretatim of ra.

NF-4410 PRECALTIONS TO BE TAKEN E

• ' '#S""*

BEFORE WELDING aminations of the welds. In those cases where there is

• 9"*

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NF-4411 Identification, Storage, and Handling interpretatt. of a radiographic film,the film shallbe compared to the actual w eld surface for interpretation gg y

and determination of acceptability.

Each Manufacturer or Installer is responsible for (b) Reinforcements are permitted in accordance control of the welding electrodes and other materials with NF-4426.

which are used in the fabrication and insta!!ation of Undercuts shall not encroach on the required (c/

components supports (NF-4120). Suitable identi-section thickness.

fication, storage, and handling of electrodes. flux, and (d) If the surface of the weld requires gnnding to other welding materials shall be maintained. Pre-meet the above criteria, care shall be taken to avoid cautions shall be taken to minimize absorption of reducing the weld or base material below the required moisture by electrodes and flux.

thickness.

~

NF-4412 Cleanliness and Protection of Weld Reinforcement of Butt Welds NF-4426 Surfaces The surface of the reinforcement of a!! butt welded The method used to prepare the base metal shall joints may be flush with the base materialor may have leave the weld preparation with reasonably smooth uniform crowns. The height of reinforcement on each surfaces. The surfaces for weldmg shall be free of face of the weld shall not exceed the followmg scale. rust, oil, grease, and other deleterious foreign thickness:

matenal. The work shall be protected from de-(

ktenous contamination and from rain, snow, and Nominal Masimum wind during welding. Welding shall not be performed hickness,in.

Reinforcement,in.

on wet surfaces.

Up to 1,inct h

Over I to 2, incl.

NF-4420 RULES FOR MAKING WELDED Over 2 to 3, incl.

b JOINTS Over 3 to 4, incl.

h Over 4 to 5, incl.

NF-4421 Backing Strips h

Over 5 The materials for backing strips,when used, shall be compatible with the base metal (N F-4240).

NF-4427 Shape and Size of Fillet Welds NF-4422 Peening Fillet welds may vary from convex toconcave.The The weld metal may be peened when it is deemed size of the fillet weld shall be determined in ac-necessary or helpful to control distortion.

cordance with Figure NF-4427-1.

NF-4423 Miscellaneous Welding Requirements Before applying weld metal on the second side to be welded, the root of double welded joints shall be When plug welds are used on component supports.

weld shall first be deposited around the a fillet prepared by suitable methods, such as chipping, circumference at the bottom of the hole.

i grinding, or thermal gouging to sound metal.

/

NF 4440 EXAMINATION OF WELDS NF-4424 Surfaces of Welds 2

All welds shall be examined in accordance with the I

As welded surfaces are permitted. However, the

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surface of welds shall be sufficiently free from coarse

, requirements of NF-5000.

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dntet 4 Ot 4 NF4000 FABRICATION AND INSTALLATION NF 4450-NT 46tl SURFACE OF

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VERTICAL WEMBERS CONCAVE

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4 CONVEX FILLET WELO FILLET OF D

SURFACE OF L

WELO g o__

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HORIZONTAL WEWBERS

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M-THEORETICAL THROATW b2E OF EOUAL LEG FILLET WELD WELO NOTE: THE " SIZE" OF AN EOUAL LEG FILLET WELD IS THE LENGTH OF THE LARGEST INSCRIBE 0 RIGHT ISOSCELES TRI ANGLE. THEORETICAL THROAT sO.7 s SIZE.

SURFACE OF VERTIC AL WEMBERS u

CONVEX FILLET WELD FILLET WELD SIZE OF SURFACE OF

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WELD

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HORIZONTAL WEWBERS

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THEORETICAL THROAT

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" SIZE OF WELD

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UNEOUAL LEG FILLET WELO NOTE: FOR UNEOUAL LEG FILLET WELOS, THE SIZE OF THE WELD IS THE LEG LENGTHS OF THE LARGEST RIGHT TRI ANGLE WHICN CAN BE INSCRIBED WITHIN THE FILLET WELO CROSS SECTIOR FIG. NF-A4271 SIZE OF FILLET WELDS

~

NF-4450 REPAIR OF WELD METAL NF-4453.1 Defect Remosa!. Unacceptable defects DEFECTS detected by the examination or test required by NF-5000 shall be removed by mechanical means or by NF-4451 Gener:1 Requirements thermal gouging processes.

{..

Unacceptable defects in weld metal detected by NF-4453.2 Requirements for Welding Materials, examinations required by NF-5000 shall be Procedures, and Welders. The weld repair shall be eliminated and, when necessary, repaired in ac-made using welding materials, welders, and welding cordance with the requirements of this subsubarticle.

procedures in accordance with NF-4125 and NF-4300.

NF-4452 Elimination of Surface Defects NF-4453.3 Blending of Repaired Areas. After repair.

Weld metal surface defects may be removed by the surface shall be blended uruformly into the grinding or machining and need not be repaired by surrounding surface.

welding, provided that the requirements of (a). (b),

NF-4453.4 Examination of Repair Welds. The and (c) are met.

examination of weld repairs shall be repeated as (a) The remaining thickness of the section is not required for the original weld.-

reduced below that required by NF-3000.

NF-4453.5 Hest Treatment of Repaired Areas. Re (b) The depression, after defect elimination, is repaired area shall be heat treated when required by blended uniformly into the surrounding surface.

gp g (c) The area is examined by a magnetic particle or liquid penetrant method after biendingto ensure that gp q g.F NMEN'T the defect has been removed orinindication reduced to an acceptable limit.

NF-4610 WELDING PRElIEAT AST)

NF-4453 Requirements for Making Repairs to Welds NF 4611 When Prebest is Nccessary Excavated cavities in weld metal, whose depths

,The need for and temperature of preheat are reduce the section thickness below the requirements dependent on a number of factors, such as the of NF-3000, shall be repaired in accordance with the chemical analysis, degree of restraint of the parts fo!!owing subparagraphs.

being joined, elevated temperature, physical prop-57 i

,p.

4

Enclosure (4) no so tos Shast 1 of 1 Interpretation: III.80109 I

Subject:

Section III.Dmsion 1.NF 4427 Shape and Sue of Fdiet Welds.NF-4452 Elimination of Surface Defe ts.NF.5.160 Acceptance Standards for Vanual Esamination. Appenda XVil 2454 Butt and Groove Welds Date issued.

May 12.1950 File.

NI 8012 Question (1): Does Section !!l. Subsection NF provide requirements for the masimum consexity of fdlet welds?

Reply (1): No.

Question (2): Is the theoretical throat of a fdlet seld the minimum effective throat?

Rep!)(2) Yes.

Question (3): Do weld metal surface defects (NF-s452) include are strikes?

Reply (3): NF-5452 provides for etuniaation of meld metal surface dere:ts without reference to the cause of the surface defe:t.

Question (4): Are undersize dimensions. greater than 1/16 in..of a seld considered as reles ant inds.

cations when detected by visual emarnina: son in acecrJanee with NF.5360(a)?

Reply (4). NF-5360 addresses sel:1 meta! mdicatter.s only h does not address underrun on fillet sue or length.

Question (5): Does XVII 24544a of the 1977 Editwn mean that a %in double partia! penetration F oove seld jouung 3 in. ths:k matenal together is unacceptable?

Reply (5). Yes.

Question (6): Is it permissible to use a single.besel full penetration stId s1thout the use of backing stnps or back gouging in the fabrication of selded tee joints in Itnear type component supports?

Reply (6). Yes.

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Interpretation. 1111 79 176 kbject.

Section 111. D:i-ion 1 Di.sion 2 Reid Sp: er Date issued Octeber 23.1979 File:

bl 79 200 Westion: Is it required by Se: tion ID, Dwision I and'or Division 2, that we!d spatter be removed for cosmetic purposes if it does not interfere with further pra:emng or the use of the item in service,or if it does not interfere with subsequent h*DE,or if pamt os other protective costu g is net required?

Reply: It is not required by Section Ill.D:dsion I and'or D: vision 2 that weld spatter be removed provided it does not interfere or Lr.n subsequent Code required activities.

Interpreta tion-III.I 79177

Subject:

Section !!!, Dinsion I, Appen&x V, N-2 Data Report Form

~

Date Issaed October 23,1979 FJe:

51 79 223 i

Questaon: % hen a Certificate of Authort2rior. is extended to a fic!d site,what data report form should be used for field fabricated par.s and appatenan:es such as cor. tai. ment veue! eqaiprnent hatches?

Reply : Rhen a Certificate of Authon12 tion is extended to a field site for field fabnestion of parts or appurtenances.the N 2 Data Repon Form shad be used for those parts and appurtenances inter.ded to receive an NPT stamp. The Authorized Inspector at the field site who has the responsibihty for assunng that Code requirements have been met that so signify by completmg the Certifi:.ation of Shop Inspection" portioc of the N 2 Data Report Form (Note The text of the Tertificat5on of Shop Inspection ** box does not address the issue of shere the inspection was made,i.e., shop or 6 eld it does address the issues that inspe: tion was performed by a duly authorned persoc at a point in time.)

hierpretation: III.I 79178

Subject:

Section 111,Dmsion I, Case N 71 Additiona' Materials for Component Supports Date issued:

October 23,1979 File:

bl 79 247 4estion: How are the maximum allowable vas to be calcu!sted for SB 150 Grade 642 m used in accordance with Section 111 Case N 714 m : lass 1,2,3, and MC component supports?

