ML20199A536

Rev 1 to Procedure WCP-6, Electronic Alignment,Performance Verification & Maint of Dimetrics Gold Track II Automatic Welding Sys

ML20199A536
Person / Time
Site:	Comanche Peak, 05000000
Issue date:	03/11/1982
From:	Baker W BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML17192A346	List: IA-85-313, Partially Withheld Transcript of Technical Review Team 840919 Interview W/Unidentified Person in Eagle Mountain,Tx Re Welding Activities ML17192A345 ML20199A477 ML20199A484 ML20199A490 ML20199A497 ML20199A503 ML20199A510 ML20199A517 ML20199A525 ML20199A531 ML20199A536 ML20199A543 ML20199A546 ML20199A553 ML20199A559 ML20199A564 ML20199A570 ML20199A575 ML20199A581 ML20199A586 ML20199A592 ML20199A599 ML20199A605 ML20199A613 ML20199A618 ML20199A624 ML20199A628 ML20199A633 ML20199A639 ML20199A645 ML20199A650 ML20199A657 ML20199A661 ML20199A667 ML20199A670 ML20199A678 ML20199A682 ML20199A688 ML20199A694 ML20199A705 ML20199A709 ML20199A715
References
FOIA-85-313, FOIA-85-59, FOIA-86-A-20 WCP-6, NUDOCS 8606120459
Download: ML20199A536 (31)

Text

{{#Wiki_filter:_ B90'5 a ROOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE 08 35-1195 WCP-6 1 3/11/82 1 of 31 ! l l TITLE: ORIGINATOR: M[ M/d 3-0 21 DATE i P.W. ELECTRONIC ALIGNMENT, PERFORMANCE VERIFICATION Y [ /J ., / f AND MAINTENANCE OF REVIEWED BY: A T wW J//D/91 i T' b DIMETRICS GOLD TRACK 11 &R QA DATE AUTOMATIC WELDING j N h/dM fM' f APPROVED BY: 4 CONSTRUCTIONPREddTMANAGER DATE ARMS INDEXED T 1.0 TABLE OF CONTENTS . -i

1.0 INTRODUCTION

DATL l 1.1 PURPOSE 1.2 SCOPE I 1.3 GENERAL DISCUSSION AND RESPONSIBILITIES 2.0 DEFINITION OF TERMS ABBREVIATIONS AND SYMBOLS 2.1 DEFINITION OF TERMS g 2.2 ABBREVIATIONS I 'i 2.3 SYMBOLS t 3.0 SPECIAL ITEMS AND OPERATIONS CPS.S I 3.1 MATERIALS 1195 l 3.2 PROCESSES 3.3 TOOLS AND EQUIPMENT j-* t l [ s 1 4.0 PROCEDURES [s 't 4.1 ELECTRONIC ALIGNMENT ( 4.2 PERFORMANCE VERIFICATION 4.3 MONITORING OF PRODUCTION WELDING h 847 COW i 4.4 TROUBLESHOOTING / REPAIR s9 4.5 PREVENTIVE MAINTENANCE 5.0 SUPPORTING INFORMATION 5.1 ATTACHMENTS i

5.2 REFERENCES

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BROWN 5' ROOT, 1NC. PROCEDURE EFFECTIVE ^ R REMON DME NE - ---- CPSES JOB # 35-1195 WCP-6 1 3/11/82 2 of 31 i

1.0 INTRODUCTION

1.1 PURPOSE 1.1.1 The purpose of this procedure is to establish a program for the electronic alignment, performance verification, and maintenance of the Dimetrics Gold Track II Welding System. 1.2 SCOPE 1.2.1 The scope of this procedure includes the operations to be performed on the Dimetrics Welding System that are necessary in order to assure that quality production welding may be accomplished. These necessary operations include the following-

1. Electronic Aligment

2. Perfomance Verification

3. Monitoring of Production Welding

4. Troubleshooting / Repair t

5. Maintenance 1.2.2 Although the term " calibration" may be used in some instances when referring to the electronic aligment procedure, the Dimetrics Welding System will not be considered a calibrated item.

1.3 GENERAL DISCUSSION AND RESPONSIBILITIES ~ 1.3.1 To insure the continued repeatability of the Welding System, only Manufacturers' Service Engineer (s), Dimetrics factory-trained Brown & Root Personnel or Haintenance Technician (s), and Maintenance Technicians who have had six (6) months of on the job training ) working with Dimetrics factory-trained Brown & Root personnel are pennitted to accomplish any operations on the Welding System requiring internal check (s), adjustment of electrical or mechanical system (s), i necessary repair (s), or required periodic maintenance, f j 1.3.2 The Brown & Root Engineer / Operators assigned to the Dimetrics Welding ) System will perfonn all functions necessary to meet the requirements [ of this procedure. l 1.3.3 All activities associated with the Dimetrics Welding System shall be i coordinated through the Project Welding Engineer. 4 e l 4 k 9 f .O t t f

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( BROWN & ROOT, INC. PROCEDURE EFFECTIVE N BER E SION DATE PAGE CPSES JOB # 35-1195 WCP-6 1 3/11/82 3 of 31 j 2.0 DEFINITION OF TERMS, AB8REVIATIONS AND SYMBOLS 2.1 DE.rINITION OF TERMS 2.1.1 Dimetrics Welding System - The complete, progrannable automatic gas tungsten arc welding system manufactured by Dimetrics, Inc. This Welding System includes the capability for welding pipe, using the pipe track system and for welding plate, using the vacuum flat track system. 2.1.2 Performance Verification - a periodic check of the four (4) basic welding variables which are critical to the assurance of quality welds. These variables are (1) current, (2) arc voltage, (3) fixture travel speed, and (4) wire feed speed. ~ 2.1.3 Welding Operator - Brown & Root employee specially trained in the operation of the Dimetrics Welding System. 2.1.4 Welding Technician - Brown & Root employee trained in the operation of the Dimetrics Welding System. 2.1.5 Maintenance Technician - Brown & Root employee specially trained for the maintenance of the Dimetrics Welding System. 2.1.6 Electronic Alignment - period check (and adjustments, if necessary), to assure that all systems are within acceptable specification limits. 2.2 ABBREVIATIONS 2.2.1 M&TE - Measuring & Test Equipment 2.2.2 DVM - Digital Volt Meter 2.2.3 PM - Preventive Maintenance 2.2.4 PWE - Project Welding Engineer 2.3 SYMBOLS 2.3.1 None 3.0 SPECIAL ITEMS AND OPERATIONS 3.1 MATERIALS 3.1.1 None _Z-- m [h. ~ ~ ^US. s-I- A

s. i BROWN & ROOT, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE CPSES JOB # 35-1195 WCP-6 1 3/11/82 4 of 31 b. 3.2 PROCESS 3.2.1 The welding process of concern in this procedure is the automatic gas tungsten are welding (GTAW) process. 3.3 TOOLS AND EQUIPMENT 3.3.1 All necessary hand tools for proper operation / maintenance of the Dimetrics Welding System are available and considered a portion of the System itself. The Dimetrics Welding System and all associated tools are the property of the Client. 3.3.2 All necessary M&TE for the electronic alignment, maintenance I and repair, (if necessary), shall be provided by the Project and shall conform to all requirements of Reference 1. 3.3.3 If the required test equipment is not available on the Project, alternate test equipment may be provided by an outside source that is approved by the Project and meets all Project requirements. 4.0 PROCEDURES 4.1 ELECTRONIC ALIGNMENT 4.1.1 The Dimetrics System shall be checked periodically to insure that its' performance is within the Manufacturers' specified limits. This electronic aligriment (calibration) shall be accomplished in i accordance with the instructions included in this procedure (Attachment 1) h

i 4.1.2 The electronic alignment procedure shall be accomplished every six (6)

L months. 4.1.3 A record of the six (6) month check shall be kept by the foreman in charge of the Automatic Welding maintenance or his designee on the i electronic alignment (calibration) record included in this procedure (Attachment 2). 4.1.4 Any items not meeting the manufacturers' reconsnended limits which cannot be corrected by the Maintenance Technician assigned to the system shall be reported to the foreman in charge of the Automatic Welding maintenance or his designee. The mainteriance foreman or his designee shall determine the action to be taken. If major electronics repair is done, the performance verification in accordance with Section 4.2 will have to be performed. NOTE: All major or minor repair (s) made will be logged in the equipment history log. ~5-h:2 m,, m-a. --r_.m== u An'- n _ f ou wg awn-r - :- - -MM b+L WMw

EFFECTfVE PROCEDURE REVISION PAGE BROWN & ROOT, INC. NUMBER DATE l 3 CPSES JOB #35-1195 WCP-6 1 3/11/62 5 of 31 The following list shall serve as a guideline in detemining [ 4.1.5 the need for more frequent checks of the electronic systems after any necessary repair work has been done on the welding Each case shall be considered individually: System. i ADDITIONAL CHECKS REQUIRED EXAMPLE OF REPAIR None required

1) Nonelectric System (torch coolant, air cooling, etc.)

Only System worked on.

2) Minor Electronics j

(motor repair, component replacement,etc.) Complete System Check

3) Major Electronics (low voltage supply repair.

board replacement, etc.) (- 4.2 PERFORMANCE VERIFICATION As a continuing assurance of the accuracy of the four (4) basic I welding variables critical to quality production welding (Sec. 2.1.2)*, i 4.2.1 a performance verification will be accompitshed every 100 hours of arc time as recorded on the are time meter. j The perfohnance verification will be accomplished in accordanc= withl 4.2.2 the instructions contained in Attachment 3 of this procedure. 6 The perfomance verification will be accomplished 4.2.3 orMaintenanceTechnician(s). A log of the verifications will be l maintained for each Automatic Welding System, The verification procedure shall not require access to the internals i 4.2.4 of the equipment. of the functions cannot be wrified, If the accuracy of one or more the Automatic Welding Group Maintenance Foreman or his designee shall 4.2.5 The be notified and action shall be taken to correct the problem. i Maintenance Foreman or his designee involved in the test should be present during any adjustments. 9 9 u.,y_ .--m ,_...ef. p n 3,_ -m

- BROWN & ROOT, INC. REVISION PAGE l PROCEDURE EFFECTIVE NUMBER DATE l CFSES JOB #35-1195 WCP-6 1 3/11/82 6 of 31 s 1 i 4.3 MONITORING OF PRODUCTION WELDING 4.3.1 Production welds made with the Otmetrics Welding System will be subject to the same monitoring program as all other welding operations on the Project. Weld parameters shall be periodically i i - monitored by Weld Technicians from the Field Weld Technical Group j ^ as outlined in Reference 3. 4.3.2 Weld parameter monitoring procedures are outlined in Appendix 3 of this procedure. l 4.4 TROUBLESHOOTING / REPAIR 4.4.1 Only Manufacturer's Service Engineer (s), Dimetrics trained Brown & Root personnel, and Maintenance Technician (s) completing } l on the job training are authorized to make any adjustments or repairs to the Dimetrics Automatic Welding System. B 4.4.2 Any problem / malfunction (s) that cannot be solved by the Welding I Operator (s)/ Technician (s) assigned to the Dimetrics Automatic Welding System shall be reported to the Automatic Welding Group j Maintenance Foreman. I j 4.5 PREVENTIVE MAIffTENANCE 4.5.1 Preventive maintenance will be perfomed on the Gold Track 11 Welding System as obtlined in Attachment 4. i l l 4.5.2 Only Manufacturer's Service Engineer (s), Dimetrics factory-trained Brown & Root personnel, and Maintenance Technician (s) completing i f on the job training are authorized to perform the required preventive l i i maintenance. 4.5.3 Any additional maintenance will be accomplished as outlined in Reference 4. 5.0 SUPPORTING INFORMATION (i 5.1 ATTACHMENTS

1. Electronic Alignment (Calibration) i i

2. Calibration Record

3. Performance Verification / Weld Parameter Monitoring j

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4. Preventive Maintenance I

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5.2 REFERENCES

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1. B & R Construction Procedure 35-1195 - CP-CPM 13.1

2. Dimetrics Gold Track 11 Operation and Maintenance Manual J

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3. B & R Construction Procedure 35-1195 - CP-CPM-6.9 i

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~ 4 BROWN & ROOT, INC. REVISION PAGE l PROCEDURE EFFECTIVE NUMBER DATE j WCP-6 1 3/11/82 7 of 31 l CPSES f JOB #35-1195 3 5 l-ATTACHMENT 1 l i ELECTRONIC ALIGNMENT (CALIBRATION) i

