- -

FINAL REPORT

ON THE

EVALUATION T AWS FIELD WEDING

ON STRUC'IURAL AND MISCELLAND7JS STEEL

AT 'IWE

WOLF CREEK GENERATING STATION

. BECWTEL POWER COPRORATION

GAITHERSBURG, MARYLA!O

DE3 MBER 27, 1984

Prepared by:
Gerald Brown

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85110g75851015
ARRICC 5-101 PDR
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WOLF CREEK

AWS KT DING EVALUATION REPORT

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I!OEX

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I. IhTRODUCTION

II. JOI M SEL C ION

A. General

B. Perspective on Field Welded Joints

C. II/I Welds
III. REINSPMION RESULTS
1
A. General
.
B. Sumary of Reported Welding Deviations
IV. JOIE EVALUATION

A. General,

B. Joints Which Exceeded Allomble Stresses

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C. Joints with Missing Welds and Material

s
D. Inaccessible Joints
V. CO!CLUSION
.

* D

4.

L s

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w -, w - - - - - ,,,e p <w,--,, - w n -
,,-w , w qv--, + g e-r-s --m e,w . - - -+e ,mx---+-w e
 -

AMACHMENT

Westinghouse Electric Corporation Letter SNP(KG)-503,

J. W. Irons an$ L. R. Benson to J. A. Bailey,
dated October 1, 1984
,

TABIIS
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1. MISCELLANEOUS /STRUCIURAL STEEL CONNIETION SUHUtY ,

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2. STATUS T AWS WEWING REINSPECTIONS AND EN3INEERING !
'
EVALUATIONS

APPENDICES

,
A. STRUC'IURALLY SIGNIFICAhT FIELD WELDED JOINTS

B. DRAKINGS REVIDED TO IDENTIFY STRUCTURALLY SIGNIFICANT

FIELD WELDED JOIICS

C. ICRs, FCRs and FIELD FABRICATION REQUESTS REVIDED TO

IDDCIFY STRUCIURALLY SIGNIFICANT FIELD WEID JOIhTS I

D. SUHUtY T REINSPCION RESULTS

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 WOLF CREEK

AWS WELDING EVALUATION REPORT

I. ICROD*ITION
on September 18, 1984 a reinspection of structurally significant AWS field
welded joints (identified by Bechtel Power Corporation) was initiated at the
Wolf Creek Generating Station by Kansas Gas and Electric (KGl.E) Project
Management. %e reinspe tion was initiated to address concerns regarding
AWS field welding as described in KGAE Corrective Action Report (CAR) 19.

be scope of the initial reinspection involved 6 structurally significant

field welded joints in each of the 6 safety related buildings: Auxiliary
Building, Reactor Building, Control Building, Diesel Generator Building,
Fuel Building and Essential Service Water System (F5dS) PJmphouse. The

results of this initial reinspection identified two missing welds (one weld
on a pressurizer support in the Reactor Building, and one clip angle weld on
a bea . support in the Auxiliary Building), ard various other deviations from
AWS D1.1-75 welding require nents as described in this report.

As part of the evaluation of AWS field welding, Kansas Gas and Electric
Project Management also initiated a separate reinspection of joints in the
Reactor Building which had missing weld inspection records i.e.

Miscellaneous / Structural Steel Weld Records (MSSWR). his reinspection

identified missing welds on the contairunent cooler supports ard missing

brackets on the incore instrtunentation supports. A potential significant

deficiency was reporta5 to NRC Region IV on September 18, 1984 in accordance

with the requirements of 1KTR50.55(e) .

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 AKS WE:3ING EVALUATION REPORT P:ga 2

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As a result of the fiMings of these two reinspections, the program to
reinsoect structurally significant field-welded joints was expanded to
include all such joints in the six safety related buildings at Wolf Creek.
This report documents Bechtel's involvement in this program, which incltx5ed
the selection of joints to be reinspected and the structural evaluation of

the as-built condition of the joints as described in the reinspection

reports generated by DIC. The results of the evaluation did not identify
any significant deficiencies in accordance with 19CFR50. 55 (e) .