Iteply: The allowable stresses an. st 733,. s ies for Plate and SheD Type Component Supports me provided in Tables I and 2 ef Code Le N h+ P x linear Type Component Suppor s for bars made from thss material, Table 3 provides the S, values needed for the appb:able forrnulas of : 7112200,and for botting trade to this specification and grade,the IJ1tzmate Tensue Strength Values of Table 5 may be amed with the equatons appbcable to austenitic steels from XVII.2460 of Appendsx XV11.

29

Enclosure (6)

Pege 1 of 3 Scribe Lines for Socket Welds The attached photographs show four samples of 3/8 inch 0.0. x 0.065 inch t

wall stainless steel tubing. Two of the samples were circumferentially marked with a scribinpftool and the other two were circumferentially marked and numbered with a vibro-graving tool.

The depth of each type of mark was measured at 100x (magnifications) and I'

the depth it reported below. The depth measurement represents the depres-sion below the original surf ace.

Wall Thickness At Sa=ple Depth of Depth of Cire. Mark Numbers No, Marked By Cire. Mark (in.)

Numerals (in.)

(in.)

(in.)

1 Vibr o-Gr avi ng 0.0005 to 0.003 0.001 to 0.002 0.070 0.072 2

Vibro-Graving Up to 0.003 Up to 0.003 0.068 0.067 0.070 3

Scribe Up to 0.0c15 0.068 4

Scribe Up to 0.003 Figure 1 shows the as received scaples.

Figure 2 shows the vibro-graving surface numbers at 10x and the cross section at 100x. Figure 3 shows the vibro-graved circumferential mark at 10x and the cross section at 100x.

Figure 4 shows the scribed circumferential mark at 10x and the cross section a t 100x. Although both of the marking techniques produced marks of approx-imately equal depth, (Samples 1, 2 and 4) the scribed surface marks are more uniform and not as sharp as those made with t he vibro-graving tool.

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Sheet 1 of 3 NB-4000-I ABRICATION AND INSTALLATION REQUIREMENTSNB.4MO NB.4:33 NB-4230 FITTING AND ALIGNING NB 4232 Stasimum Offset of Aligned Nctions (a) Alignment of sections shall be such that the i*

NB-4231 Fitting and Aligning Afethods maximum offset of the finished weld will not be Parts that are to bejoined by weldinE may be fitied.

greater than the appbcable amount hsted m Table NB-42321. where i is the nominal thickner of the aligned. and retained in position danng the weidmg thinner section an thejoint.

operation by the use of bars. jacks, clamps. tack (b/ Joints in sphencal sessels. joints with:n heads.

welds.or temporary attachments.

and joints between cylindrical shells and hem-NB-4231.1 Tack Welds. Tack welds used to secure ispherical heads shall meet the requirement m TaNe alignment shall either be remosed completely, when N B-42321 for longitudinaljoints.

they hase sersed their purpose, or their stopping and NB-4232.1 Fairing of Offsets. Any off et withm the starting ends shall be properb prepared bs crmding allowable tolerance proyded abee stall be fared io s'o that the[ ' mas be at least a 3 to I taper stur Jbe width of the firnbed or other scitable means satisfactonly incorporated into the fmal " weld.' Tack

• Sd cr. if necessary by adding additionalw e'd nic:.il

.y.

welds shall be made by quahfied welders usinc beyond what would vierwise he the cdce of the wcid.

quahfied weld.nc prwedures. When tack welds are t(s in addition offseis creater than those stated in Table become part of the fmi hed weld, they sha!! be NB-42321 are accep:able prouded the icq.irements visualh esamined and defectne tack welds removed.

of NB-3200are met.

NB-4231.2 Temporar3 Attachments and Their Re-mosal. Attachments which are welded to the com-NB-4233 Alignment Requirements Mhen ponent during construction but which are not Component inside Eurfaces Are such as inaccessible incorporated into the fmal component.

When the inside surfaces of components are alignment lues or straps. tie 5 traps. braces, preheat inaccessible for weiding or fairing m acsordance with equipmen:. postweld heat treatment equipment. are NB_232.1. the inside diameters shall n.atch each permitted. presided the requirements of (a) through other withm S m.When the wmponent arc shgned th) below are met.

(of The matenal is identified and is suhaMe for concentncalh. a uniform mnmatch of 8.:in. around welding but need not betertified material.

the joint can' result as show n in hp. N B 4233-1 sk 8a >

(bj The matenal is compatible for welding to the However. other sariables not associated with the component matenal to which it is attached-diameter of the component often result in abgnments (r/ The weldmc matenal is compatible with the that are offset rather than concentn6. In these sase.

base material and is certified in accordance with NB-the manmum misshenrnent at am one pomt around 2130; the jomt shall not euced !nm.. as show n m Fic. N B-(d> The welder and weldmg procedure are qualified 4233-1 sk. (bl Should component tolerante such as in accordance with Section IX and the additional diameter wall thickness, out of roundness. result in requirements of SB 4320.

inside diameter vanations which do not meet the-e (c/ The immediate area around the temporary hmits. the inside diameters.shall be counterhored.

attachment is marked in a suitable manner so that sized.or ground to produce a bore w ithin thesc hmit-after remosal the area can be identified until af ter it has been esamined in accordance with (g) be!ow.

(f) The temporary attachment is completely re-TABLE NB 42321 moved in accordance with the procedures of NB-MAXIMUM ALLOWABLE OFFSET IN FINAL WELDED JOINTS 4211.

(gf After the temporary attachment has been o.rection of Jo.nts removed, the marked area is examined by a magnetic san oa me a=

particle or liquid penetrant method in accordance with the requirements of Articles 6 and 7 of Section V and meets the acceptance standards of NB-5340 or un io it2. mci.

t/4 t /d r i12 io 314..nci.

Its m.

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N B-5350. as applicable.

A",,', 3,a,, t.ii2. mei.

o its m.

3ris.

(h) The attachment weld or the area after removalo,,1 it2 io 2. met its m.

its i of the attachment is postweld heat treated in ac-on/2 tmer et tasse' on 1/16 i o. 3/s m.

II8eo. 3/4.a cordanee with NB-4600.

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a-Sheet 2 Or 3 Fig. SB 42331 SECTION III, DIVISION I - SL'BSECTION NB lW' 45 W t. X ; W U M 8

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CONCENTRIC CENTERLlHES k

f 3/32 m MAXIMUM AT ANY ONE POINT AROUND THE COPJPONENT {

JOINT f

(b)

OFFSET CENTERLlHES NOTE THE COMBINED INTERNAL AND EXTERNAL TRANSITION OF THICKNESS SHALL NOT EXCEED AN INCLUDED ANGLE I

OF 30' AT ANY POINT WITHIN 1% i OF THE LAND.

FIG. NB-42331 BUTTWELD AllGNMENT TOLER ANCES AND ACCEPTABLE SLOPES FOR UNEOUAL 1.D. AND O. D.WHEN INSIDE SURF ACE IS INACCESSIBLE FOR WELDING OR FAIRING I

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t TRANSITIONS ARE FOR VALVES, flTTINGS, AND EQUIPMENT J.

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FOR WELD END PREPS SEE DRAWING 40048 00 40049.

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t = NOMINAL WALL THICKNESS.

4 INTERIOR AND EXTERIOR TRANSITION ANGLES SHAll NOT BE 4.

COMBINED SO At To ofCREASEMINIMUMREQUIRED WALL

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SECHTEL POWER CORPORATION WElDEO END TMS/T/ONS M4 VAL VES, f/TTINQt _ AND EQU/PMENT FILE l

SORWALE, CALW GRRIA SOUTHERM C ALIFO R MI A EDISO N, CO MP AM Los u cttts. cAur see eso.

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c.ncaosure ros Sheet 1 of 2 NC.4650- N C.4 610 SECTION III. DIVISION 1 - St;BSECTION NC

.N C-*ASO HEAT TRE AT. MENT AFTER NC-4700 MECHANICAL JOINTS BENDING OR FOR311NG FOR

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PIPE. PL'MPS AND VALVES NC-4710 BOLTING AND THRE ADING E'E"' '

NC-4651 Conditions Req' string Heat Treatment After Beding or Forming All bolts or studs shall be engaged in accordance the design.

w (a) Ferritic a!!ay steel pipe or formed portions of pumps or sab es that has e been heated for bending or NC-4712 Thread Lubricants other forming operations sha!! receise a heat treat.

ment in accordance with NC-.1620 or a full anneal. a Any lubricant or compound used in threadedjoir.ts normalizing and tempering treatment or a quenching sha!! be suitable for the sersice conditions and shall and temper ng tre.tment.

not react unfasorsb!) with either the sersice Durd or (b/ Carbon steel pipe or formed portiens of pumps any component materialin the sy stem.

or sahes with a wall thickness greater than % in.

inc!uded in group P-Number I in Section IX that has e

.N C-4713 Remoial of Thread Lubricants bcen cold bent or formed shall receis e heat treatment in accordance with NC-4620.