1.0 INTRODUCTION

The following sections describe the procedure for aligning the electronic circuits in this system so that the perfomance is within Under nomal operation, only a small adjustment spkified limits. should be required if at all, to bring the system back into acceptable specification limits. If a subassembly has been replaced to correct a malfunction, the electronic circuitry associated with that function 3 should be recalibrated. Some calibration adjustments, such as the low voltage power supplies may affect the calibration of other functions], l i 1.1 GENERAL INFORMATION AND PRECAUTIONS Because of the complexity of the sys' tem, the calibration procedures I. 1 I are given in step by step fomat. Error may result if the pro-i cedure is not rigidly adhered to. t j The sequence should never by initiated in the operate mode unless a torch is properly positioned and connected, or a load bank if con-Some of the test points can nected across the power supply output. cause improper operation or component failure if inadvertently l grounded or shorted to adjacent points so care should be taken in The system should be energized for at connecting test equipment. least fifteen (15) minutes prior to starting the calibration pro-cedure. i 1.2 EQUIPMENT REQUIRED f Digital voltmeter (DVM) 3-1/2 decade Cana Model 2000 or equivalent. l 1.2.1 I Digital counter interval Timer Hewlett Packard Model 5304 or equivalent.1 1.2.2 1.2.3 A six-foot tape measure 1 2.0 LOW VOLTAGE SUPPLIES l' i Unless othemise stated all calibrations to be done in Test Mode NOTE: I\\ 2.1 +24 VDC Supply i 2.1.1 Connect sense lead of DVM to A13-A7-TP2. Connect return lead to A13 chassis GND. I Record reading, g 2.1.2 Verify presence of +24.0 plus or minus 3.0 VDC. 2.2 -24 VOC Supply Connect sense lead of DVM to A13-A7.TP4. Connect return lead to 2.2.1 A13 chassis GND. ..w u.<was e ....~ o use-u N - -a w 'e-** N mWL.- e..=* @

EFFECTfVE PAGE PROCEDURE REVZ510N BROWN & ROOT, INC. DATE NWBER CPSES 8 of 31 WCP-6 1 3/11/82 JOB #35-1195 { i. f Record reading. Verify presence of +24.0 plus or minus 3.0 VDC. 2.2.2 2.3 +15 VDC Supply i l 2.3.1 . Connect sense lead of DVM to A13-A7-TP3. Connect return j lead to A13 Chassis GND. Observe voltage and adjust A13-A7-R6 for +15.00 plus or minus 2.3.2 .02 VDC. 2.4 -15 DC Supply i Connect sense lead of DVM to A13-A7-TP5. Connect return 2.4.1 lead to A13 chassis GNO. 2.4.2 Observe the voltage. Adjust A13-A7-R6 for -15.00 plus l or minus. 02 VDC. t-I R6 is the balance control for the 15 VOC regulator. NOTE: i If adjustment is needed, recheck the +15 VDC after adjustment. 2.4.3 Record +15 VDC 2.4.4 Record -15 VOC 2.5 +32 VOC Supply Connect sense lead of DVM to A13-TB2-1. Connect return lead 2.5.1 to A13 chassis GNO. Verify presence of +32.0 plus 10.0 or minus 0.0 VOC. 2.5.2 2.5.3 Record reading. I. 2.6 -32 VDC Supply i Connect sense lead of DVM to A13-TB2-9. Connect return t 2.6.1 lead to A13 chassis GND. I t j Verify presence of -32.0 plus 10.0 or minus 0.0 VOC. l 2.6.2 i 2.6.3 Record reading. 2.7 +12 VDC Supply l Connect return Connect sense lead of DVM to A13-TB2-4. 2.7.1 1ead to A13 chassis GNO. i i i 'o I W~- i g__ _ 'Y j _U, 1M_'

\\- BROWN & ROOT, INC. PRCCEDURE IS3UE CPSES NUMBER REVISION DATE PAGE WCP-6 1 f 3/11/82 9 of 31 JOB 35-1195 2.7.2 Verify presence of +12.0 plus or minus 2.0 VDC. 2.7.3 Record reading. 2.8 +5 VDC Supply i 2.8.1 Connect. sense lead of DVM to A13-A7-TPl. Connect return i lead to A13 chassis GNO. I 2.8.2 Verify presence of +5.00 plus or minus.20 VDC. 2.8.3 Record reading. \\ l 3.0 WELD CONTROL BOARD Al 3.1 Pre-Purge Time (A16 Service Panel) 3.1.1 Set pre-purge switch to 5 seconds. Set upslope and downslope switches to 00 seconds. ( l Connect stop trigger of interval counter to Al-J6-1. 3.1.2 f Connect start trigger to Al-J6-4. Connect return lead ( to Al-J7-10. Set start trigger to r:egative slope and stop trigger to negative slope. Set counter mode to separate. 3.1.3 Initiate sequence start switch on weld head and observe i pre-purge time. Adjust Al-R38 for a time of 5.0 seconds plus or minus.5 seconds. It is necessary to initiate sequence stop, either NOTE: automatically or manually after each measurement. 3.1.4 Repeat sequence several times and verify repeatability. gl Record final reading. l 3.1.5 Set pre-purge switch to 3 seconds. Initiate sequence and ~ record reading. 3.1.6 Set pre-purge switch to 15 seconds. Initiate sequence l and record reading. 1 3.2 POST PURGE TIME j 3.2.1 Set pre-purge switch to 15 seconds. Set both counter trigger slopes to positive. Initiate sequence. After upslope, reset li counter and initate sequence stop. Observe post purge time of 45 seconds. Slope settings on counter should start at approx-imately 3:00 and stop at approximately 2:00. ? =--- m--- wM er ow, T s 1m

v BROWN & ROOT, INC. PROCEDURE EUENE l REVISION PAGE CPSES NUMBER DATE JOB #35-1195 WCP-6 1 3/11/82 10 of 31 3.2.2 Record reading. I 3.2.3 Set pre-purge switch to 5 seconds. Initiate sequence stop. Observe and record post purge time of 15 seconds. Record reading. 3.2.4 Set pre-purge switch to 3 seconds. Initiate sequence stop. Observe and record post purge time of 9 seconds. Record reading. 3.3 UPSLOPE TIME 3.3.1 Connect start trigger of interval counter to Al-J1-10 (cathode CR7 or CRI). Connect stop trigger to Al-J7-7. Connect return lead to Al-J7-10. Set start and stop l i trigger slopes to negative. Set mode to separate. 3.3.2 Set pre-purge switch to 3 seconds. Set upslope switch on remote programer to 10 seconds. Set downslope time to 00 seconds. 3.3.3 Initiate sequence and observe upslope time. Adjust A18-511-R9 remote programer (Model "A") or A18-52-R9 (Model "B") for 10.0 plus or minus.1 seconds. Repeat sequence several times l and verify repeatability. a f 3.3.4 Record reading. y 3.3.5 Check each digit on upslope switch for proper time. l 3.4 DOWNSLOPE TIME l i 1 c 3.4.1 Connect start trigger of interval counter to Al-J1-10 I (cathode CR7 or CRI). Connect stop trigger to Al-J1-9. Connect return lead to Al-J7-10. Set start trigger for j positive slope and stop trigger for negative slope. Set mode to separate. I' 3.4.2 Set upslope switch to 00 seconds. Set downslope switch i to 10 seconds. Initiate sequence, reset counter, initiate sequence stop and observe downslope time. Adjust A18-512-R9 remote programer (model "A") or l A18-55-R9 (model "S"), for a time of 10.0 plus of I t minus.1 seconds. i 3.4.3 Repeat sequence several times to verify repeatability and record final reading. i i w - '-~ ['_ ~ ' ~ x i. 3 ~

t BROWN & ROOT, INC. PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 j g g WCP-6 i l 1 i 3/11/82 11 of 31 'e \\ i .3.4.4 Check.each digit on downslope switch for proper time. 3.5 HI PULSE \\ a d 3.5.1 Connect frequency counter sense lead to Al-J7-4. Connect return lead tar Al-J7-10. Set trigger levels on i negative. Observe hi pulse frequency of 16,000 plus or minus 500 hertz. 3.5.2 Recored reading. 3.6 PULSED ARC GENERATOR ~ 3.6.1 Connect start and stop triggers of interval counter to ~ t Al-J7-5. Connect return lead to Al-J7-10. Set counter i slopes to negative. Counter to COMN mode. }- 3.6.2 Set low pulse mode switch on remote programmer to P.A. j Set low pulse frequency switch to 9.9 PPS. 3.6.3 Set low pulse width to 50% trigger counter to read one pulse and adjust Al-R1 for a time of 101 ms plus or minus 1 ms. Record final reading. [1 Set low pulse frequency to 0.2 pps and adjust Al-R8 for 3.6.4 5000 ms plus or minus 50 ms. Record final reading. 3.6.5 Check each digit on pulse frequency switch for proper time. 3.6.6 Connect interval counter start Al-J6-7. Connect return lead to Al-J7-10. Set low pulse width switch to 05%. Set low pulse frequency switch to 0.5 pps. START slope = (-), i STOP slope = (+). Both trigger levels on counter are positive. j Time should be 1 ms. 3.6.7 Measure negative pulse of one cycle. Adjust Al-R20 for a reading of 100 ms plus or minus 1 ms. Record final reading. b 3.6.8 Check each digit on pulse width switch for proper reading. q 4.0 MODEL "A" TIMING NOTE: This section for model "A" machines only. 4.1 MASTER OSCILLATOR i L ( I ( l5-1 ~ w. ~ ~ " ' ' ' ~

~ ISSUE BROWN & ROOT, INC. PROCEDURE NUMBER REVISION OATE PAGE . CPSES J08 35-1195 WCP-6 1 3/11/82 12 of 31 Connect frequency counter sense lead to A18-A14-TP2 (renote progransner). Connect return lead to A18-A14 4.1.1 I l chassis GND. Set trigger level to positive. Adjust A18-A14-R10 for 10,000 hertz plus or minus 100 hertg. 4.1.2 Record final reading AUTO SEQUENCE MODE 4.2 Set up remote progransner and service panel as follows:

A 4.2.1 l

l fixture mode = off test /operata = test purge mode = 3 seconds upslope time = 00 seconds 1st thru 4th level period = 015 seconds oscillator amp = 00 downslope time = 00 time-off-distance =, time Initiate sequence and verify that system goes into ist level for 15 seconds, then to 2nd, 3rd, and 4th and then downslopes 4.2.2 and post purges. t 5.0 SERVO J0GS 5.1 SERVO J0GS The manual fixture jog speed is controlled by A2-R26 forward, 5.1.1 and A2-R27 reverse. The adjustment of these should be set by service personnel 5.1.2 to the operators desires. i The manual wire feed jogs speed is controlled by A3-R26 feed, 1 5.1.3 and A3-R27 retract. j The manual AVC jog speed is controlled by A4-R2 9 5.1.4 A4-R27 up. 9 I Y ~ i [ E ~ ~~ a*-.-+s.

ISSUE BROWN & ROOT, INC. PROCEDURE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 I 3/11/82 13 of 31 1 WCP-6 6.0 FIXTURE SERVO 6.1 FIXTURE DELAY TIMER Connect interval counter start trigger to A2-J5-3 (anode CR33). Connect return to A2-J6-12. 6.1.1 Connect stop trigger to A2-J6-9. Set mode to separate. Set Set counter slopes to negative. trigger level start on positive and stop on negative. Set pre-purge to 3 Set fixture start delay to 10 seconds. Set downslope to 5 6.1.2 Set upslope to 00 seconds. seconds. Set single level speed switch (model "B") or 1st seconds. through 4th level speed switch (model "A") to 01.0 I.P.M. Set fix. mode to fwd., time mode switch to off (model "A"). Initiate sequence and observe the delay time after pre-purge 6.1.3 and before the fixture starts into motion. Adjust A2-R69 for a delay time of 10.0 plus or minus 0.1 seconds. Record final 6.1.4 Repeat several times to verify repeatability. reading. Stop Delay. ' Observe that fixture continues to run for length 6.1.5 of downslope time. N'JLLS AND OFFSET CIRCUITRY 6.2 Section 6.2 is a factory initial adjustment and should not need to be performed in the course of normal NOTE: However, in case of a repair of fixture calibration. i drive circuitry or if section 6.3 does not calibrate properly, perfonn the following steps. Connect a Insure that fixture drive motor is not running. jomper between A2-J2-13 (junction R-19, R-16) and grou 6.2.1 i side of A2-R30. return lead to ground side of R30. Record reading. Adjust A2-R82 for 0.00 plus or minus 0.002 VDC. I 6.2.2 Remove jumper between A2-J2-13 and A2-R30 ground. Connect f .a 2 microfarad capacitor across the sense and return leads o 6.2.3 Connect a 2 meg ohm resistor in series with the sense the OYM. j lead of OVM, f A . up c ~- -9 vi ' ' _.eg 3 , g