All threading lubricants or compounds she.ll be remos ed from surfaces which are to be sea!-w elded.

R/ Femtic a!!oy pipe or formed portions of pumps or vahes with an outside diameter greater than 4 in.

NC-4720 BOLTING FLASGED JOINTS and a wall thickness greater than % m. included m groups P-Number 3 through P-Number 5 m Section IX that hase been cold bent or formed shall require a In boltinc easketed flangedjoints.the contact faces hest treatment in accordance with NC-4620.

of the flang'es'shall bear uniformly on the casket and the gasket shall be properly compressed in a'ecordance with the design principles appbcable to the type of gasket used. All flar.ged joints shall be made up with

.N C-4652 Exemp6vis From Heat Treatment relativeh undorm bolt strest

(

After Bending or Forming NC-4730 ELECTRICAL AND MECHANICAL If the conditions described m. (a) through (d) are PENETRATlON ASSEMBLIES met. heat treatment after bendmg or forming is not "9'I

Electrical and mechamcal penetration assembbes foi Carbon steel pipe or portions of pumps and shall be constructed in accordance with the rules for vahes that have been bent or formed at a temperature components. except that the design and the matenals of 1650 F or higher shall require no subsequent heat performing the electrical conducting and insulatine treatment. providing the requirements of NC-4213 function of electrical penetrations need not meet the has e been met.

requirements of this Subsection. Tubes or pipes of 2 (b) Austenitic stamiess steel pipe. or portions of in. nominal pipe size and less may be joined to a pumps or vahes that hase been heated for bending or penetration assembly in accordance with the rules of other forming operations may be used in the absent NC-4350.

condition unless the Design Specifications require a heat treatment following bending or forming.

(c) All austenitic stainless steel pipe. or portions of NC-4800 EXPANSION JOINTS pumps or valves that have been cold bent or formed may be used in the as-bent condition unless the NC-4820 FABRICATlON AND De'ign Specifications require a heat treatment fol-INSTALLATION RULES FOR s

lowing bending or forming.

BELLOWS EXPANSION JOINTS (d/ Carbon steel and ferritic alloy-steel pipe or portions of pumps or valves with size and wall The requirements of (a) through (f) below shall be thicknesses less than specified m NC-465)(b) and (c) met.

may be cold bent or formed without a heat treatment (a) All welded joints shall comply with the re-following bending.

quirements of NC-4000.

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-N ARTICLE NC-3000 - DESIGN NC. 3647.2-N C. 3649.1 9

A = the sum of the mechanical allowances, in.

heavy hexagon head bolts and shall hAe ANSI i

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Standard heavy semi finished hesagon nuts.

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(NC-3613)

(c) Alloy steel bolt studs shall be threaded full l

length or,if desired. may have reduced shanks of a 4

(8) diameter not less than that at the root of the threads.

i i =

16S They shall have ANSI Standard heag hexagonal j

nuts. Headed alloy bolts are not recommended.

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where (41 A!! alloy bolts or bolt studs and accompanyinc j

de-the inside diameter of the gasket for raised or nuts are recommended to be threaded in accordance l

flat face flanges or the pitch diameter of the with ANSI Bl.1 Class 2A external threads and Class j

gasket for retained gasketed flanges.in, 2B internal threads.

P-design pressure, psi j

S= the allowable stress i

4 NC-3647.3 Temporan Blanks. Blanks to be used for Reducer fittings manufactured in accordance with test purposes only shall have a minimum thickness not the standards listed in Table NC 3691-1 shall be less than the pressure design thickness.t. calculated considered suitable for use. Where butt weldmg 4

from Equation 8 above, except that P shall not beless reducers are made to a nominal pipe thickness, the 3

than the test pressure and the allowable stress, S, may reducers shall be considered suitable for use with pip'e l

be taken as 95% of the specified minimum yield of the same nominal thickness.

strength of the blank material (Tables 1-2.0).

l NC 3647.4 Flanges. Flanges shall be integral or be attached to pipe by welding, brazing. threading. or NC-3649 Pressure Design of Other Pressure other means within the applicable standards specified Retainlag Piplag Products in Table NC-3691-1.

Other pressure retaining piping products man-ufactured in accordance with the standards listed in k...

NC 3647.5 Gaskets Tame E 36M shan & conMerd suWe b use (a) Gaskets shall be made of materials which are in P P ng systems at the specified pressure-temp-i i I

not injuriously affected by the fluid or by temp.

erature ratings. Pressure retaining piping products not j

eratures within the design temperature range, c vered by the standards listed in Table NC 3691 1 (b) Only metallic or asbestos metallic gaskets may and for which design formulas or procedures are not be used on flat or raised face flanges if the expected given in this Subsection may be used where the desi n 5

1 normal operating pressure exceeds 720 psi or the of 588ularly Shaped, proportioned. and sized com-temperature exceeds 750 F. However, compressed Ponents has been proved satisfactory by successful sheet asbestos confined gaskets are not limited as to Pedormance under comparable service conditions.

pressures provided the gasket materialis suitable for Where such satisfactory service experience exists, I

the temperatures.

interpolation may be made to other sized piping i

(c) The use of metal or metal asbestos gaskets is not Products with a geometncally s,inular shape. In the limited as to pressure provided the gasket materials absence of such service experience, the pressure l

are suitable for the fluid design temperature.

design shall be based on an analysis consistent with l

the general design philosophy of this Subsection and l

NC 3647.6 Bolting substantiated by at least one of the following:

(a) Bolts, nuts and washers shall comply with (a) Proof tests asdesenbedin ANSI B16.9; I

applicable standards and specifications listed in Table (6) Experimental stress analysis ( Appendix II).

i NC-3691 1. Unless otherwise specified, bolting shall be in accordance with ANSI B l6.5. Bolts shall extend NC-3649.1 8t' Joists-General Re-completely through the nuts.

giairements. Expansion joints of the bellows, sliding.

l (b) Carbon steel bolts or bolt studs may be used if l

expected normal operating pressure does not exceed, ball or swivel types may be used to provide f

{

300 psi for water or 250 psi for steam and the expected for piping systems.The design of the piping systems l

normal operating temperature does not exceed 450 F.

and the design, material, fabrication, exarrunation.

Carbon steel bolts shall be ANSI Standard square or and testing of the expansion joints shall conform to

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Supplementary Data Structural Welding Design and Construction Adequacy Allegations:

In the walkdown of SONGS 2 and 3 conducted by Bechtel, Edison, and NRC representatives with Mr. E. Kent on October 25, 1982, several allegations were tude concerning the subject of weld end returns, structural connec-While the subjects tions, and structural design adequacy in general.

addressed in Bechtel's original response to the NRC remain unchanged, this to the fullest extent, supplementary information is provided to address,these issues of conce

~

valkdown on October 25, 1982.

These include:

The weld return requirements of AISC, Specification $1.17.10 and I.

Mr. Kent alleges that these requirements are not

~

AWS Code $8.8.6.

followed by Bechtel Power Corporation according to his interpreta-tions.

The need for fully welded or fully bolted standard structural con-nections or box sections which can develop the full shear and bend-II.

ing capacity of the section.

Mr. Kent alleges that connections used to resist seismic stress conditions should develop the full capacity of the section irrespective of load magnitude, direction, or other design considerations.

I.

Weld End Returns interprets AISC $1.7.10 and AWS Code $8.8.6 as applicable to Mr. Kent all structural details irrespective of load magnitude, direction, type shear, bending), or actual stress of load (e.g. tension, compression, In particular, he has various concerns over the validity of condition.

specifying 9 eld end returns for three types of connection details l

not as follows:

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Bechtel Engineering Position The design of all welded connections utilized on the SONGS 2 and 3 project are made in accordance with the relevant code for which the structure or is classified, consistent with the design criteria and SAR re-component The allegation concerning veld end requirements is incorrect quirements.

and is based upon an inappropriate interpretation of the AISC Specification The AWS Code in its forward specifies the following:

and the AWS Code.

"This Code does not concern itself with such design considerations as of parts, loading and the computation of stresses for pro-a rrangement portioning the ' load-carrying members of structure and their connection.

Such considerations, it is assumed, are elsewhere covered in a general code or specifications such as a Building Code, AISC Specification for the Design, Fabtication an Erection of Structural Steel for Buildings,

........., or other specifications prescribed by the owne r."

is Bechtel's position that the AWS excludes from its jurisdiction the Itdesign responsibility of the veld details, and further directs the design f unction to the designing prof essional engineer who is required to adopt and interpret other appropriate design specifications including the AISC In this regard, AISC $1.17.10 is considered in the Bechtel S pecificat ions.

design and utilized accordingly. This AISC provision states as follows:

" Side or end fillet welds terminating at ends or sides, respectively, of parts or members shall, whenever practicable, be returned contin-less than twice the nom-uously around the corners for a distance not inal size of the weld. This provision shall apply to side and top fillet velds connecting brackets, beam seats and similar connections, End returns on the plane about which bending moments are computed.

shall be indicated on the design and detail drawings."

The provisions of this requirement are clearly specified to apply to struc-tural components subject to bending where high stress concentrations due to These high local weld stresses may exist in extreme edges of weld details.

include selected connection details subject to high stresses which warrant The purpose of this provision is elaborated upon and such consideration.

discussed in considerable detail in technical references and textbooks used by practicing professional engineers internationally. For greater insight The into this provision, several references are included in this response.

purpose of weld end returns are to assist in the redistribution of high local stresses when the following conditions apply:

Where vertical welds are subject to high stresses which are calculated 1.

to exist at extreme tips of a weld group, generally from large bending moments which have a tendency to " pry" the veld apart.

Where the weld stress is required to perform to its maximum allowable 2.

s tress value, and further, where maximum loading conditions can readily carry the local weld stress intensity into yield conditions.

In applications for which the local tensile stress f rom extreme bending 3.

ef fects are required to be resisted by small, narrow weld details.

IS.

e Pcga 3 i

• r(

In the design of all structures and components in the SONGS 2 and 3 project, AISC $1.7.10 has been considered. Where the provisions of this section are appropriate, Bechtel has provided weld details, including veld end returns, which meet the provisions and intent of the AISC Specifications. As a whole, Bechtel has specified weld end returns for appropriate design appli-These cations when calculated weld stresses approach code allowable values.

veld end returns have been provided conservatively even though the San Onof re 2 and 3 design criteria limits the Design Basis Earthquake (DBE) com-bines stresses to 90% of yield. Typical types of details where veld ends have been specified include to enhance local stress conditions include:

Welded double angle structural connections with high veld stresses (e.g.

1.

weld stresses near code allowables) which are field welded to inter-secting beams and columns and for which " prying" is a credible failure me ch anism.

Special beam connections where beam brackets or seats are required de-2.

signed for high stresses (e.g. weld stresses near code allowables) whose behavior has a tendency to " pry" the veld detail.

resisted in 3.

Special highly stressed design connections which are not tension by a large weld segment whose behavior could result in " prying" a ct ion.

As such, the San Onof re 2 and 3 structural design appropriately accounts for the provisions of AISc 51.7.10 and utilizes this provision for those spect-fic conditions for which it is intended to apply.

however, has refused to recognize the clarification specified in Mr. Kent, the second sentence of AISC $1.7.10 which states

......"This provision shall apply to side and top fillet welds connecting brackets, beam seats, and similar connections, on the plane upon which bending moments are computed."

His criticism extends not only Bechtel's interpretation of the provision, but also with the AISC with whom he apparently disagrees.

He contends that f ull velding all-around is " optimum" and should be adopted for all details which are subject to seismic considerations. This feeling obviously ex-is tends his interpretation of weld end returns to conditions for which it neither recommended by the code, nor required by the specific structural design conditions by the designing prof essional engineer.

Mr. Kent contends that weld end returns should be specified for Type A and B connection details. Bechtel disagrees for the following reasons:

1.

The details are not appropriate for the types of connections for which AISc 51.7.10 is intended to apply.

The top and bottom welds (for Detail A) are designed to take the tension 2.

and compression loading components from bending with a weld sized to take the full load accordingly. The vertical welds are designed to take the full shear load. In essence, the top and bottom welds behave in a tension and compression mode, not one of " prying".

If the veld is sized O

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W to withstand the full design load at allowable stress levels the wel i

end return would be located below the extreme weld fiber and would have limited value. The weld end return, if provided according to his in-terpretation, would remain below the stresses at the top fiber until the section reached yield levels.

Since this design condition is pro-hibited by the DBE criteria, the weld end return, if installed, would the full have no meaning provided that the top weld is sized to resist design force.

The full "2t" weld may not be constructible orthogonal to the top weld 3.

since the curvature of the weld at the tip of the structural member may prohibit its installation. This condition is prevalent for angle mem-ber extreme ends and certain structural shapes. In addition, the high I

stress concentration caused by the non-orthogonal weld end return may increase stress concentrations.

I ade-4.

The entire veld detail must be proportioned in such a manner that quate veld exists to withstand the loads. Beam sizing is of ten made utilizing stock size member selection which provides some uniformity in It is, there-ordering steel and some consistency in field erection.

fore, not unusual to see a member with oversize beam section properties connected by a weld detail which does not develop its full section.

The important and relevant design consideration is that the veld detail

)

should be sized to withstand all design loads imposed upon it.

The arbitrary selection of weld details which develop all beam sections j

would lead to excessive costs for the plant, while adding nothing to the structural integrity of the design.

I 5.

The detail utilized for tension and compression members (e.g. axial struts) do not require the same attention to weld end returns since i

)

" prying" is not, in general, a crelible f ailure mechanism. In conve r-I sations held with Mr. Kent in the walkdown, it was evident that he did not comprehend the behavior of such members, and was unable to make j

i such a determination.

In Detail C, Mr. Kent contends that the veld detail is inadequate and should be velded all around. This interpretation is not only highly subjective but in clear violation of the AWS Code 58.8.5.

This section clearly prohibits an orthogonal veld detail fillet welded, which is welded from two indepen-j dent directional planes, from being welded continuously. This section re-I quires that the veld be broken at the junction of the two welding planes.

j This shows the lack of understanding of specific and relevant code provi-In the application of the detail, the veld has been

[

I sions by Mr. Kent.

conservatively sized to maintain weld stresses considerably below allowables and the design meets the design criteria for the project. Here again the weld end interpretation by Mr. Kent 'is in error and clearly violates the

.i specific provision of the AWS Code.

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of Peg 2 5 II. The Need for Fully Welded or Bolted Connections to Develop the Full Shear and Bending Capacity of Structural Sections manner his disagree-This contention by Mr. Kent addresses in a more direct He contends that all connec-ment with the governing AISC Specification.

tions should be designed and constructed to develop the full shear and In essence, bending capacity of every beam section utilized in the plant.

is his contention that AISC $1.2 should not be applicable for structures it in seismic' zones.

Bechtel Engineering' Position is Bechtel Engineering's position that this contention contradicts over 60 years of experience in the preparation of the AISC Specification and It equivalent experience and design practice by practicing registered engineers throughou t the industry internationally. AISC Specification $1.2 clearly permits the utilization of three primary design types which have been dis-Some additional comments are cussed in the previous response to the NRC.

Mr. Kent has thrust himself in a position of engineering deci-warranted.

sion-making, a position for which he is neither qualified academically, nor licensed professionally.

Bechtel has utilized highly qualified licensed prof essionals in the selec-tion of weld details sad such professionals have interpreted code require-Mr. Kent's unqualified, sub-ments under the close scrutiny of the NRC.

jective approach to design would have the following impact:

in a highly complex, highly in-o Welding of all connections would result deter =inate design which would be prohibitive to analyze and design.

connections arbitrarily would invali-The use of full moment-resistant date all detailed analysis and design performed over 10 years.

o The project design and construction schedule would be increased several years.

o The use of full moment-resistant connections would add significant and and not necessarily add to the safety prohibitive costs to the project, or structural integrity of the plant. This design concept, if selected, is not optimum.

For these reasons, Mr. Kent's position is inappropriate and Bechtel dis-agrees with his contention emphatically.

In summary, Mr. Kent's contentions in the structural design and construction of the San Onofre 2 and 3 project are inaccurate and unjustified, and Bechtel rejects all of his unqualified allegations without reservation.

2

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w References the The following are technical and prof essional references which support 4

position taken by Bechtel in the applicability of Code provisions of AISC Specification $1.7.10 with respect to weld end returns and the need for welding all-around.

(A) AISC Steel Construction Manual, 7th Edition,1970, pp. 4-43, 4-50, 4-51, i

4-53, 4-101, 4-102, 4-103, 4-104, 4-105, 5-113 a

(B) Structural Steel Design by Jack C. McCormac International Textbook l

Company, Scranton, Pennsylvania, pp. 214-216, 253-267 l

(C) Steel Structures - Design and Behavior, 2nd Edition by Charles C. Salmon 1

213-242 and John E. Johnson, Harper & Row Publishers, New York, pp.

(D) Design of Welded Structures by Omer W. Blodgett, James F. Lincoln Arc 4

Welding Foundation, Cleveland, Ohio, pp. 3.3-1 to 3.3-18, 5.2-1 to 5.4-14 l

(E) Structural Steel Detailing, American Institute of Steel Construction, i

l New York, pp. 6-27 to 6-30 i

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TASK No. 82-68 DATE: Nov:mb:r 10, 1982 YA N I: 141415 TASK INTERFACE AGREEMENT PROBLEM:

San Onofre 3 - Welding Allegations LEAD OFFICE: C IE C NRR h

REGION O

JOINT NOTIFICATION:

REFERENCES:

Memo to DEisenhut from JCrews dated 10/29/82, subject: Request for Technical Assistance - Allegations by E. Earl Kent.