BROWN & ROOT, INC. PROCEDURE ISSUE [- CPSES NUMBER REVISION DATE PAGE J08 35-1195 WCP-6 1 3/11/8E 14 of 31 6.2.4 Connect sense lead of DVM to wiper of A2-K4 (junction R28). Connect return lead of DVM to ground side of A2-R30. Set fixture speed switch or switches to 00.0 IPM. Set start delay to 00 seconds. 6.2.5 Initiate sequence. Allow several seconds for die R.C. network ~ to charge and stabilize and adjust A2-R37 for a reading of 0.00 VDC plus or minus 0.002 VDC. 6.2.6 Record final reading. l 1 6.3 FIXTURE SPEED cal.IBRATION 6.3.1 Accurately mark off 20 inches on the circumference of the l fixture track. i 6.3.2 Select'an arbitrary reference point on the weld head fixture [ and jog it to the 1st or 0 inch mark in the forward direction of travel. l l 6.3.3 Set the single fixture speed switch (model "B") or the 1st through 4th level speed swithces (model "A") to 20.0 IPM. Set fixture start delay to 00 seconds. Set upslope and down-slope switches to 00 seconds. Set fixture mode switch to fwd. Set time mode switch to Time (model "A"). Set 1st through 4th I level period switches to 015 seconds (model "A"). Set test / l operate to Test. 6.3.4 Initiate sequence after 60 seconds (one minute), initiate sequence stop (model "B"). NOTE: Model "A" machines should do this automatically. Model "B" machines need to be stopped manually. i 6.3.5 Measure the distance traveled and adjust A19-R4 (weld head) for a distance of 20.0 plus or minus.2 inches. Repeat step E several times to verify repeatability. f 6.3.6 Set Fixture speed switch (es) to 02.0 IPM. Repeat Step E. \\ f 6.3.7 Measure the aistance traveled and adjust A19-R2 (weld head) for a distance of. 2.0 plus or minus.040 inches. i [ 6.3,8 Repeat step E and F at 20 inches and readjust if necessary. Recheck 2 IPM and readjust if necessary. Continue nulling [ the adjust pots A19-R2 and R4 back and forth until both 20 and l 2 IPM are within specifications. l ( -m = - ' M _Q

~ ISSUE BROWN & ROOT, INC. PROCEDURE NUM8ER REVISION DATE PAGE CPSES 15 of 31 J08 35-1195 1 3/11/82 WCp-6 Record final measurements for distance traveled on both settings. 6.3.9 Set fixture speed switch (es) to 010 IPM and initiate sequence. Monitor fixture speed meter on service panel and adjust A2-R81 6.3.10 for a reading of 10 plus or minus.5 IPM. 7.0 WIRE FEED SERVO WIRE FEED DELAY TIMER 7.1 Connect interval counter start trigger to A3-JS-3 (anode CR33). Set counter slopes to negative. f 7.1.1 Connect stop trigger to A3-J6-12. Set mode to separate. Set wire start Set wire feed stop switch (weld head) to on. l delay switch to 10 seconds. Set upslope to 00. Set pre-purge 7.1.2 to 3 seconds. Initiate sequence and observe the delay time after pre-purge j 7.1.3 before wire feed motor starts to run. time of 10.0 plus or minus 0.1 seconds. Repeat several times and record final reading. 7.1.4 7.2 WIRE FEED RETRACT Set downslope to 10 seconds. Set A20-R3 to minimum (retract pot).After start delay initiate sequen 7.2.1 Observe that wire feed motor stops imediately Initiate sequence. Initiate sequence. After Set A20-R3 to maximum (retract pot). Observe that wire feed motor 7.2.2 start delay, initiate sequence stop. stops imediately upon start of downslope and then retracts for l approximately one second. I 7.3 NULL AND OFFSET Section 7.3 is a factory initial adjustment an NOTE: I HOWEVER, IN CASE OF A REPAIR TO WIRE FEED DRIVE CIR OR IF SECTION 7.4 00ES NOT CALIBRATE PROPERLY, PER i FOLLOWING STEPS. l l P d-e.41dshmanes Ae.. apeK512MM Nebs.En @ C s

1 BROWN & ROOT, INC. PROCEDURE EFFECTIVE NW R ON WE WE CPSES JOB # 35-1195 WCP-6 1 3/ 11/82 16 of 31 7.3.1 Insure that wire feed motor is not running. Connect a jumper i from A3-J2-13 (Junction R16-R19) to ground side of A3-R30. Connect DVM sense lead to A3-J6-8. Connect return lead to ground j side of A3-R30. l 7.3.2 Observe voltage and adjust A3-R97 for a reading of 0.00 plus or minus 0.002 VDC. Record final reading. l 7.3.3 Remove jumper between A3-J2-13 and A3-R30 ground. Connect a 2 microfarad capaciter between the sense and return leads of a DVM. Connect a 2 meg ohm resistur in series with the sense lead of DVM. Connect the sense lead of DVM to wiper of A3-K4 (junction R28). Connect return lead of DVM to A3-R30 ground side. Set wire feed ~ primary and background switch to 00 IPM. Initiate sequence. 7.3.4 Allow several seconds for R.C. network to charge and stabilize I and adjust A3-R37 for a reading of 0.00 plus or minus 0.002 VDC. 7.3.5 Record final reading. 7.4 WIRE FEED SPEED CA!.IBRATION 1 = l 7.4.1 Prepare wire feed mechanism to feed wire. Set wire feed primary g speed switch to 99 IPM. Set upslope to 00 seconds. Set wire feed start delay to 00 seconds. Set downslope to 00 seconds. Set

• wire feed retract A20-R3 to minimum. Set low pulse mode to off. Set i

time mode to time (model "A"). Set 1st through 4th level periods to 015 seconds. 7.4.2 Initiate sequence and. allow wire to feed for exactly 60 seconds (one minute). Initiate sequence stop (model "B"). NOTE: Model "A" systems should end sequence automatically. Model "B" - it is necessary to do it manually. i 7.4.3 Measure the amount of wire fed out and adjust A19-R5 for 99 inches plus or minus 2 inches. L 7.4.4 Set primary wire speed to 10 IPM and initiate sequence, after ] 60 seconds, initiate sequence stop. l 7.4.5 Measure wire fed out and adjust A19-R3 for 10,.0 inches plus or 4 minus 0.2 inches. 7.4.6 Repeat steos B and C at 99 inches per minute. Repeat steps D and E at 10 IPM. i l .2 E s -.. waw-_. u - a v a M Ml h am ,/nw, W w rP C

r u s BROWN & ROOT, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE CPSES JOB # 35-1195 WCP-6 1 3/11/83 17 of 31 7.4.7 Continue nulling between A19 R3 and R5 until both speeds are within specification. Record final amount of wire fed on each setting. i 7.4.8 Set primary wire speed to 50 IPM. Initiate sequence and monitor wire speed meter on service panel. Adjust A3-R89 for 50.0 plus or minus 1.0 IPM. Initiate sequence stop. i 7.4.9 Set low pulse mode switch to P.A. Set pulIe frequency to 1.0 pps. Set width to 50%. Set primary wire to 80 IPM. Set background wire to 40 IPM. Initiate sequence and allow wire to feed for 60 seconds (one minute). Measure and record amount of wire fed. It should be l 60.0 plus or minus 1.2 inches. i I 8.0 OSCILLATOR SERVO 8.1 OSCILLATOR MECHANICAL CENTER ~ 8.1.1 Connect DVM sense lead to AS-J8-4. Connect return lead to A5-J6-12. Set oscillator amplitude switch to 00 inches. Adjust vernier slide (weld head) for a reading of 0.00 VOC on DVM. 8.1.2 Measure distance from rear of AVC housing to front of fixture carriage. The distance should be 1.00 inches plus or minus 0.010 inches. If adjustment is needed, loosen set screw on wiper shaft of A19-R11 oscillator feed back pot and move shaft until distance is within specification. 8.2 OSCILLATOR GAIN l 8.2.1 Set oscillator amplitude switch to 0.50 inches. Insure that DVM Engage set up switch "IN". DVM should still reads 0.00 VDC. read 2.50 VOC plus or minus 0.025 VOC. Check for proper reading and record ~ Engage set up switch out. Reading should be the same as step A, 8.2.2 but reversed polarity. Record reading. t Measure distance that oscillator moves when set up switch is en-8.2.3 gaged in or out. S/S 0.250 plus or minus 0.002 inches. 8.3 OSCILLATOR VERNIER SLIDE GAIN Move the vernier slide to maximum in one direction and note s I 8.3.1 l voltage (ignore polarity). Move vernier slide to maximum in opposite direction and note 8.3.2 j voltage (ignore polarity). Add voltage from 8.3.1 and 8.3.2 and check that tatal is 10.00 8.3.3 ( plus or minus 0.1 VOC. Record final reading. I L -e l ..s .. me :* e2 y.1 e Mc ,a; t. m jg j,j A. " _~.7 >~ v

PROCEDURE FFE @ E BROWN & ROOT, INC. REVIS!ON PAGE NWBER DATE CPSES 18 of 31 JOB #35-1195 WCP-6 1 3/11/82 8.4 OSCILLATOR VC0 Connect start and stop triggers of interval counter to A9-J2-5. 8.4.1 Set triggers to positive slope. Sat in/out and excursion switches i to 0.9 seconds. Set amplitudt switch to 0.20 inches. Set counter to COPHON. Initiate sequence and adjust A9-R16 for a reading of 9ms plus or 8.4.2 minus 0.09 ms on counter. Record reading. l 8.4.3 Set in/out and excursion switches to 0.1 seconds. Adjust A9-R25 for a reading of 1 ms plus or minus 0.001 ms. Record final reading. 9.0 WELD CURRENT LOOP I. 9.1 MINIMUM CURRENT I 9.1.1 Connect DVM sense lead to Al-J6-11, Connect return lead to Set test / operate switch to test. Set primary current i Al-J7-10. i (model "B") or 1st threbgh 4th level current (model "A" ) to 000 amps. Set low pulsa mode to off. Initiate sequence and after upslope adjust Al-R166 for a reading of -0.050 plus or minus 0.005 VDC. Record final reading. 9.1.2 t. 9.2 CURRENT GAIN 9.2.1 Set up sequence panel and rc. note programer as fo11ms: i Pre-purge = 3 seconds Primary current = 020 amos (model "B"). i Ist through 4th level = 020 amos (model "A") Background current = 020 am Time mode = off (model "A")ps l i l Low pulse mode = off Pulse width = 50% AVC mode = Lock Pulse Frequency = 1.0 pps OSC. amp = 00 inches Test / operate = operate i Upslope = 2 seconds wire feed stop = stop 9.2.2 Connect up suitable ground and prepare weld head to strike an arc. Set argon gas flow of 20 CFH. 'I-g. ? sf 2 } _'],

-5 PROCEDURE FFE W E BROWN & ROOT, INC. REVISION PAGE W R DATE CPSES JOB #35-1195 WCP-6 1 3/11/82 19 of 31 a l 9.2.3 Initiate sequence. After arc is stabilized connect DVM sense lead to Al-J6-10 and return to Al-J7-3. 9.2.4 Observe the voltage on DVM and adjust Al-R90 for 0.020 plus or minus 0,001 VDC..(IMV/ AMP) Record reading l i f 9.2.5 Momentarily set primary current to 150 amps. Observe DVM for reading of 0.150 plus or minus 0.001 VDC. Record reading. 9.2.6 Observe weld current meter on service panel. Adjust Al-R96 for i a 150 plus or r.rjnus 1 amp reading on meter. Intitiate sequence j stop. f 10 ARC VOLTAGE CONTROL I 10.1 SAMPLE AND HOLD OFFSET ,l 4 i 10.1.1 Connect DVM sense lead to function A4-R36 wiper A4-37. Return lead l to.A4-J6-12. Adjust A4-R37 for reading of 0.00 VDC +.100. ~ 10.1.2 Connect a jumper between A4-J7-3 (R79) and A4-J7-4 (R78). Co.mect sense lead of DVM to A4-J8-4. Connect return lead to A4-J6-12. Measure and record voltage. 10.1.3 Connect DVM sense lead to A4-J8-2. Connect return lead to A4-J6-12. i , Adjust A4-R93 for same voltage as recorded in Step A. l i 10.2 OVERALL OFFSET 10.2.1 Connect sense lead of DVM to A4-J8-6. Connect return lead to A4-J6-12. Set primary and background are voltage switches to 00.0 volts. L L 10.2.2 Observe the voltage and adjust A4-R95 for a reading of 0.00 plus I l or minus 0.1 VDC. Record final reading. i 10.3 AVC GAIN } } 10.3.1 Remove jumper between A4-J7-4 and A4-J7-3. Set up remote j progranner as in Step 9.2A with the following changes: ?, Set AVC mode to Cont. li Set primary ARC volts to 11.0 volts l j' Set primary current to 050 amps Set response fully CCW l l h n p l L. - --. ~m = w - v c~mmam - - - wmm

BROWN & ROOT, INC. PROCEDURE EFFECTIVE REVfSTON PAGE CPSES NtMBER DATE i JOB #35-1195 WCP-6 1 3/11/82 20 of 31 10.3.2 Prepare weld head to strike an arc. Set argon gas flow to 20 cfh. 10.3.3 Initiate sequence and strike an arc. After are is stabilized, connect 4 DVM sense lead to A4-J7-3 and return lead to A4-J7-4. j 10.3.4 Observe voltage and adjust A4-R103 for a reading of 11.0 plus or minus t 0.1 volts. Record final reading, i i 10.3.5 Monitor are voltage meter on service panel and adjust A4-R105 for a reading of 11.0 volts plus or minus 0.5 volts. I l 4 l-i \\. i t i 3 t l l l l I J[~-,. m e t#' N Thh M- - ' '+

s Iachine# M Oper. Nurs ATTACHMENT 2 i Arc Hours ELECTRONIC ALIGNMENT PAGE 21 of 3 (Calibration) Record 3/11/82 LIST OF EQUIPMENT USED FOR CALIBRATION EQUIPMENT CAllBRATION TEST CAL.DUE MANUFACTURER MODEL TYPE TEST NO. DATE DATE i 4 4 PARAMETERS FOUND TO BE OUT OF CALIBRATION . SECTION NO. DESCRIPTION h i CORRECTIVE ACTION b' SECTION NO. DESCRIPTION i I L l .) W Maintenance Tech. -g; - = ;_. _ ew. .., ~-. ~ j~m u c.MG

PAGE 22 of 31 CALIBRATION RECORD 3/11/82 1 i Date Factory Section Function Calib Reading Accept Date Accept Date Accept I 2.1.2 +24 VDC t3.0 VDC 2.2.2 24 VDC t3.0 VDC 2.4.3 +15 VDC 20.02 VDC I 2.4.4 -15 VDC t 0.02 VDC 2.5.3 +32 VDC +10.0VDC ~ -0.0 VDC D 2.6.3 32 VDC +0.0 VDC 10.0 VDC 2.7.3 +12 VDC +2.0 VDC 2.8.3 +5VDC 2.0 VDC 4 3.1.4 Prepurge 5 sec 0.5 see 1 3.1.5 Prepurge 3 see 10.3 sec j 3.1.6 Prepurge 15 sec 1.5 see O i k J i - = - c,. ,xv.

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i C I PAGE23of31) CALIBRATION RECORD 3/11/82 Date Factory Section Function Calib Reading Accept Date Accept Date Accept 3.2.2 Postpurge 45 see 14.5 sec 3.2.3 Postpurge 15 see t1.5 sec 3.2.4 Postpurge 9 sec 10.9 sec 3.3.4 Upslope 10 see 10.10 sec 3.4.3 Downslope 10 sec *0.10 see 3.5.2 Hi Pulse 16KHz 1500Hz 3.6.3 Lo Pulse 10!msilms 3.6.4 Lo Pulse

• S000ms 50ms 3.6.7 Pulse 100msilms 4.1.2 Master Osc 10KHz *100Hz 6.1.4 Fix Start Delay l

10 see 10.1 see i 6.2.2 Null 0.002 VDC 6.2.6 Offset l 0.002 VDC e h 6.3.3 Distance 2 in. 0.040 in. l 6.3.9 Distance 151n. _0.15 + .m mm

Q r y i PAGE 24 of 31 CALIBRATION RECORD 3/11/82 Date Factory Section Function Calib Reading Accept Date Accept Date Accept i 7.1.4 Wire Start Delay j 10 sec *0.1 sec 7.3.2 Wire Null 0.002 VDC l 7.3.5 Wire Offset 0.002 VDC 7.4.8 Wire 99 l d h. 7.4.8 Wire 10 in.

• 0.2 in.

7.4.10 Pulsed Wire 60 in. it.2 in. i 8.2.1 OSC Gain In +2.50 VDC 10.025 VDC 8.2.2 OSC Gain Out i -2.50 VDC 0.025 VDC l 8.3.3 Vernier GIin 10.0 VDC l 20.1 VDC 8.4.3 OSC VCO 9ms *0.09ms - 8.4.4 OSC VCO Ims *0.001 ms 9.1.2 Minimum Current 0.050 VDC

• 0.005 VDC L

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C I D PAGE 25 of 31 CALIBRATION RECORD 3/11/82 Date Factory Section Function Calib Reading Accept Date Accept Date Accept 9.2.4 Cumnt Gain 20 Amps 0.020 VDC 0.001 VDC 9.2.5 Cumnt Gain 150 Amps 0.150 VDC t0.0015 VDC 10.1.2 AVC Sample Hold 10.2.2 AVC Offset 0.00 VDC h 10.1 VDC 10.3.4 AVC Gain i1.0 VDC 10.1 VDC b O e 91 p ... N [ ~. ,_ l 1 l" O~}

BROWN & ROOT, INC. PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 WCP-6 1 3/11/82 26 of 31 ATTACHMENT 3 PERFORMANCE VERIFICATION / WELD PARAMETER MONITORING 4 The following four functions should be checked every 100 hours per 4.2 of this procedure and at a frequency detemined by Reference 3 for production weld monitoring. These four functions are the main items of interest where quality welds, made in accordance with a qualiffed W.P.S., are to be assured. 1.0 WELD CURRENT 1.1 Weld current may be checked while welding on a scrap workpiece or during production welding. Weld current may be checked while welding in any)of the three modes, (1) continuous current, (2) pulsed arc (PA or (3) sync pulse. 1.2 After the arc is stabilized (upslope is complete) connect the DVM l sense leads to the yellow terminal jacks orovided on the side of l the machine. These two jacks will give a millivolt reading corresponding to the welding current, e.g. 50 mv = 50 amps, 150 mv = 150 amps, etc. These two jacks are connected across the internal shunt of the welding machine and correspond to the teminal con-i nections Al-J6-10 and Al-J7-3 (See Attachment 1, 9.2 3.) l 1.3 Whileweldingknthecontinuouscurrentmode(nopulsing),theDVM should indicate a millivolt reading that ecuates to the value set r on the primary current thumbweel of the remote programer pendant. 1.4 While welding in either pulsed are (PA) or sync pulse (SP) modes l the DVM should give two millivolt readings, one corresponding to l the value set on the primary current thumbwheel and the other corresponding to the value set on the background current thumbwheel. 1.5 Jolerance for perfonnance verification of current by this method is 1 mv (1mv/ amp). 2.0 ARC VOLTAGE 1 2.1 The arc voltage may be checked while welding on a scrap workpiece or during production welding. 2.'2 All welding procedures for the automatic welding s'ystem have been accomplished with the are voltage response in the sampled mode. With this type of mode, voltage checks with continuous current and pulsed current will yeld the corresponding results as described below. ~ Md -f-- _T V f, m

8ROWN & ROOT, INC. PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE J08 35-1195 ~ WCP-6 1 3/11/82 27 of 31 4 After the arc is stabilized (upslope is complete), attach the DVM 2.3 sense leads to the red and black teminal jacks provided on the side of the machine. These two jacks will give a voltage reading corresponding to the actual arc voltage, e.g. 9.5v = 9.5 arc volts., These two jacks are connected internally to terminals A4-J7-3 and A4-J7-4 (See Attachment 1, 10.1.2). While welding with continuous current (no pulsing), the DVM should 2.4 indicate a voltage reading corresponding to the primary are voltage setting on the thumbwheel of the remote programer pendant. 2.5 While welding in pulsed arc (PA) and the sync pulse (SP) mode the DVM should give two readings. The first reading, indicating the arc voltage during primary current pulse, should correspond to the primary are voltage thumbwheel setting on the remote programer The second reading will bemeaningless due to the fact pendant. that the physical are length is locked during the background current pulse while operating in the sampled mode. Tolerance for pe'rfomance verification of arc voltage by this method 2.6 is t 0.1 volts. 3.0 FIXTURE TRAVEL. SPEED Travel speed may be checked with the welding head attached to either 3.1 the flat track system or the pipe track system. In all cases, the travel speed setting on the thumbwheels of the remote programer pendant corresponds to the movement of the head with respect to the surface of the track. I To measure travel speed, set the following switches to the positions / 3.2 j settings as indicated: Fixture Delay - 00 Seconds Upslope - 00 Seconds Fixture Mode Switch - Fonvard Wire Feed Switch - Off Time Mode Switch - Off Test / Operate Switch - Test Mark an arbitrary start point on the surface of the workpiece. ( 3.3 Position the tungsten electrode directly over the mark, initiate sequence, and after 60 seconds, mark the position of the electrode, Measure the distance traveled on the surface of the workpiece. f This distance, divided by the time traveled, gives travel speed at the surface of the workpiece. When checking travel speed with the head on the flat track 3.4 system, the measured travel speed should correspond to the travel speed setting on the thumbwheel of the remote pro-i i gramer pendant. ,g__ - " H7N,: v_.,,, f,,;, _ t;*p s : 3 t" _k_ fTL7 ~ ' y -v "TW v ---7 -

BROWN & ROOT, INC. PROCEDURE -ISSUE CPSES NUMBER REVISION DATE PAGE J08 35-1195 WCP-6 1 3/11/82 28 of 31 3.5 When checking travel speed with the welding head on the pipe track system, the measured travel speed corresoonds to the travel speed on the surface of the pipe and must be modified by the following formula: SThumbwheel = S easured X CT M W - where CT = Circumference of Track (stamped on track) Cp = Circumference of Pipe 3.6 Tolerance for travel speed determined by this method is t 10 %. 4.0 WIRE FEED SPEED 4.1 To measure wire feed speed set the following switches to the position / settings as indicated: Upslope - 00 Seconds Wire Feed Delay - 00 Seconds Downslope - 00 Seconds Low Pulse Mode - Off Time Mode - Off Test / Operate Switch - Test 4.2 To measure wire feed speed, retract the wire until it is even with the end of the wire feed nozzle, initiate sequence and time exactly 60 seconds. Measure the amount of wire fed out and divide by the time. This value should correspond to the value set in the primary wire feed speed thumbwheel of the f remote programmer pendant. 4.3 Tolerance for wire feed speed determined by this method is t 2%. ( I e P i W J e 4 v % C' y 4 / h_

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BROWN & ROOT, INC. PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE J08 35-1195 l WCP-6 1 l 3/11/82 29 of 31 ATTACHMENT 4 MAINTENANCE 1.0 PREVENTIVE MAINTENANCE 1.1 GENERAL INFORMATION A. There are two classes of maintenance required on this system, preventive and corrective. This section deals with all aspects of preventive maintenance as follows: 1. Cooling system 2. Cables and connectors 3. Remote programer 4. Power supply console and filter 5. Pipe / Tube weld heads 6. Remote junction box The few short minutes it takes to do these steps will save hours of work at a later date. 1.2 COOLING SYSTEM: A. As described in the installation section, the torch coolant system requires a 25% to.50% anti-freeze (1.7 gallons total) solution, to be mixed with the water coolant. The water does not have to be distilled, but should be filtered before being put in coolant tank. The anti-freeze, in addition to preventing freeze up in cold climates, also lubricates the coolant pump and prevents rust on water connections. B. Every six months from date of installation, the coolant tank and hoses should be drained and flushed and a ns.w fill of coolant added. C. The water level should be checked at least once a week and added to at once if level is low. 0. All quick disconnects should be checked for fit and l leaks periodically. Replace quick disconnects if their plunger seals fail to close properly. Clean the connects off with a wire brush if corrosion appears. E. Check the torch water connections IN/0VT at torch body for old and brittle hose and cut back and remount clamps when necessary. . = 6 .4m M MY UN'I t T. Y be*em._ mA 'h h.m-#mh W N M - dm -e alm

s 4 BROWN & ROOT, INC. PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE 408 35-1195 WCP-6 1 1 3/11/82 30 of 31 F. The fifty foot weld head cable requires about 0.6 gallons to fill. If new torches are connected to the system, be sure to refill tank. 1.3 CA8LE AND CONNECTORS A. Even though the weld head cable is covered with a rugged flex hose shielC, the cable cannot be abused. Caution should be taken to protect the cable in any situation where machinery or heavy objects are present. Whenever possible, hang the cable. Avoid laying cable on concrete slabs where traffic or moisture is usually present. Put cables in clean dry area when not in use. B. Be aware that the cable will melt if layed directly on hot pipe or plate. If wrapping cable on preheated pipe, insulate first with asbestos. Always unwrap cable the same way it was prewrapped. C. All exposed connectors should be protected when not in use. The threads or bayonet locks will b.e damaged and require replacement if not taken care of. D. All connector pins should be cleaned with a soft brush and blown off with dry air, argon, or dry nitrogen whenever they become dirty. Check at least once a week. E. Check all strain reliefs on connectors for tightness and effectiveness at least once a week. F. Exercise extreme care when inserting and removing connectors. 1.4 REMOTE PROGRAfEER A. The remote programer is housed in a rugged metal case and supplied with a latching cover. When not in use, l cover the remote programer to prevent the programing l switches and dials from damage. Even though it is j housed in a rugged package, do not throw or drop the remote programer. i l B. At least once a week the programer switches should be air blown clean with hi pressure, clean, _ dry _ air, argon l l or dry nitrogen. Do not use any tyoe of cleaning solvent on switches. j l C. Do not grind in the vicinity of the pendant. l l w_ t t ~-