ACTION PLAN:

NRR:

1.

Provide assistance to Region V in resolving welding allegations, as requested in Region V memo of 10/28/92.

(MTEB) 2.

Provide evaluation input to PM suitable for use in Regional investfgation report. (MTEB)

Region V

1. Arrange meetings with licensee and site visi,t.

2.

Issue investigation report.

NOTE:

1.

D. Smith (MTEB) and H. Rood (LB3) scheduled for plant visit on 11/3/82.

2.

San Onofre 3 license issuance scheduled for 11/15/82.

i Designate Lead Project Manager to assign TACS and coordinate correspondence, NRR:

H. Rood

).

Prepare memo transmitting NRR meetings, and reports ( LB#3 evaluation to Region V for DL signature.

OFFICE COORDINATORS:

P 7f' I

gf VO'th

( 27207)

T. Ippoli (27415)

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F.(M] 6g1(3 RIGION y NRR Ext.

cc:

V. Stello, R0GR J. Sniezek, IE S. Hanauer NRR G. Holahan, NRR Regional Admin.

R. DeYoung, IE D. Eisenhut, NRR LEAD Project Manager J. Taylor, IE C. Michelson, AEOD R. Vollmer, NRR R. Purple, NRR B. Grimes, IE H. Denton, NRR G. Lainas, NRR R. Wessman, NRR E. Jordan IE E. Case, NRR T. Novak NRR W. Hazniton, NRR l

R. Baer, IE R. Mattson, NRR T. Ippolito, NRR W. Mills. IE J. Kramer, NRR F. Miraglia, NRR

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NOV171982 Docket Nos. 50-260, 361, 362 NEMORANDUM FOR:

Thomas M. Novak, Assistant Ofrector for Licensing Olvision of Licensing FROM:

William V. Johnston, Assistant Director for Materials & Qualifications Engineering Division of Engineering.

SUBJECT:

ALLEGATIONS BY EARL' KENT CONCERNING ADEQUACY i

0F WELDENTS AT~ SAN ONDFRE UNITS 1, 2, ANO 3 l

Plant Name:

SanOnofre.Nuhjee6Eenerating'StationUnits1,2and3 l

Licensing Stage: Unit 1.operatirig. Unit 2 and 3. OL Docket Numbers: 50-206, 361,J362 -

Reviewer:

D. E. Seith::

N.1%'t,.

l..

Responsible. Branch;& ProjectMentiger:X LB #,3 H.1 Rood Description of tTask:.' Safety'. Evaluation.4epo

of.. statements by

~

' Mr..E. EN 5ent col.thiCadquacy af the Aseldsents#

these'p1' ants Dates Reviewed:

10/26/82 to.11/8/82-f,,[*f-i :,.' 3p 3" i

Review Status: Complete

,Q shogineehingBranch.

l The Materials Application Sectied Me ri Olvision of Engineering has completed;its rev ew.of Mr. E5 Earl Kent's statementfof!conce in; tai adequacy.oftheM1ds at these units.atsthe.~iSan nefre's t Thel r.ieview.has.includedi (1) interviewing the people who.acico@upent Mr. iKent on4 walk" through tour of the plants for his to poi to. specific,W 1ds which demonstrated his. concerns, (2)*fspeating

..tbur and inspecting those welds which he. pointed out'were of concern to him. (3) review of the documents provided by the applicant demonstrating conollance with the appilcable codes.

Region V in their.le'ter of 0ctober 29, 1982 requested the Office t

of Nuclear Reactor Regulation's (NRR) support on specific alleg,a-tions by Mr. Kent.

This safety evaluation report is our response to this request.

We conclude that there is no merit in the allegations made by Mr. Kent, and recommend that no further action be taken.

The Bechtel Power Corporation (8PC) provided documentation to refute the allegations by Mr. Kent.

This documentation was gathered

Contact:

0. Smith x-24553

- OL N

1290023 021117 ADOCK 05000206

- i

s Thomas M. Novak NOV171982 and assembled without.8PC having the specific allegations by Mr. Kent as.. expressed iri his statement.. The documentation was thorough, and refuted all'of the allegations.

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"Sechteldesignersluse. fillet'weldslitconnectionsofbeamsin j

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pipe 544 sports and trey hengers and often do not weld all around the joint to restrain forces in all directions.

I feel this is code violation.

No proto-type tests, to my personal knowledge, were conducted to verify the adequacy of these welds.

Therefore,

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"Section 1.5 Allowab e. Stresses

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His statement concerni.ng composition'ef materials; weld and base metal, of electric tray hanger / tube steel welds not being known or of unknown strength, is unsubstantiated. We believe the quality Control by all parties concerned, and

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- the audits conducted by the region are adequate to address this concern.

The BPC documentation on design of individual joints to the particular application code was through.

We see no merit in this allegation.

Allegation Itse 5 "I an of the opinion that weld end returns are not required on Bechtel drawings. This is in violation of AWS-61.1, Section 8, 1974 Edition. paragraphs 8.8.6 8.8.6.1, and 8.8.6.2.

These conditions ekist on details in many structural applications.

AtwopageSechtel}PowerCorporationtable

~

establishes that certain pipe and other items must conform to AWS-01.1 requirements." '

Evaluation In the walk through inspection tour, end returns were observed on some structural welding.

A review of drawings showed Bechtel had specified end returns.

The use of end returns was determined by the loads (including design base earthquake) causing a prying apart of fillet welds.

.i 1

l i

~. There were places where end returns were not present.

The l

applicable version of AWS 01.1 for these plants has the follow-ing requirements for end returns; l

"8.8.6 End Returns (8exing) 8.8.6.1 Side or end fillet welds terminating at ends or sides, respectively, or parts or members shall, wherever practicable, be returned continuously atwund.the corners for a distance at least twice the nominal size of the weld except as provided in 8.8.5.

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..n 8.8.6.2 End returns shall.be indica.ted,by.the. drawings."

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i struction Mar.ual, 7th Edition.

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2 & 3 it invokes the AWS 01.'1, and it has the following i

wording concerning end returns:

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"1.17.10 End Returns of Fillet Welds o i

l Side or end fillet welds terminating at ends or sides, respec-tively, of parts or members shall, wherever practicable, be

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i l. 9 Specific defects are not addressed in Subsection NF, and the requirements of 8echtel's CS-P207 provioes additional detailed guidance to their (8ect.tel's) personnel in making judgments of fabrications. Therefore, Mr. Kent's statement concerning CS-P207 Rev. 7 not being in accordance with ASME Subsection NF is not accurate because the CS-P207 Rev. 7 requirements are beyond the acceptance criterion of Subsection NF. In regard to the implications of. allegations concerning 5.6.1.3, 5.6.1.9 and 5.6.1.11, Mr. Kent'apparently has mistakenly applied the requirements of one code (AMS Otl.1) to ASME, Section III, S 4section NF. Therefore,hisiblegationhasnoscrit. In M regards to the allegation conceriting 5.7.2, this. paragraph is -&? applicable.to American Nationaf. s;tandards Institute 8 31. ~' ^ " Power Piping" Code which at' San'Onofre 2 and 3 is used only ..:f 4 c 1 on non nu: lear safety related piping. The use of fillet welds in lieu of full penetration welds is a common design option. Other code requirements, usually maximum stress 11alts, deterstne i the actual sizes of the particular weld geometries used. Accordingly, this allegation is viewed as not having any i serit. In addition, as this section of the Bechtel Construc-tion Specificatinn concerns non-nuclear safety related piping, it is not in the jurisdiction of the NRC.

1 1 10 - The comparison of one code, such as AWS 01.1 with another, such as ASME Section III, Subsection NF on a pragraph by paragraph basis is l not appropriate. These codes,are oriented towards different purposes, and are based upon diffe. rent philosophies of design, and written by different groups.of; people.. It is the,whole code which must be ccepared, and their requirements as' applicable for their purpose. -+ Both codesfesploy ceaservatises, in differient areas and have n different approaches.f.!None 8f Mr. Kentts. allegations on the ct...ae;:,, inadequacy,of ag.partichlar,'cededias merit. There', fore, it e p : ; - is our judgeent BPC!s' Construction.5pect(ications' CMP 207,

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~** .. o v. "8echtel has not in av opinion. complied with';the requirements ...w . - -.s: of AWS-01.1.(1974 Edition). para M M.12iL S.'(2).(b)'and O I y...:. e ,a 8.15.1.3. regardinJ filling cf. OPen weld crators' on try hangers I: ^ L !- .t i and other itses to full crossIs . ion of the weld." 5 i l Evaluation l Paragraph S.12.1.5 (2) (b) concerns inspections of qualifica-tions weldments and has no relevancy to inspection of production weldments. Paragraph 8.15.1.3 reads as follows: "All craters are filled to the full cross section of the welds".

- l In Mr. Kent's walk through tour, ha pointed to only one weld which he maintained had a crater. In.the judgement of the people who accompanied Mr. Kent, the crater was filled to the theoretical i D roat dimension of the weld. This means the full joint strength l oftheweldwouidbeobtained. This particular weld had been painted. The alleged crater occurred setside of the strength part I ~ l ' p'.n Lt. l of the weld betwown a flat mounting' jfsts'and a cornered square gh;q;;;}. ~. ptece of structural.telag.' The weld'teminated at both ends where the round corner. of the%1ng was,dep?hXh;-,! ', f.'y.4f u

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. f l eptjgfrom n;;tt9f,fiq[.,. fin:;. .s ' % plate. This: same painted. weld was 'alsola6ted.it%;Nr5 Kent.to have 3 5: ' Th's'porosit[ywasinthepei [Q:gyLSV' ). ".Oy q>j jy y;- porosity. . -;:" - r., : iklol?.* li,..w. n x..; e. .0. ..m%$. 0.$ C 3 'u: Ofthethousandsofweldsavailablefes, Mont's: tour' Lhe: .c g

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ig u x,::%.iG59 R T "found" only one weld which 'in'his opf SNdnot-see6the: :lC u.Msdi:k: is. 6WH- @?k 5 ~ crater filling' requirements of 8.15l.13l$: ~ . K extent off -'r:9:Wh 3isMq;@p;-'f1111ag 72

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rossired is defined in paragraph 3.6.1,N @etche$.%priresthetitheil re YRM T 7 weld have the minlaum throet, thickness of.!the diagreemetic weld s

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,.V.: : ( in the drawing. Such had.been obtained 'on'J' :;g = ?1 . the one; weld he F g..y maintained did not have adequate crater fill. l The SPC Construction Specification, CS-P207 Rev. 7, covers-i i underfilled craters as follows: 0

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,g. y. V e i 6 , \\ ) t " 5. 6.1. 9 Underfilled groove weld craters shall be accepted provided the depth of underfill is 1/16 inch or less. Unde r-filled single-pass fillet weld craters shall te accepted provided the crater length is less than 10 percent of the i weld length. On multipas.s'. fillet welds, crater depth 1/16 k ~ inch or less shall be accepted." . ~. ~ At the November 3, 1982 ast%fng at San,Onofri, BFC personnel .,3 Informed this reviewer that %he 1/16 limit was' measured with 7 pit gauges as a standard quality control procedure. Accordingly, we find this allegation has 'no serit. Overall Evaluation [. l The other allegations by Mr. Kent lwere evaluated by Region V e personnel. The documentation provided by SPC through the ?:. applicant addressed all of the allegations. The thorough

.u review by Region V as augmented by San Onofre personnel demonstrated the allegations by Mr. Kent had no merit.

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s 9809 Spruce Court i Cypress, California 90630 Date: October 16, 1982 Time: 12:30 p.m. I, E. Earl Kant, voluntarily make the following statement to Messrs. Philip V. Joukoff and Owen C. Shackleton Jr., who have identified themselves to me as investigators for the U.S. Nuclear Regulatory Commission (NRC). I make this statement freely with no threats or promises of reward having been made to me. I am 57 years old and have worked since June 1942 as a welder, welding quality control inspector, welding engineer, etc., and author of welding articles for welding journals. In January 1955, I received a diploma for completion of the Structural Engineering Course from the International Correspondence School, Scranton, Pennsylvania. I worked for Bechtel Power Corporation as a Senior Quality Control Engineer in welding at the ~ San Onofre Nuclear Generating Station (SONGS) from October,1980 until August, 1981. During my employment at SONGS, I identified the following concerns which were identified to me by the NRC personnel who interviewed ne on October 15, 1982 as possibly affecting nuclear safety systems, and other items. i (1) pipe fitters sometimes used pipe cutters to make scribe marks for socket weld fitup measurements. These scribes marks caused grooves in both stainless and carbon steel pipes about 1" back from the weld area. I am concerned that these grooves might cause stress raisers. These conditions exist on socket welded fittings at random in Units 2 and 3, and possibly a few in Unit 1. (2) Bechtel designers use fillet welds on connections of beams in pipe supports and tray hangers and often do not weld all around the joint to restrain forces in all directions. I feel this is a code violation. No proto-type tests, to my personal knowledge, were conducted to verify the adequacy of these welds. Therefore, the actual structural strength of the electrical tray hanger / tube steel welds used or the actual material at SONGS may not be truly known. This also applies to pipe supports. I also feel that the partial joint strength (less than full joint integrity) and failure to weld all around the joint is a generic problem. Unfortunately, and in my opinion, the codes do not always demand fuel strength welding, whether all around or not. 4 (3) ASME requires adequate root penetration of fillet welds. I recall that some of the vendor supplied welded' hardware appeared to not have adequate root penetrations. The one vendor I can recall is Zack, I believe a supplier of HVAC equipment. I remember one i t

F s -2 ~ instance on a piece of Zack hardware where a fillet weld with inadequate welding was identified during inspection on site. This instance was subsequently corrected by weld repair after installation in the plant. I don't remenber if this equipment was used in SONGS Units 2 or 3. I recommend that the NRC examine the beginning and end of fillet welds to assure root penetration at these areas, and verify that all craters are filled, and conduct destructive testing of selected supports supplied by this vendor to determine if other fillet welds, and groove welds, have inadequate root penetrations or other code violations. (4) A steel bracket would be placed, I was told, between a Unit I hydrogen line on trip for steam generator. This was done because the hydrogen line had worn thin due to rubbing with another line. I believe maintenance people at the site who were working during the period when damage due to the Unit I diesel generator fire was being corrected would remember and be able to locate the design change and spacer. I don't recall the exact location of the hydrogen line. To my best recollection, there wasn't equipment within ten feet. I don't remember if there was any nuclear safety.related equipment nearby. I am concerned for the interity of nuclear safety-related equipment, if located nearby, and about the potential for loss of human life and fire, should this line rupture. I recommend NRC conduct an examination of this hydrogen line and make certain it has sufficient wall thickness to be safely operated. Most likely, I prevented a major fire in Unit 1, and probably saved the lives of several (or ' ore) workers there. m (5) I am of the opinion that weld end returns are not required on Bechtel drawings. This is in violation of AWS-D1.1, Section 8, 1974 Edition, paragraphs 8.8.6, 8.8.6.1, and 8.8.6.2. These conditions exist on details in many structural applications. A two-page Bechtel Power Corporation table establishes tha.t certain pipe supports and other items must conform to AHS-DI.1 require-ments. l (6) Bechtel Construction Specification CS-P207, Revision 7, dated April 18, 1980, paragraphs 5.6 and 5.7, contains visual examination criteria used by Bechtel for pipe supports and reference the ASME 3&PV Code, Section III, Subsection NF. I may have told John O' Dell, investigative reporter for the Los Angeles Times,' that I believe the visual criteria of CS-P207 are not in accordance with the above code requirements, particularly in CS-P207 paragraphs 5.6.1.3 (porosity and slag), weld convexity height acceptance criteria, 5.6.1.9 (underfilled groove weld craters), 5.6.1.11 (arc strike acceptance criteria), and 5.7.2 (allowing groove. welds wi.th fillet caps to b _ welded _as filleii welds). S (7) Sechtel generated (I was told) a 92-page NCR on electrical tray hangers. I question whether the welds made on electrical supports i prior to the NCR. resolution were adequately or completely fixed. i ..~m. g-

e_. e - (8) Bechtel has not, in my opinion, complied with the requirements of AWS-DI.1 (1974 Edition), paracraphs 5.12.1.5.(2).(b) and 8.15.1.3, regarding filling of open weld craters on tray hangers and other items to full cross section of the weld. (9) Bechtel has not, in my opinion, removed all arc strikes or blemishes from base metal on pipe supports or structural steel as required by AUS-01.1, paragraph 4.4. (10) I observed instances where run off plates had not been used as required by AWS-01.1, paragraph 4.6, of groove weld terminations. e I cannot recall any specific locations, but I do recall observing this condition on beam and girder splices, as supplied by at least one vendor. (11) I believe.that a spacer plate is missing on the upper inside door hinge of the Unit 2 containment personnel hatch because I observed a gap in the weld joint of about 1/4 inch. I brought this to the attention of my supervisor (Don Martin), who also shared that belief. I believe that by bringing this condition to the attention of my supervisor I had properly perforned my duty to identify this condition. I did not compare the drawing requirements to the installed condition in making this determination of a missing spacer plate, because my supervisor had indicated to me that it was the vendor's problem to correct it. I had other work to do immediately. (12) I believe that Bechtel has misinterpreted the requirements of the ASME Section III welding standards regarding socket weld engagement length without initiating a code case and obtaining appropriate code relief. The ASME code requires a gap between the pipe end and the fitting of "approximately 1/16 inch." I believe that the code should provide a more definitive acceptance criteria than merely "approximately 1/16 inch." Evidently, Bechtel will allow any dimension, as long as the pipe is not totally withdrawn from the socket. (13) Bechtel specification WQ-2, sheet 20, note 1, requires "shall not exceed 1/3 inch..." regarding maximum groove weld reinforcement height at Midland Michigan's Twin Nuclear Plant. This requirement should read "shall not exceed 1/8 inch..." as required by the ASME Section III code on groove weld reinforcement. The 1/3 inch height may be, also, mistakenly implemented at San Onofre. (14) I believe that the caliber of individuals employed by Peabody Testing and others to perform nondestructive examination (NDE) on welds in nucleir service applications was not acceptable. This belief is based on the observation of many documentation Mistakes and spelling errors, such as the incorrect spellings of the words " fillet" and " weld," as " filet wel," on NDE reports prepared by these individuals. Because of these observed spelling and other 4 ^ ^d due*= ebe en*ee#