V [ v. BROWN & ROOT, INC. PROCEDURE EFFECTIVE i NUMBER REVISION DATE PAGE j CPSES I' J08 i 35-1195 31 of 31 WCP-6 1 3/11/82 D. Exercise extreme care when inserting or removing the cable connector. 1.5 POWER SUPPLY CONSOLE AND FILTER A. At least once a week check that the input power cable clamp is tight and that the power cable is not frayed or cracked. B. All weather sealed covers should have all screws in and tightened down at al.1 times except when under repair or calibration. C. At least once a month, remove the louvered grill above A15 connect panel and remove and clean air filter. If in an extremely dusty environment do at least once a week. D. Use extreme care when inserting or removing connectors. 9 E. WARNING: Disconnect 480 VAC line from wall or turn off wall mounted breaker before removing power supply covers. Even with machine circuit breaker off, 480 volts is present in the machine. 1.6 PIPE / TUBE WELO HEAD A. The welding heads should be cleaned off with a soft brush and dry air pressure after each days use. B. Store head when not in use in the rugged container that it was shipped in. ( C. REFER TO THE OPERATION SECTION OF MANUAL FOR OTHtR GUIDELINES FOR CARE OF WELD HEADS. r ? i l l I i 1 u,m u .. ~ m m-m _-,. _ w-w.. -m

Investigation of Allegations in Ragard to Piping Activitics i ities. b. The RRI also looked into two allegations related to piping act v bear-The allegations, while not directly safety re l the site QA/QC program implementation. Grinder Trapped in Pipe _ (1) 79, One of the allegations which appeared i f In an instance personnel using the piping system as a " bedroom". l had related in the news article, one of the craft personne i fallen allegedly been welded irito a pipe section after hav ngT 445/79-12; asleep in the pipe.the alleger involved in Inspection Report 50-50-446/79-12. The RRI inquired of QA/QC and construction manage d during to any incidents of this type which may have occurre(Th Subsequently, a pipe-the spring of 1979 for the alleger to have this knowledge.) fitter c h inside have given rise to the story. volunteered to go into a fourteen inch pipe to grind t e i test. of a weld joint that had begn rejected by radiograph celbo This involved entering a 90 feet, turning over and going through another elbow an When he was about half finished with the h t he joint, he decided to get out to rest only to discover t a to reach the joint. h both of the elbows and was effectively tra The fitter related that the people with him on the outside w l ready to cut a joint to let him out but soon i h ite and bonnet removed, which was done. coincides with the original alleger's employment on t e s h out of may have been the basis for the allegation, even thoug context with the facts. Calibration of Automatic Welding Machines _ I f O,h (2) d 4 The RRI investigated another allegation that had been b i of the through another IE inspector regarding the cali rat on l p6 $ I ]J['I, lg,l j l S 10 c F01A-85-59 l E7I NY

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1 ( [... Dimetrics cutcmatic walding eschinrs. (Celibratica of welding nachinzs is not en ASME Cada nor NRC rtquire= Int unless such r ' ~ calibration is necessary in the control of the welding process.) Many machines in use, in and out of the nuclear field, do not have an instrumentation on them. When knowledge of the measur-l able welding parameters is required, separate calibrated instru-ments are connected to the welding leads to measure the welding parameters in order to verify that the welder is welding within the weld procedure requirements, not to verify that the machine is operating properly. The licensee is committed to and has imple-mented such a program which is applicable to all welding of a safety related nature whether accomplished by machines or manually. The Dimetrics machines are sophisticated, electronically con-trolled units which have the capability of adjusting themselves to accommodate several variables usually encountered in welding. (During manual welding, these variables are usually adjusted by welder technique.) The machine operator has control facilities I available to him to adjust the center point of the automatic correction range and it is desirable that these adjustments be accurately indicated. The RRI found that a select group of pipefitters had been charged with the responsibility for main-l taining, adjusting and calibrating the machines. Discussions with several of these personnel indicated that, in reality, they were electronic technicians administratively assigned to the pipe department. The RRI reviewed the procedures of the group, which are the recommended manufacturer's procedures, and reviewed records of j the calibrations. The lead pipefitter-technician indicated to the RRI that he has taken care of the machines almost since their receipt at the site, but that he previously was under the Welding Engineering Department where the work had been performed I under Procedure WCP-6. Now that he worked in the Pipe Department, he worked entirely to the manufacturer's procedure. j The RRI reviewed a copy of WCP-6 entitled, " Electronic Align-ment, Performance Verification and Maintenance of Dimetrics Automatic Welding System." It was determined that the Brown and Root, Houston based welding engineering center had estab-lished requirements that the steps of performance verification (calibration) be aicomplished by QA/QC and that the site welding engineering also verify, at a relatively high frequency, that L f the machine output correlate accurately with manual adjustment 9 indications on the machine control unit. Further discussions j with QA/QC managementspersonnel revealed that they have not accomplished the requirements of the procedure, nor has welding j 1 li 11 j L 6 s m.-. ( - - ~.. t + a. 2

i e engineering. It appeared to th2 RRI that thn grcups wara not aware of the requirements of the procedure and/or that they thought that the procedure had been cancelled. The RRI determined that the weld parameter monitoring program discussed above verifies with adequate frequency that the machine output is within the range allowed by the qualified weld pro-cedure even though this may not be accurately indicated by the machine control unit. The RRI pointed out to the licensee that he was in noncompliance with Criterion V of Appendix B in that a procedure was issued by the licensee's agent for application at the site and that it was not being followed. 10. Installation of Unit 1 Containment Electrical Penetrations The RRI observed the installation effort relative to electrical penetra-tion IE-60 which was the seventh of approximately seventy-five to be installed. The RRI observed the uncrating of the component, (which is manufactured by. Amphenol-Sams), the pre-installation inspection by assigned QC personnel, and the insertion of the component into the designated containment nozzle. The craft and QC personnel were performing the required activities in accordance with a detailed " Operations Traveler" specifically prepared for the unit. The two QC personnel assigned to the activity appeared to be both diligent and knowledgeable of requirements. No items of noncompliance or deviations were identified.

11. Equipment. Maintenance The RRI selected four identical components for inspection of the Brown &

Root equipment maintenance effort during the period. These items were the Unit 1 containment spray pumps and their electric drivers. The pumps and three of the drivers were observed to have been installed during several tours of site at an earlier time. The pumps are maintained by the mill-wright group of construction, while the drivers are in part maintained by electricians and in part by the same millwright group caring for the pumps. The RRI initially reviewed the Ingersoll-Rand manual for the pumps and the l Westinghouse manual for the drivers to obtain the manufacturer's recommended storage maintenance proceduros. The cards in the files of the millwrights, for both the pumps and their portion of the work on the drivers, reflected l these manufacturers' requirements accurately and appeared to have been accomplished ip accordance with these instructions. The records of the electriciaa 'likewise reflected the accomplishment of their scope of re-The single driver not installed was identified through the ~ quired work. records as not yet having arrived on the site and therefore as not being within the program. 12 i^ 4, n m.w - -,ver

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'F ~ Inspection R; port No. 73-18 i. Ly= TXX-3071 z= Page 7 a-i D. Failure to Follow Procedure for Verification of Performance of Automatic Welding Machines I 10 CFR 50, Appendix B, Criterion V, " Inspection Procedures and Drawings," requires that activities affecting quality shall be prescribed by docu-i mented instructions, procedures, or drawings. Comanche Peak Steam Electric Station Construction Procedure 35-1195-WCP-6, " Electronic Alignment, Performance Verification and Maintenance of Dimetrics Gold Track 11 Automatic Welding System," (Interim Change 1 to 4 Revision 0) requires, in paragraph 4.2.3, that performance verification be accomplished by the QA/QC department and requires, in paragraph 4.3.2, i that weld parameter monitoring be accomplished in accordance with Appendix 3 of the subject procedure. j Contrary to the above: The NRC Resident Reactor Inspector verified through interviews with l personnel who maintain the automatic welding machine, with QA/QC super-visory personnel, and by a. review of pertinent records, that QA/QC has not verified the perfomance of the machines as required by the above i procedure nor has the weld parameter monitoring been accomplished in accordance with Appendix 3 of the procedure. 4 This is an infraction. Corrective Steps Which Have Been Taken and Results Achieved i { As discussed by the RRI in NRC Inspection Report No. 79-18, as formally l transmitted on November 9, 1979, the stated infraction is procedural in nature with no bearing on the quality of the completed installations. The i l automatic welding machines have in fact been maintained in good working i condition, although accomplished by personnel other than those apparently formally delegated by Procedure WCP-6. For these reasons, corrective action j will be limited to the preventive measures discussed below. Corrective Steps Which Have Been or Will Be Taken to Avoid Further Noncompliance i Procedure WCP-6, Revision 0, was revised by Interim Change Notice 2. Major changes include:

1) Paragraph 4.2.3 now requires performance verification by(s)elding W

Engineering with the assistance of the Welding Operator or Maintenance Technician (s). m m -,=_

Inspection Report ha. 79-18 - ggg: TXX-3071 gr Page 8 ?

2) Welding Operator (s) and Maintenance Technician (s) have been de-fined as Brown & Root employees specially trained in the Operation (Maintenance) of the Dimetrics Welding Systems.

3) The frequency of performance verification has been revised from a calendar to a machine (Arc) time basis.

To assure full compliance, QA staff personnel will periodically verify compliance to the established procedural requirements utilizing CPSES audit and/or surveillance procedures. Date of Full Compliance y ---4 ThesubjectprocedurewasformallyrevisedonSeptembeb.1979/The procedural verification program will be implemented starting December 1979. 9 i I ( e l ( 0 e _ _. -pr - * * -- m1 ww. ~, - + - .-mh _m

y, GK-O a u 1. 1 O, 3 you talk about' around fourteen hundred packages of permanent 2 records that were apparently lost in the course of moving ) packages from one location to another. Can you tell us a 4 little more about what happened during the move of those packages? 6 A . These were hangar packages, They were moving them p 7 to the task fo.rce..In the moving, whether they,were sent g to a different E the~y were broke up into reactor build'ing, k- 'auxili,ary building, et cetera. They were moved down in boxes ~ ~~ 10 in open-back trucks. During the process'of the move, they had,atthtattime, misplaced,Iheardthemsay,aro'und'fourI 11 12 .p teen hundred packages they were looking for. It.is my g 33 ~ p understanding, they have since found-all of them. I meant, 14 the last I heard was when two men came into our office look-15 ing for about ten packages that they hadn't found. And I \\ N 16 y tried to -- We looked through everything that we had and they i 17 even suggested the possibility that they might send everybody l 18 outside and go through their desks to see if they had them I9 lost in their desk somewhere. i fa 20 Q Do you know of any packages that are still lost? Is hl 21 there any examples that we could go looking for? l 22 A Yes. There 'was one that was lost when I left. They 23 came in the day before I left trying to find a weld attachment. s .:L- - 24 to a hangar package. The number is. CCl^MYoo,WAliA- ^-^G 5s'S. It!'s a i TF C C. io i 25 twenty-four inch line. It is about the size of this table, L F0lT-85-5 F L E

e .o 1 the saddle. They had to send it to Fort Worth to get it 2 rolled. They burned over two thousand rods on it. And if 3 they don't find the documentation that is necessary to cut i 4 it down and rebuild it, which would be a cost of over a hundred 5 and fifty thousand dollars, iso I assume that they will find l 6 it because the hangar itself had never been transmitted to 7 the vault. When they came into my office, they had it ^ 8 .. listed as a. weld :sttachmentr'it was a hangar package. .I had

9 cliecked the check sheet that. it had come.in and all they had.