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4 errors, I question the abilities of these NDE personnel to oerform the reouired examinations as reouired by their procedures. I believe that established industry and Bechtel standards regarding the cualification of NDE personnel are not sufficient to assure an adequate level of personnel capability and knowledge in this very important area of inspection. I have advised the above named NRC personnel of other concerns I have regarding inadequacies that I know exists in Industry Codes and Standards (i.e. AWS, ASME, AISC, etc.). Some of these allow inadeouate weldino processes (for example, short-circuiting arc in gas metal arc welding). Adhesion instead of cohesion is po'ssible in critical areas. The NRC representatives have told me that these areas are not within the jurisdiction of the NRC and although I do not necessarily agree with this, I do understand this may be the case. The NRC representatives have also told me that I can report my areas of concern regarding Codes to the apolicable code committee. However, where safety and life is at stake, I ask them to help my efforts as much as possible, not only at San Onofre, but all ~ nuclear plants in the United States. I need help in resolving problems that I know exists. I further have advised the NRC representatives that I have many concerns regarding welding done on non-nuclear safety-related systems and equipment. I have been advised by the NRC representatives that these areas are also not within the jurisdiction of the NRC. The NRC representatives have told me that.I can report these concerns directly to the utility, SCE, or whatever other local, state, or federal agency that has jurisdiction. / l 1 3 l ....+s.. s. l

. ~ I have read the foregoing statement consisting of this and four other typewritten pages. I have made and initialed any necessary corrections and have signed my name in ink in the margin of each page. I swear that the foregoing statement is true and correct. Signed on at Si gna ture: E. Earl Kent Subscribed and sworn to before me this day of 1982 at Investigator: Owen C. Shackleton Jr. Witness: Philip V. Joukoff Investigator, OISFF0 l y a wr e ew r t e

. l, o-Octo ber 19, 1982 On Saturday, October 16, 1982, at approximately 2:44 p.m., in the city of Cypress, California, E. Earl KENT stated to the undersigned that he would not sign his attached sworn statement. iir. KEtiT, in response to questioning, further stated that the statement, as amended by him, was true and correct as amended. i INVESTIGATOR: / z ~~>/ en ~ Ow~en C. - Slackleton Jr., Actyg' Director, DISFF0 WITilESS: M e'r5 ! PhilipV.[oukoff,inve+t+ , GISFF0 i e / I 1 ^^^^^^^^ ~.. ~........ ~.. ~.. ~. - - g _ --

o ur !% Q[o, UNITED STATES j NUCLEAR REGULATORY COMMISSION d7 WASHINGTON, D. C. 20555 a b, w., j g N...../ Docket Nos. 50-260, 361, 362 MEMORANDUM FOR: Thomas M. Novak, Assistant Director for Licensing Division of Licensing FROM: William V. Johnston, Assistant Director for Materials & Qualifications Engineering Division of Engineering

SUBJECT:

ALLEGATIONS BY EARL KENT CONCERNING ADEQUACY OF WELDMENTS AT SAN ONOFRE UNITS 1, 2, AND 3 Plant Name: San Onofre Nuclear Generating Station Units 1, 2 and 3' Licensing Stage: Unit 1 operating, Unit 2 and 3, OL ~ Docket Numbers: 50-206, 361, 362 Reviewer: D. E. Smith Responsible Branch & Project Manager: LB #3; H. Rood Description of Task: Safety Evaluation Report of statements by Mr. E. Erol Kent on the adquacy of the weldments at these plants Dates Reviewed: 10/26/82 to 11/8/82 Review Status: Complete eo.- The Materials Application Section, Materials Engineering Branch, Division of Engineering has completed its review of Mr. E. Earl Kent's statement of concerns in regard to the adequacy of the welds at these units at the San Onofre site. The review has included; ,(1) interviewing the people who accompanied Mr. Kent on a walk through tour of the plants for him to point to specific welds which demonstrated his concerns, (2) repeating the tour and inspecting those welds which he pointed out were of concern to him, (3) review of the documents provided by the applicant demonstrating compliance with the applicable codes. Region V in their 16tter of October 29, 1982 requested the Office of Nuclear Reactor Regulation's (NRR) support on specific allega-tions by Mr. Kent. This safety, evaluation ' report is our response to this request. We conclude that there is no merit in the allegations made by Mr. Kent, and recommend that no further action be taken. The Bechtel Power Corporation (BPC) provided documentation to refute the allegations by Mr. Kent. This documentation was gathered

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4 Thomas M. Novak and assembled without BPC having the specific allegations by Mr. Kent as expressed in his statement. The documentation was thorough, and refuted all of the allegations. W% v. ik William V. Johnston, Assistant Director Materials & Qualifications Engineering Division of Engineering Attachment j j cc: R. Vollmer W. Johnston E. Sullivan S. Pawlicki B. D. Liaw C. Cheng W. Hazelton R. Klecker i H. Rood F. Miraglia R. Bosnak ey. F. Schauer i D. Smith 8 9 a 6 .7- .T v' e ~-T- ' ' ' '*r-~ +*----T v" ', ' -

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I ATTACHMENT SOUTHERN CALIFORNIA EDISON SAN ON0FRE NUCLEAR GENERATING STATION UNITS 1, 2 AND 3 DOCKET NOS. 50-206, 361, 362 SAFETY EVALUATION REPORT MATERIALS ENGINEERING BRANCH MATERIALS APPLICATIONS SECTION References j (a) USNRC Region V Memo of October 29, 1982 from J. L. Crews to I

0. G. Eisenhut,

Subject:

Request for Technical Assistance, Allegations by E. Earl Kent (San Onofre). co (b) Earl Kent's statement of concerns dated October 16, 1982. Reference (a) requested NRR technical assistance in resolving items ~ (2), (5), (6) and (8) of Mr. Kent's statement (reference (b)). Our evaluations of these items are as follows: Allegation Item (2)* i "Bechtel designers use fillet welds in connections of beams in pipe supports and tray hangers and often do not weld all around the joint to restrain forces in,all directions. I feel this is code violation. No proto-type tests, to my personal knowledge, were conducted to verify the adequacy of these welds. Therefore, 4

. the actual structural strength of the electrical tray hanger / tube steel welds used or the actual material at SONGS may not be truly known. This also applies to pipe supports. I also feel that the partial joint strength (less than full joint integrity) and failure to weld all around the joint is a generic problem. Unfortunately, and in my opinion, the codes do not always demand full strength welding, whether all around or not. 1 Evaluation The loads to be withstood by structures fabricated in accordance with American Institute of Steel Construction

• ~""

(AISC) Steel Construction Manual are defined as follows: 4 "1.3.6 Other forces Structures in localities subject to earthquakes, hurricanes ' l and other extraordinary conditions shall be designed with due regard for such conditions." "1.3.7 Minimum Loads In the absence of any applicable building code requirements, the loads referred to in Sect. 1.3.1, 1.3.2, 1.3.5 and 1.3.6 above shall ba not less than those recommended in the USA Standard Building Code Requirements for Minimum Design Loads in Buildings and Other Structures, USASI A58.1, latest edition. 7_,-,,, _, -,rn,

3-The allowable stresses are as follows: "Section 1.5 Allowable Stresses

• Except as provided in Sects. 1.6, 1.7, 1.10, 1.11 and in Part 2, all components cf the structure shall be so proportioned that the stress, in kips per square inch, shall not exceed the following values, except as they are rounded off in Appendix A" We reviewed the documentations provided by the applicant and concluded that the applicable sections, of the AISC Steel 1

Construction, Manual have been followed. The allowable stresses of the weld metal determine the size of a given fillet weld in a given configuration. j OC> 1 I l The codes acknowledge that there are many failure modes other than tensile overload. These other failure modes can occur, depending upon configurations, at much lower stress levels than tensile overload. Accordingly, the codes are fashioned to address all the various failure modes to assure safe fabrica-tions. The designer sizes parts and welds to meet code require-ments. His statement concerning composition of materials, weld and base metal, of electric tray hanger / tube steel welds not being known or of unknown strength, is unsubstantiated. We i believe the quality Control by all parties concerned, and l l ~ -g.n -w- <m, p y-p -nem.--, e nm ,q v, + w p n, .-~..

' the audits conducted by the region are adequate to address this concern. The BPC documentation on design of individual jointstotheparticularapplicationcodewasthrough. We see no merit in this allegation. Allegation Item 5 4 4 ) "I am of the opinion that Weld end returns are not required l ' on Bechtel drawings. This is in violation of AWS-01.1, Section 8,1974 Edition, paragraphs 8.8.6, 8.8.6.1, and 8.8.6.2. These conditions exist on details in many structural ec-applications. A two page Bechtel Power Corporation table ] establishes that certain pipe supports and other items must conform to AWS-01.1 requirements." Evaluation In the walk through inspection tour, end returns were observed on some structural welding. A review of drawings showed Bechtel had specified end returns. The use of end returns was determined by the loads (including design base earthquake) causing a prying apart of fillet welds. i t O l

t i l S-4 d There were places where end returns were not present. The applicable version of AWS D1.1 for these plants has the follow-j ing requirements for end returns; i "8.8.6 End Returns (Boxing) i 8.8.6.1 Side or end fillet welds terminating at ends or sides, i respectively, or parts or members shall, wherever practicable,, be returned continuously around the corners for a distance at least twice the nominal size of the weld except as provided i in 8.8.5. i 8.8.6.2 End returns shall be indicated on the drawings." i. l l i The engineering reason for end returns is addressed in the American Institute for Steel Construction's (AISC) Steel Con-j struction Manual, 7th Edition. i ~ i The Steel Construction Manual is applicable to San Onofre i 2 & 3, it invokes the AWS 01.1, and it has the following i { wording concerning end returns: l "1.17.10 End Returns of Fillet Welds Side or end fillet welds termina' ting at ends or sides, respec-l l tively, of parts or members shall, wherever practicable, be t Te 1-P a a 9 a w g

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_ returned continuously around the corners for a distance not less than twice the nominal size of the nominal size of the weld. This provision shall apply to side and top fillet welds connection brackets, beam seats a similar connections, on the plane about which bending moments are computed. End returns shall be indicated on the design and detail drawings." a The engineering reason for end returns is to reduce the prying open ~ ~ of welds by applied load inoments. This is a calculatable stress and accordingly, the design engineer can make judgements as to the need for end returns on individual pipe supports and electrical cable tray hangers. If there is no advantage to requiring end oo-returns, the design engineer is not obligated to require them. The 1981 edition of AWS 01.1 has a commentary section which addresses end returns, as follows: 9 I I I I l I i l r ) l l / I l I g i/ l / &A (A) Boxing of header angles (8) Boxing around top of seat angle connections i i Fig. C8.8.6-Examples of end returns (boxing) l l .... _ ~,. _... _ -. - - -

- "8.8.6 In earlier testing of flexible beam-to-column connections in which the welds were subjected to combined shear and bending, it was found that end returns (hooking the weld) around the top of seat angle connections (see Detail B of Fig. C8.8.6) did not i necessarily increase the strength of the connection. In the case of header angles, as shown in Detail A, end returns (boxing) tend to delay the initial tearing of welds under ultimate failure conditions. This commentary makes note that the ultimate, static load (which is applicable to cable tray hangers and pipe supports at these plants) are not increased by end returns. so. In conclusion, the Bechtel Power Corporation showed knowledge of the end return requirements, and used them when there was ~ a design need. Accordingly, this allegation is viewed as not having any merit. Allegation Item 6 "Bechtel Construction Specification CS-P207, Revision 7, dated April 18, 1980, paragraphs 5.6 and 5.7, contains visual examina-tion criteria used by Bechtel for pipe supports and reference the ASME B&PV Code, Section III, Subsection NF. I may have i told John O' Dell, investigative reporter for the Los Angeles $'" i ,,e, .?_^I' .+.s.__ 4._. = 1 ~ 8-Times, that I believe the visual criteria of CS-P207 are not in accordance with the above code requirements, particularly in CS-P207 paragraphs 5.6.1.3 (porosity and slag), weld j convexity height acceptance criteria, 5.6.1.9 (underfilled) groove weld craters), 5.6.1.11 (arc strike acceptance criteria), and 5.7.2 (allowing groove welds with fillet caps to be welded as fillet welds)." d J Evaluation The acceptance standards for visual examination welds of the eso-j Winter 74 Edition of the ASME Code Section III, Subsection NF is as follows: "NF-5360 ACCEPTANCE STANDARDS FOR VISUAL EXAMINATION OF WEL'DS i i ~ l (a) Only indications with major dimensions greater than i l 1/16 in, shall be considered relevant. (b) Unless otherwise specified in this Subsection, cracks or other linear indications are unacceptable. l l 1. =

• =

~ 9-Specific defects are not addressed in Subsection NF, and the q requirements of Bechtel's CS-P207 provides additional detailed 4 guidance to their (Bechtel's) personnel in making judgments of fabrications. Therefore, Mr. Kent's statement concerning 'l CS-P207 Rev. 7 not being in accordance with ASME Subsection l NF is not accurate because the CS-P207 Rev. 7 requirements j are beyond the acceptance criterion of Subsection NF. l. ~ In regard to the implications of allegations concerning 5.6.1.3, 5.6.1.9 and 5.6.1.11, Mr. Kent apparently has mistakenly applied i the requirements of one code (AWS 0 1.1) to ASME, Section III, Subsection NF. Therefore, his allegation has no merit. In regards to the allegation concerning 5.7.2, this paragraph is applicable to American National Standards Institute B 31.1, " Power Piping" Code which at San Onofre 2 and 3 is used only 4 on non nuclear safety related piping. The use of fillet welds ~ in lieu of ' full penetration welds is.a common design option. I Other code requirements, usually maximum stress limits, determine I the actual sizes of the' particular weld geometries used. ~ Accordingly, this allegation is viewed as not having any merit. In addition, as this section of the Bechtel Construc-i tion Specification concerns non-nuclear safety related piping, 1 l it is not in the jurisdiction of'the NRC. l 1 i .;~ ; . _. y 7.- , q, - -..

.o s I _ The comparison of one code, such as AWS D 1.1 with another, such as ASME Section III, Subsection NF on a pragraph by paragraph basis is not appropriate. These codes are oriented towards different purposes, and are based upon different philosophies of design, and written by different groups of people. It is the whole code which must be compared, and their requirements as applicable for their purpose. i Both codes employ conservatisms, in different areas and have different approaches. None of Mr. Kent's allegations on the inadequacy of any particular code has merit. Therefore, it is our judgment BPC's Construction Specifications CS-P207, Rev. 7 meets appropriate code requirements. e<>. Allegation Item 8 "Bechtel has not in my opinion complied with the requirements of AWS-01.1 (1974 Edition), paragraphs 5.12.1.5.(2).(b) and' 8.15.1.3, regarding filling of open weld craters on tray hangers and other items to full cross section of the weld." Evaluation . Paragraph 5.12.1.5 (2) (b) concerns inspections of qualifica-tions weldments and has no relevancy to inspection of production weldments. Paragraph 8.15.1.3 reads as follows: "All craters are filled to the full cross section of the welds". i

.a-4, In Mr. Kent's walk through tour, he pointed to only one weld which he maintained had a crater. In the judgement of the people who accompanied Mr. Kent, the crater was filled to the theoretical throat dimension of the weld. This means the full joint strength of the weld would be obtained. This particular weld had been painted. The alleged crater occurred outside of the strength part i j of the weld between a flat mounting plate and a cornered squar,e piece of structural tubing. The weld' terminated at both ends where ~ the round corner of the tubing was departing from the flat plane of plate. This same painted weld was also noted by Mr. Kent to have porosity. The porosity was in the paint. .o-Of the thousands of welds available for Mr. Kent's tour, he "found" only one weld which in his opinio'n, did not meet the crater filling requirements of 8.15.1.3. The extent of filling ~ required is defined in paragraph 3.6.1, which requires that the weld have the minimum throat thickness of the diagrammatic weld in the drawing. Such had been obtained on the one weld he maintained did not have adequate crater fill. The BPC Construction Specification, CS-P207 Rev. 7, covers underfilled craters as follows: / 1 lr ~ l l

r-e, - "5.6.1.9 Underfilled groove weld craters shall be accepted provided the depth of underfill is 1/16 inch or less. Under-filled single pass fillet weld craters shall be accepted provided the crater length is less than 10 percent of the weld length. On multipass fillet welds, crater depth 1/16 inch or less shall be accepted." a At the November 3, 1982 meeting at San Onofre, BPC personnel ,I informed this reviewer that the 1/16 limit was measured with pit gauges as a standard quality control procedure. Accordingly, we find this allegation has no merit. ee-Overall Evaluation The other allegations by Mr. Kent were evaluated by Region V' personnel. The documentation provided by BPC through' the applicant addressed all of the allegations. The thorough review by Region V as augmented by San Onofre personnel demonstrated the allegations by Mr. Kent had no merit. / l l .}}