~ if ~ on there.was the number and then, " weld attachment". I put 11' .it in a file where it was supposed to be kept until it went 12 to ANI as a full package concept. And,when they. game back -~^ 13 j looki,ng.for the weld attachment, they tried to say it was 14 with the hangar package. What I had signed for was this 15 I didn't op'n it up to see if it was a hangar package. e 16 I package or weld attachment, but the only thing I showed 8 17 ( receiving from, or signing for, was this number as a weld I 18 attachment, so I don't know if they found it or not. But I I 19 I do know that they were looking for it pretty desperately. 20 a I'didn't even get a chance to find out if they found it. ~ l 21 ( Q Are there log sheets that we should go look for or 22 look at that would describe the passage or the progress of 23 this package into the system or the log sheet that you 24 ) s..Ei logged it in on? Where should we go look, I guess, to try and see anything we can with the trail of the progress i 1 n

I, a j i 1 of this package until it got lost? r r t 2 l* A All right. I maintain a set of logs. I maintain a 3 set of logs for piping and then another log for hangars. r L 4 / I have the transmittal sheets on the hangars as to when they y 5 j come in and then I have a little index that I made up -- just I ~ a small index showing what numbers had come in, so I could 6 L 7 t-refer.back to,them. If they're still in place, there where ~ i ' ~ _ _. d -j"~ g my desk kasi.I don't know who'is filling 3. hat pos,ition%ow..,, t 10 But I will have a set of log books showing that tha packages ' 11 came in, piping and hangar. packages. I will also have a 12 i transmittal slip from the task.fo'rce, and.when I send the l 0 ' ^ ~ " - - 13 ~ documentation out, I make a transm. ttal slip when I send it 14 to the vault or I send it to ANI. I don't make the trans-3 15' mittals out on ANI anymore becau.se they put that responsibilit.y t i !'I 16 in the hand of the person who is. handling the transmittal I 17 of the N-5. status sheets and everything over there. They i 18 ?

• send it all over together.

I get it when it comes back I 19 from ANI and then I transmit it to the vault., But as.'you i $a- ~ 20 ig go back each step, I w5.ll'have a transmittal slip showing .f where I had signed for it. should have a N 2 22 I transmittal slip showing where it came'into his office. Them ~ k.l' 23 [. it should go back to whatever craft department or whatever. ? 24 I = Each one should have a transmittal slip showing whom they 25 got it from and the date it'was received. I l t

7. 1 Q so, a. trail like this.should exist for any of these m== 2 P documentation packages as they come through the system? 3 A Yes.. 4 Q And at least for this specific package that was mis-5 placed when you left, the trail should come through the 6 logs and then, of course, we assume it ends at that point i 7' if they hadn't found the package. .g. ~ . T' .. l 'A: I N* * =. - 9 m .Q' .If.the' package has been found,'where.is itilikely } 10 to be at this point? Would it have probably gone on.into =,. 11 the vault or in to N-5 review? '12 I A It didn't go to the vault. i- ^ ~ 13 ~'- ~ \\. Q Okay. ? 14 A Everything that goes to the vault comes through our 15 office, now, and before, it went through the hangar depart-l { ment.- At one time, they had the hangars separated from the I 17 piping. I also have the old log books from the hangars that ( l 18 were given.to me when they combined our two together. I I 19 went into the log book showing the date that these things wer o a 20 sent to the vault and there is no indication that it was ever g 21 t in the vault or that it has ever come into our office, other r 22 than when the hangar package came in marked " weld attachment" As I said, I was checking the numbers on the side of the i 24 i

25:.

index. I didn't go into it. It does not say "with weld j u.nF 25 attachment". It says the hangar number and" weld attachment" I .4 i M. .a ~ ~ ~y 't"K.__._wmg -F Pm " m,,, gh.

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cv TQ 8-1 which I assumed in checking it in, this was the weld attach-M 2 ment, separate from the hangar. And then I find out I've got the hangar package and the veld attachment is still 4 missing. <3 Okay. Help me out a minute on the logs that you're Q' keeping. Are these an informal log that,you elected to establish and: Keep or is this a log that the procedure says. 7. ..s.

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?' you are,to keep'and will pass on to whoever oecupies'the, d. 9' i: position to continue inaintaining it? 2. g

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~" s s. A. It is a procedure. I-did five procedures. Each' =: party receiving packages; piping, hangars, otherwise, :are to keep a log on where the hangars are<. If they have -transmittec L ~ " - - - 13 [.. them, to where they go. This is the-way they maintain 14 traceabilitiy. Without this, it would be impossible, but it is a procedural -- It's ' required by the. procedures. i 16 I Q Okay. Are there any other examples of a lost package 8 17 from this group of fourteen hundred that you can think of l 18 or send us to go look. at? I 19 k-That'stheonb.ynumberIhaveinmymindthatstuck. A f 3 And I guess it was when they told me it was going to cost [g }k; I' g a hundred and fifty thousand dollars to replace it, I } nearly flipped out. There'have been other packages, but fb r ' they have eventually turned up.- F ar. S 4 are you aware of any lost packages like this_, Q p =- 25 l that we could go look for? e e a

I I don't hava cny numbero. k MR. HARRISON: Can you just recall maybe what piping [ 3 syctem it may have applied to? The missing packages? 4 ' h Well, as I said, they've turned up since, 5s so that they're not missing anymore, but'-- 6 MR. HARRISON: What I'm saying, the prefix on this l' 7 number that you gave us is probably a component - f Ch, I'm sor 'Le'_t me give.you the j.

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~ 9 iso number., j. /.h c..' .y ~ 1.0 MR.' HAARISON: Okay. That's fine. e 11 It's CCIAB013ris the iso number #. I2 MR. HARRISON: CC1AB0137 i 13 ~ ~ " " Yes. M ^ MR. WESSMAN: Let me leave that issue of the lost 15 packages for a tainute and digress a minute. Just so that we 16 'have a better understanding of how the N-5 due process works, 17 could you give ns a little general description of how that r [ 18 works; what it's supposed to do when everything works I 19 correctly on it. i. a 20 ~ At one time, the QES review and the TC j 21 N-5'ccde'dsta status reports were separate departments. The r 22 QES reviewer would receive the -- we handled only the piping .s 23 in the beginning. Back in about April, they brought the 24 hangars down for us to handle,also, but they both worked v 25 about the same. The piping packages would come in; their .m ge g 7 .c _9 2 ___m__ mm

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47 C0riTROL/ ROUTE SHEET Allega-ion fia

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Subject of AllegatJon _% eev r 6, N... .% \\ o c A u,.e N A 4 c. h c - & TRT Group M e elm'e, I i P v' GWn Ms _ )V Author: C R.,u h ' i 4 6 This sheet will be initialed by each reviewer. It stays with all revisions to the 1 SSER writeup and serves as a routing and review record. It will be filed in the ' work package when the writeup is published. l Draft Number j Draft 1 2 3 4 5 Ag. thor d.)5b d d.N' b '{ h b b:k _ Group Leader 16 4 & / /_ - ~ i Tech. Ed1 tor WS3 S//7 W. VM 4/5 1/2 < Wessman/vietti l J. Gagliardo T. Ippolito Revision Number l Final 1 2 l ~ 4 5 Author Tech. Eoitor Group Leader ~ J. Gagliardo T. Ippolito A l Y. ~ Administrative V j Writeup integrated in. Potential Violations tt i Workpackage File Complei i Forkpackage Returned to L. i f ~ FCIA-85-59 u -n,a!y L

Draft 5 9/IS/E4 s SSER AW-63/CP2a SSER 1. Allegation Group: Mechanical and Piping No. 8 l I 2. Allegation number: AW-63 3. Characterization: It is alleged that a weld data card for a field weld was lost, that the data card was reconstructed, and that the reconstructed version was accepted by Brown & Root quality control personnel. 4. Assessment of Safety Significance: The alleger did not identify the field weld or system associated with the alleged lost card. Therefore, the TRT's best effort was to review weld documentation packages and detennine the extent of available resources where duplicate data is recorded and the feasibility to reconstruct a lost i field weld data card. A random sample of twelve documentation packages was reviewed. The givan approach to each package was, should that package become lost, are the available resources of information sufficient to reconstruct that package. The TRT also reviewed a real j case which had been discovered and previously reviewed by the NRC l' Region IV (RIV) inspection team (IR 83-07). This real case is documented on NCR No. M-3425R2 where a weld data card package for weld FW-1-on Drawing BRP-MS-2-RB-19 for the main steam system had been lost and reconstructed. l ( L l W!*"* N "*usu*-- .F

, The TRT Review revealed: a. The welders certification update (rod house) and weld material issue records provide: (1) The welder's symbol number. (2) The rod container number in which the weld material was issued, and time of issuance. (3) The drawing and field weld number for which the weld material was issued. (4) The welding process (i.e., SMA, GTA, etc.) and the weld procedure specification number used. (5) The type, quantity, and Heat No. of weld material issued, and quantity of material returned. b. Copies of NDE reports are obtainable frcm QA records for any method of examination (i.e., liquid penetrant, magnetic particle, ultrasonic, and radiograph) required for a given weld number. Where such reports show rejectable indications, these indications are identified and located which provides evidence to determine the type and quantity of repairs that was needed and ultimately the final report of acceptance. ,. c. 7-- e--- ,ac. -- m

l Note: The QA-NDE Rerrt reccrcs are mait.it r: in chronological order. The finding of pertir.ent reports wou' require a search f through a time frame from the earliest activity discovered in (a) l above (given reasonable safety margins) to tne time that the loss of data occurred. Copies of any special reports generated to support NCR's are also retrievable. The above NDE reports identify the certified individuals performing the QC hold point inspections. c. For Weld Technician (WT) hold point signoff, it would be necessary-to reconstruct within a reasonable time frame where knowledge of the WT perfonning these inspections (cleanliness, fitup, preheat and interpsss temperatures) is retained by the involved QC personnel whose activities include monitoring the WT inspections and/or by the welder. Any preheat or interpass temperatures need not be recalled except that they were within the required range specified in the WPS. If necessary fitup can be reasonably reverified by a review of the radiographic film and/or mechanical dimensioning. In any case, the WT hold points are of little or no significance to satisfy the ASME requirements for weld documentation. ,*r= ._w,

( l 4 ( ) d. Other sources of a#Mie infonnation are: weld material certification records, crawing requirements, component or piping F f material certificatior. records, welder qualification records, and l i procedure qualificatter, reports. 5. Conclusion and staff positior.: The TRT conclude's and concurs with the RIVinspectionthhtalostwelddocumentationpackagecouldbe sufficiently reconstructed. from available documentation to satisfy the ASME welding documentation recuiremen,ts. The TRT also concludes that i 1 L the allegation (that a weld cata card was lost, reconstructed, and accepted)issubstantiated. However, the allegation has neither safety significance nor generic implications. 6. Actions Required: None. i W N 8. Attachments: None. ' 9. Reference documents: I. NRC Region IV Report IR 50-445/83-07, 3/9/83 2. NCR M-342S-R2 3. ASME B&W Code Section III and Section IX, '1974 Edition thru .s Susiner 1975 Addenda. t v. a-

~ . 10. This stater.ent prepared by: C. Richards Name Date Revievied by: Group Leader Date Apprevert by: Project Director Date 1 l i I ea sa,s .#aar h-mw.,ww-w pp A IWMDVM-hsW e <J

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I..,..,, i Draft 5 / CP5A AQ-55 and AQ-78 ( 10/9/84 SSER 1. Allegation Group QA/QC, Category 8. As Built 2. Allegation Number: AQ-55 and AQ-78 3. Characterization: It is alleged that fuel transfer canal liner documentation was f alsified, that required weld radiography was not 'tVe>((cy s completed, and that hold points on inspectionnfor the fuel building were signed off improperly. ( ' 4. Assessment of Safety Significance: The implied significance of this allegation is that the fuel transfer canal liner (" liner") f abrication and installation were incomplete and incorrec d may not comply with design requirements, therefore, rendering the quality of the liner i indeterminate. The liner consists of a series of 3/16-inch-thick stainless steel plates l welded together and attached to the inside of a concrete support within 1 l the fuel building. Transfer tubes at either end of the canal connect to similar fuel storage pools inside Containment Units 1 and 2. The method of construction first requires the presssembly of all vertical liner plates, after which concrete is poured around the outside of the plates. t l l l l ' ' ~ =w& - ~ ':. X". '~ i M' ^

. i ( bh l The plates are joined with a backup bar on the backside a full r I penetration veld that forms the structural joint sad seam weld between I the liner plates. A channel is then welded over the backup bar to fora l the leak chase cavity. After the concrete backfill the backhide becomes j inaccessible. The finsi (pool side) seas weld is made as auch as three years after the initial bac ide welds, and, in some cases, og a concrete,poursag. After completion of welding, the seam welds are examined by dye penetrant testing, vacuum box testing, and visual examination. The allegations refer to a time early in 1983. Part of the subject allegation was that a B&R inspector was coerced into signing off 112 I liner travelers that supposedly were inspected by at ther inspector. The NRC Technical Review Team (TRT) reviewed all inspection travelers f3r the l fuel building, plus selected travelers for the fuel irage pool in the Unit 2 containment building. The TRT located 47 inspection travelars l l related to the Unit 2 containment building, which were signed by two different inspectors and for which hold point No. I had been signed-off l out of sequence (i.e., after later hold points had been signed off). A t " Late entry footnote was placed at the bottom of each traveler, stating: l E, @ndas4 tor.MVt 4%AMd( per CP-QCI-2.11-11 Para. 5, see Note. Refer NDge' attached i j documentation." The footnotes were signed by the it,ectors and dated in early March 1983; however, the actual inspection had supposedly been completed in Oc.tober 1978. 1 .m . ~

., (~ j tjTM a Jttrview of CP-QCI-2.11-11. " Welding Inspection sud Fit-up of ' Stainless Steel Liners," showed that the correct number for this procedure was CP-qCI-2.11-1, although pages in the procedure used either number. However)the TRT found that Procedure CP-QCI-2.11-1 had been deleted from ~ the QC Manual on January 10, 1979, by B&R interoffice meno IM-16606. This procedure was replaced by Procedure QI-QAP-10.1-4, which was also entitled"WeldingInspectionandF1 up of Stainless Steel Liners." ) The TRT found the " chits" referred to in the traveler footnot attached to the travelers. The Para. 5. CP-QCI-2.11-1, " Note" referred to in the footnote states: "The QC Inspector shall use information on the NDE , Report chits to update Attachment 4-A (i.e., the inspection traveler) dsily and subsequently forward t e NDE request thits to the QA vault daily as a status indicator." l TheTRTdeterminedthattheinspector'sfailure.tosign-offonholdpoint No. I at the time of inspection may have been dae, in part, to inadequate procedures, as indicated by the following: l l l a. The use of the chit was first introduced in B&R Procedure CCP-38 Revision 2, dated October 1977. The chit was to be used solely . to notify QC of a pending i spection. The QC inspector signed the chit after the inspection, which provided crafts personnel with a i record of completing the hold point and allowed them to proceed. I The chit was intended as a construction document, not a QC record to a m- - v: ~2 c ~ ,v:> - :- uw. m.;= ,_-a;3 3,1;s..mc m x:;-;g.,, g7;__

(.. ',.. document completed inspections. Revi_sion 3 of CCP-38, dated May 23, J 1979,hara.3.4.2dindicatedthatthechitwastobeusedonlyfor miscellaneous inspections that were not included on the traveler hold points. This conflicts with the instructions given intprocedure CP-QCI-2.11-1. Para. 5. " Note," quoted previously. b. There were frequent changes in the inspection tiraveler form attached ~ to Procedure CCP-38. The form initially was issued as part of CCP-38 on August 14, 1978, and showed five weld hold points. The use of five hold points was probably inadequate for some welds, in that two fitup and cleanliness inspections of the same gap were appropriate for plate-to-plate welds, but the use of five hold points a lowed for only one inspection. The form was modified to include eight hold points, one of which was an additional gap fitup and cleat. ness inspection. The form was then reissued on April 18, 1979. The form was also reissued with minor revisions on May 23, 1979 July 26, 1979, June 22, 1982 (decreased to seven hold points), and September 7,1982 (increased to eight hold points). Procedure CP-qCI-2.11-1, Pars. 3.1.1 states: "A minimuc of five (5) NDE L h - inonauss m s 2,-- L.; request chits are to be issued by the Mi11 wright Do, ertment in order to complete these hold points," that is, - the five chits corresponding to the five hold pesints listed on the original inspection traveler. The TRT found inat, in general, five chits 9 'q - 2 ], '" [ i _.4 'F7"~6 F, - i =

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(- for each traveler were not availablQ nly those chits related to the signoff of hold point No. I were generally available. t j The TRT was able to locate 47 travelers with a delayed sign-off for hold point No.1 in a manual search of all of the liner traveler files. The TRT found that welding of stainless steel liners for the fuel pool in b4MCephiqrge, yte g g the Unit 2 containment building was also the subject of g R)M83-00795, issued on March 17, 1983, which stated the following nonconforming i conditions: CC a. "A randon review of stainless steel linar travelers for Reactor II I cavity liner velds has found required fit-ups/ cleanliness inspec-i tions of inside~ (waterside) welds cannot be verified as being f performed." ) i l b. " quality of welds indeterminate." c. "See attached sheet for welds randomly reviewed." l j d. "Five hold tags applied." l I This NCR was dispositioned and closed on March 23, 1983. However, the I NCR was reopened and issued as Revision 1 on about March 29, 1983, for the stated purposo of changing the nonconforming condition, i.e., the ( g g e e I' ] ' 4*

. ( words " random" and "rsndomly" were deleted. Deletion of those words h a ca; I,'.., g limited the scope of the NCR to the welds listed on the NCR* Mich was not the meaning of the original NCR. It appeared to the TRT that this revision was issued solely to avoid the ensuing investigation that the original would have required.- No explanation was providid for revisi::g the description of the nonconforming condition, and there vss no indication of the original inspector's concurrence with the changed description. t yg'W bard'4M 4E " c,I, ~~ A Revision 2 of the NCR was issued on or about August 13, 1984, for the N S. stated purpose of deleting veld No. 1225 from the NCR. 4ed was an a.Od additional change in the description of the nonconforming condition) 4 'I y14ouT N b WA.S #*Ie I 2 also(without explanation or concurrence ed.the original inspector. Q his a change was not in compliance with the procedure for revising NCRs, as described in QA/QC Category 5D, Allegation AQ-124. <C / 'N This NCR was dispositioned on August 8, 1984, as follows: " Subject velds are seas welds utilized to provide leak tightness of l the linee. Acceptability of welds shall be based on vacuum box and l hydrostatic tests." The use of the term " hydrostatic tests" is inaccurate, as the test referred to is a nonpressurized leak test. s. l ~ - ~x x.. , n

j' i. ( The TRT then reviewed part of the allegations regarding the falsification of inspection travelers. The TRT noted the following irregularities in the travelers for the fuel building liner: I a. Step 5 of the traveler for Wald No. 580, Dwg. WFB00831, was signed and dated 8-5-811 then the date was changed to 7-2-80, and was initialed an'd dated 7-2-80. The traveler for Weld No. 567 for the same drawing was similarly modified. l b. Travelers for Wald No. 595, 591, 588, and 589 g Dws. (. WFB00831, were signed by a QA inspector on 12-4-81. However, part of the signature does not match the inspector's signature on i penetrant testing inspection forms httached to the travelers. It appea to the TRT that someone entered " SAT" and the date on the travelers, then obtained the QA inspector's signature. The R(s inspector confirmed during an interview that this bad, in fact, occurred. c. The traveler for Weld No. 564, Dvs. WFB00831, was signed off as j i [ complete on 7-23-81. Ecwever, apparently in reviewing the traveler b before transmittal to 3he B&R QA files, the inspector noted that [ vacuum box testing had not been completed. The vacuum box testing was performed on 8-26-81, the signoff date for veld completion.was changed to 8-26-81, and the travelsr was receipt-stamped by B&R QA f i m.u.A_* I'_ d$ ~ h q 9 S [ e i

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1 *.*' ..J*. '~...,.._.,,o kQ Uc Sfr M-h*j, rp files as 8-27-80.f,,S(milar occu % o C* r ~:< ~ * ' ~ ' f rrences c d es on travelers for 1 Weld Nos. 584 through 586, 558 through 563, 565, and 592. i 4 ,/ d. The procedure numbers for the vacuum box and leak tests were changed during construction of the liners; however, the numbers on the ,/ inspection forms were not changed. Since the former was not I changed, the inspector was required to write in the correct proce-j j dure numbers, as shown on travelers for Wald Nos. 568 through 571, 8 l 573, and 575, dated July 2, 1980pjand August 10, 1981, and signed by another inspector. However, travelers for Weld Nos. 536A through 544A and 546A through 549A, with the same inspector's signature, t were dated in November and December of 1981 and did not have the procedure numbers corrected. The procedure nuaba s were corrected separately in December 1981 and January 1982, a few days before t.he g l travelers were received and date-stamped by the B5 QA files. Inspection travelers, signed by a third inspector, would e. frequently have the sign-off dates changed by the same inspector, without explanation. .l' otal of 5,022 inspection travelers relatedeo the if rs, were issued as of September 14, 1984. Of these, 1,209 were for Co. ainment No. 1, 5, i; 2,612 were for the Fuel Building, and 1,201 were for Containment No. 2. L }N Obviously, seme s)0v! N a 4 -emount of irregularities wi.11 occur because of human

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}- 4 . (' There are also three lift getes in the fuel building fuel transfer canal. I The gate supports are welded to the liner. B&R Specification CCP-38 requires radiography for veld Nos. 1759 through 1772, 1803 through 1808, y and 1823 through 1826. The TRT locate _, . - _ _.. _..__ the radiography l N t c., Y C.C.n v e T. ko uYd e i records in the radiogr trailere cceptance of all the above welds. I ) N $'i Il.( V Wd f)C TM i Therefore the required radiography inspection was completed. a l-i ~ The fuel building fuel pool liner was satisfactorily leak tested on . March 22, 1983 Test No. ISF-055. f 5.. Conclusion and Staff Positions: The allegation that radiography was not & S t)leS$u)& A.N A-) QE completed was umfamad, the TRT found records showing the results of radiography velds. The TRT conclui s that there are record anomalies which are not adequatger plained, vioiste procedures, and((employA)Mk VJMN + i 'YNVYOWib s) inadequate proc dures. TL. 2_ _: we-eensedes. the footnote on the b 5S W inspection travel r to4e adequate substantiation for the late signoff of Hold Point No.1 '9 the procedure referenced had been / ~ deleted 4 years and 2 months previously, and $ the signoff years i,' and 5 months after the inspection was performed, not on the day of f l inspection as required by procedure CP-QC1-2.11-1, Para. 5. Therefore, 4 these allegations do have safety s -ificance and generic implications of QA/QC breakdown. 1 j 6. Actions Required: Before loading fuel in Unit 1. TUEC shall complete the L } l following: i n i i

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4.:.,..? .' <- ,. g G i .y,g 8. Attachments: None. 9. Reference documents: i 1. Logbook pages for radiography of Weld Nos. 1759 through 1772, 1803 l I through 1808, and 1823 through 1826. 2. Signoff sheet for Test ISF-055. I 3. Fuel Building Spent Fuel Pool Liner Detai's, 23235-0831 through [ l -08 3 *.. .r e f 4. Fuel Pool Liner - Fuel Building Weld Map, fWFB-00831. 5 G 1 t K 4 b d i h M

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.y . :.Q,4 5. Liner inspection travelers. r-3 f.]. 6. B&RProcedureCCPd8,"StainlessSteelLinerErection." l- ,w l 7. B&R Procedure CP-QCI-2.11-1, Welding Inspection and Fit-up of f Stainless Steel Liners, with IM-16606, dated " January 10, 1979." E~ s 8. Of fice Memorandum TUQ-2340, " Stainless Steel Liner Travelers Unit II," dated September 11, 1984. 9. Interview, pages 60 through 89. ( 10. C&H Specification 2323-SS-18 for Stainless Steel Liners, Revision 3. 11. Bostrom - Bergen Dwg. 2401. 12. 84-006, March 7,1984, pgs. 18,19, 20. 1. -/ (. i e I l_ __.____m____ _____._____m__'____' ,A.__'. (. m s ._m _m .m.

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10. This statement prepared by:

T. E. Curry Date Reviewed by: Group Leader Date Approved by: Project Director Data { f. J P m, g [~" 7 4' ' E t -T,

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revansons to the SFCl-w: s te v; 4.r.d t.ee. et... t t. rout:r er.d r e i r.w r a. c or d. It wa11 bit 421td in t h t. wari p oe. ! e.a r when *

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r I pntl'1 1 f.htad. Draft IJun.b cce ^ 4 i or u t g /c 4 s 1 ~ Ci hnr [M M--.;, 3 ji3i@M t in _r., r_..n t a.= *i-j Tecn. Ed2 t or ) fe.pf 1 L s1. t. n1 s arrin 1. I S N Cel 1 t C' I Revision Numbe'r '4 5 Final 1 c...+ h er. Tech. Editor Grouo Li?ader J. r,s.,1 3,.c e n T T n e r.1 i t n 1 ) o lt Admi ni str ative Writeup t ritegrated into SSER___ _______ Fotential Violations to Region IV___,_______ Wort. package File Complete _________,_____ Wort.paclage Returned to Group Leader __________ 1 l .7 ? 'l f m h F01A-85-59 Inzg3 1

t DCP2A SSER AW-63 Draft 10 1/29/85 S3ER 1. Allegation Group: Mechanical and Piping No. 8, Lost and reconstructed weld data cards 2. Allegation Number: AW-63 and AW-67 ~ 3. Characterization: It is alleged that a weld data card for a field weld was lost, that the data card was reconstructed, and that the reconstructed version was accepted by Brown & Root (B&R) quality control personnel. 4. Assessment of Safety Significance: The alleger did not identify the field weld or system associated with the alleged lost card. Therefore, the NRC Technical Review Team (TRT) reviewed a sample of documentation packages to determine the j feasibility of reconstructing a lost field weld data card using i information available in the documentation package. I l The TRT reviewed a random sample of 12 documentation packages to ? determine if sufficient information was available to reconstruct the ( package if the original package were lost. The TRT also reviewed a l l case in which a weld data card package was reconstructed. The NRC Region IV (RIV) inspection team previously reviewed this case and i l iim p 6 I 1- .gg,,,, pgl

l ,. 1 1 reported it in inspection report (IR) IR 83-07. Nonconformance report i (NCR) No. M-3425R2 documents the case of a weld data card package (Weld FW-1-on Drawing BRP-MS-2-RB-19 for the main steam system) which was lost and later reconstructed. ~ The TRT learned that the welder certification update (rod house) records and weld material issue records provided the following s information: (1) the welder's symbol number; (2) the rod container number in which the weld material was issued and the time of issuance; (3) the type, quantity, and heat number of the weld material issued and quantity of material returned. (4) the drawing and field weld number for which the weld material was issued; (5) the welding process (i.e., SMA, GTA, etc.) and the weld i procedure specification number used; and The TRT also learned that copies of NDE reports can be obtained from QA records for any method of examination (i.e., liquid penetrant, magnetic particle, ultrasonic, and radiographic) required for a given i weld number. When NDE reports showed rejectable indications, the j indications were identified and located to provide evidence to determine the type and number of repairs that were required. Ultimately a final report of acceptance was issued. This report was also retained in the file. P= \\, ,, hr as_-- ...h--- T "NYM N - -W M h'W b ahMW \\ -+. L

.3 4 QA-NDE report records are mainte M in chr,onological order; therefore, a search of the records beginning with the earliest date of , g\\, weld material issue records (given reasonable safety margins) to the p y-7 5,' date that the loss of data occurred would be required to obtain the pertinent records. The TRT found that copies of any special reports generated to support NCRs were also retrievable. In addition, the TRT determined that NDE reports provide the information necessary to identify the certified individuals who performed QC hold point inspections. Sign-off for the welding technician (WT) holdpoints is not necessary to satisfy ASME requirements for weld documentation. However, the TRT 4 l detemined that this infomation can also be reconstructed by the WT who signed off at the holdpoint if the QC personnel who monitor the welding activities or the welder who made the weld can recall the WT's ~ identity. Obviously, determination of the WT sign-off wouTd have to' 4 take place shortly after the weld was made, since it depends on the recollections of personnel. The TRT found that other sources of infomation, including weld t, ( material certification records, drawing requirements, component or piping material certification records, welder quelification records, and procedure qualification reports are also available if it is necessary to duplicate the information for the weld data card. 1 L The alleger has refused an interview with the TRT to review its findings on his allegations AW-63 and AW-67. i m _r ,#. : v. 2 - - www % _,, ,qL _,1

1 - 5. Conclusion and Staff Position: The TRT concurs with the RIV ~ inspection and concludes that a lost weld data package could be - sufficiently reconstructed from available documentation to satisfy the ASME welding documentation requirements. The TRT also concludes that.:e y., the allegation that a weld data card was lost, reconstructed, and , 5.. ~ accepted is substantiated. However, the allegation has neither safety significance nor generic implications. g et*S ~ f, ' C @.u -.. ", C S. & c' .J 'y, { , g o'~ 6. Actions Required: None, g op s ,c 8. Attachments: -None. 9. Reference documents: 1. NRC Region IV Report IR 50-445/83-07, dated March 9, 1983. 2. NCR M-342S-R2. 3. ASME B&PV Code Section III and Section IX, 1974 edition through - Suaner 1975 Addenda. 10.[Thisstatementpreparedby: C. Richard. TRT Date -Technical-Reviewer i Reviewed by: L. Shao Date Group Leader F . Approved by: i Date V. Noonan-ProjectDjrector:

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F \\ Lf. )' fc, 1 DCP2A - SSER AW-63 Draft TR - 85 II 'SSER M f f 1. Allegation Group: Mechanical and Piping No. 8, Lost and reconstructed weld data cards 2. Allegation Number _: AW-63 and AW-67,' woc) A It is alleged that a weld data cardk(or a field 3. Characterization: g .pl W. hd was lost, that the data card was reconstructed, and that the ,) reconstructed version was accepted by Brown & Root (B&R) quality 20wh ~" .i

• g control personnel,.

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Assessment of Safety Significance: ggp y,pc j .j 't h,3 6 alleger did not identify the field weld or system associated /th ~ c g,;.,.,4,[the al ed lost card..Therefore,theNRCTechn1[a1R Team (TRT) sw i reviewed a sa e of documentation packages etermine the-4.- M pk.v..*4 feasibility of. recons ting a lo eld weld data card using 1 ,f ] Qinformation available in . oc .tation package. ) (. c{ wk'r ut.v3 i ' *. D'#1* W 'I"

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l TRT re d a random sample of 12. documentation ages to {N. ,j; dete n Mf sufficient information was available to reconstru e lE package.if the rhQal packag[were lost.[The TRT +1se reviewed a i t.ah n. !a case in which a weld data,, package was reconstructed. The NR p / 1 Region IV (RIV) inspection team viously reviewed this IN)o.I D e u, \\ 'c h l w-(x IV-t4[a["';1 h b r. % a w .+. A,A.# a. M *.

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8 j ! i 1 reported it in inspection report (IR) IR 83-07. Nonconformance repor't -(NCR)No.M-3425R documents the case of a weld data ca packpife (Reld FW-1-on Drawi g BRP-MS-2-R3-19 for the main ste system)which \\ / wasslost and later r constructed. / / ,i The TRT learned that th welder certification update (rod house) records and weld material issue records provided the following ',l l \\ i information: .\\ e .N / l (1) the w' elder's symbo1 number;e i i (2) the rod container number ib which the weld material was / issued and the time of.i.fssuance; (3) the type, qua ty, Indsheat number of the weld material // I issued and quanti Yof material returned. ./ i (4) the drawing and fiel weld' number for which the weld / \\ material was issuea; i r / (5) rocess (i.e., , GTA, etc.) and the weld the weldjng p/ s ? procedu/ re specification number sed; and / ~ \\ l The'TRT also learned that copier e NDE reports can be obtained from ~ QA records fo/r any method of examination (i.e,1uid penetrant, 1 l / / magnetic rticle, AJ1trasonic, and radiographi ) req ired for a given weld number. WhebNDEreportsshowedrejectab indica ions, the l / ? indic6tions were identified and located to prov e evidene to j j determine the type and number of repairs that were required. J / J Ultimately a final report of acceptance was issued. This report was l also retained in the file. 4 s l__ C , ;p _ g gy lqr

. gg4 g,,,g g %,,/ QA-NDE report records are maintained in c nological order;, herefore, a search of the records beginn ng with the earliest date of i weld material issue = 2. _[_. 757.25 ntt, to the 1 j l dateihatth loss of data occurred would,be requi. red _to obtain the

s. [The TRT(fen'@ that copies of [y/'special repor

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v v ! *p..,. 'generhed to,supp rt NCRs were also retrievable [Di addition, the TRT .\\ - ports provide the infor,ma, tion necessary to ,i Ef \\ determined that ND '/ i identify the certifi individuals who performed QC hold point * \\ l l g f w.:... inspections.) - j u ,s. . s.. : j Sign-offforthewelding'tSchnician(WT)holdpointsisnotnecessary to satisfy ASME requirements fof weld documentation ver, the TRT 4 l detemined that this informatio' can also be reconstructed by the WT g bc A:s-ue o signed off at the holdpoint ik the QC personnel who monitor the wh e welder w\\ . b u( g ' < welding activities or th. ho3made the weld can recall the WT's / \\\\ rw M - identity. Obviously,'detemination o{the WT sign-off would have to 4 / takeplaceshortly.$ftertheweldwassiede,sinceitdependsonthe g-# Mid,ube,15 %s[ /, (recollections of.* personnel. g 3 \\ s s \\ x The TRT fou 'd that other sources of infomation, includirig weld material ertificationrecords,drawingrequ\\ement component or ' piping / terial certification records, welder gualification records. \\ and procedure qualification reports are also ava\\ilable if',it is l l 8 neckssary to duplicate the information for the we data card. / t cx Soj'un h % d h ob tWh MD DJr Q(.[ 1 % M g e (lleger has refused an interview with the.TRT to review its (g mi Q, g f ings on his allegations AW-63 and AW-67. (" M s u oy? c f,.m _ 1 me

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il g De c. / Ndt-E*'7 - bp ,,,~, m ye.w%w} Rey *\\y. h Conclusion and Staff Position: TheTRJ[oncurswiththeRIV) j ction)and concludes that a-lost weld -fata package could be sufficiently reconstructed from available documentation to satisfy the ASME welding documentation requirements TRT also concludes tha T the allegation fliat a weld data card was' lost, reconstructed, and j y accepted is substantiated./Noweve.r the allegation has neither safety significance nor generic implications. 6. Actions Required: None. I 8. Attachments: None. 9. Reference documents: 1. NRC Region IV. Report IR 50-445/83-07, dated March 9, 1983. NCRM-342f-R2. 2. NCR H/*/f4o 3. ASME B&PV Code Section III and Section IX,1974 edition through Summer 1975 Addenda. gy-co& m C q, 3 / 7 ) B 'l + 2 / /3. If-- G $ 0/,8l//fs$ f ss 7w s.

10. This statement prepared by:.

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ATTACHMENT TO NCR M-3425 R2 'DISPbSITION: i Through MDS distribution records and copies of RT requests obtained from the QC/RT group, a weld history of MS-2-RB-19 FW-1 has been obtained which provides the information necessary to satisfy the documentation requirements of the ASME Code. Records obtained from the MDS which are maintained for Welder Certification Update have provided the welder identification, welding procedure, filler material type, date of issuance and heat numbers of the filler material issued. From the RT Reports obtained from QC, the areas of repair have been identified. Accept-able joint fit up can be verified from the RT film, which is available. Based upon the above it is suggested that Welding Engineering prepare a new Wald Data Card and WFML and enter information referenced above. A copy of the records from which this information was obtiained shall be attached to the WDC as well as a copy of NCR M-3425. All final NDE will be re-performed and documented. Revision 2: Add welder identification, welding procedure, filler material type, date of issuance, and heat numbers of filler material used to make repair #1. l l 9 PY*s _& OpWV- ,?* Y -a-ww-

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/ e Category 8 Comanche Peak Open Issue Action Plan Task: Welding - Reconstruction of a lost weld data card. Ref. No.: M-63, AQW-67 Characterization: It is alleged that a weld data card (WDC) was lost, reconstructed, and accepted by B&R QC. Initial Assessment of Significance: M-63 was dispositioned in IR 50-445/83-07, March 9,1983 (Item #4). AQW-67 is an identical allegation. There appears to be enough remaining concern to warrant followup. 1 Source: Mechanical & Piping Category No. 8; see allegation list. Approach to Resolution: l 1. Review 84-006, Allegation Source document. I 2. Review IR 83-07 Region IV Investigation Peport. I 5 3. Review ASME Code requirements for weld documentation. l i. 4. In any case where a WDC should become lost, determine the feasibility to reconstruct the WDC (or weld data package) without violating h code requirements: h, F01A-85-59 erL t

t a) Review a random selection of weld doctmentation packages. I b) Detemine all available sources of redundant records traceable to a given weld number (QA files, NDE Reports, NCRs, Rod House issue records, Qualification Records, etc.). c) Inquiries (as required) with welding engineer, QC, ANI, etc. If necessary, interview the alleger, d) Where repairs were made, determine if the repair data can t be reconstructed. d 5. Evaluate findings for safety significance and generic implications. 6. Does assessment support Region IV's conclusions? f f 7. Report on results of review / evaluation of allegations. Related Open Issues: I J 1. Using system codes from the tracking system open item list and j identify any open items. 2. Review activities necessary to close or partially close related n it items. [ ri l b,

l o o . 3. While performing physical inspections, examine surrounding system, components, and structures for any apparent defect or indicator of faulty workmanship, i 4. Complete portion of IE Module on welding if it relates to effort made on allegation. 1 i l l t I i

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• AW-60 leproper welds on supports 1

84-006 3/F/84 ART A-4. Testloony, P. 6-8, 10 z AW-61 Welding done without 1 84-006 3/7/84 A-7 proper inerting ART Testimony, P. 35,36 AW-62 Stainless pipe weld 1 84-006 3/7/84 A-20 crepancy ART 10 stlenable weld repairs & $7 1 i ART '--! L..,

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