II. JOItc SELECTION

A. General

the joints in ltx5ed in the reinspection and evaluation program are all
structurally significant, AWS field weld joints, which:
,
1) support or potentially support safety related equipment an3 building
camponents,

2) are located in the Reactor Building, Auxiliary Building, Control

Building, Diesel Generator Building, Fuel Building or Essential Service

Water System Pumphouse,

3) were installed tmder the structural steel erection contract (Bechtel

Specification 19466-C122) or the miscellaneous steel erection contract .

(Bechtel Specification 19466-Cl32), arr!

4) were originally inspected under the Daniel International Corporation
(DIC) " Miscellaneous / Structural Steel Weld Records" (MSSWR) Inspection
Program.

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AWS WE DIlO EVALUATION REPORT Pag? 3

ror the purpose of this reinspection program, a joint is defined as the

connection between two structural members. A joint may contain more than
one weld, or a ecmbination of welds ard bolts. A joint may also be refered
to as a connection.

AWS field welds for the following items were not considered to be
structurally significant:

1) handrails
2) toeplates
;
3) grating
4) checkered plate
5) stair towers
6) ladders
7) monorails
S) te v rary construction welds
9) temporary de: king supports
10) plug welds in unused bolt hole's
11) cask loading pit hatch covers
12) cask washdown pit hatch covers
13) Reactor Building bracket shims
14) Drbedded beam to seat welds

A total of 2669 structurally significant joints were identified for

reinspection. Appendix A identifies these joints and provides information
on their locations, the nonconformance reports DCR) on which any welding
deviations from AWS D1.1 are documented, and a cross-reference to Bechtel
engineering evaluations.
.

Most of the structurally significant joints were identified on the

structural steel (American Bridge Canpany) ard miscellaneous steel (Cives
steel Company) erection detail and field work drawings, and Bechtel detail
drawing (C-0X Drawing Series) . Appendix B lists the drawings which were

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 ARS WIIDItC DIALUATION REPORT P;92 4

reviewed in order to identify the structurally significant joints and

indicates those drawings on which joints were identified. In addition, DIC

reviewed field generated nonconforman:e reports (PCRs) , field chance

regaests (EGts) and field fabrication regaests. Rose documents identifying
field welds which DIC considered to have a potential structural significan
were provided to Bechtel for review. Structurally significant joints

identified by Bechtel on these doctrnents were also included in the

reinspection program.. A listing of the doctrnents submitted to Bechtel is
included in AppeMix C of this report.

B. Perspective on Field Welded Joints

In crder to provide a perspective on the reinspection of field welded

joints,
Bechtel engineering made an in5ependent count of the various joir}t
types (i .e.
shop welded, field bolted or field welded) reqJired for the
erection of miscellaneous and structural steel at Wolf Creek. We drawings
listed in Appendix B of this report were used as the basis of this count,
aM the results are tabulated in Table 1. Approximately 11,15e total joints i

are regaired for the fabrication aM erection of structural aM

l
miscellaneous steel.
)

Table 1 indicates that there are 2320 field weld joints while the
reinspection program identified 2669 joints. Dere are two major reasons
'for this difference:

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 AWS h?:. DIN 3 EVALUATION REPORT Page 5

1) Table 1 does not in:1u3e field welded joints required by field

f abrication regaests, ICRs an3 ICRs, and
2) miscellaneous *differen::es in counting (i.e., een joints are partially

shop welded aM field welded, etc.).

Overall, even considering 2669 field welded joints instead of 2320, field

welding accounts for less than 25 percent of the total joints regaired for
fabrication and erection of structural and miscellaneous steel at Wolf
Creek.

C. II/I WE:DS
AWS field welds on seismic II/I items included in the
miscellaneous / structural steel contracts were not included in the
reinspection. ':hese seismic II/I items are handrails, toe plates, grating,
checkered plate, stairs, ladders an$ monorails. Typically these are shop
welded, field bolted items W ich are designated seismic II/I only to assure
that they will not fail durirg an earthquake. In general, they do not act

as seismic supports for other items. Monorails were load tested as part of
the Start-up procedures. Typically the seismic loads on these itens are
much less critical than the service loads inposed during construction. We

believe that significant deficiencies in any field welds that may have been
made on these types of items would have been identified during the
construction period. In addition, we have not identified any welding
deficiencies in the safety-related joints Which have been inspected that
would have resulta5 in a failure of those joints. Me would expect the same
results fran a reinspection of welds on II/I items,

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AWS hT. DING EVA?.,UATION REPOR! Page 6

III. REINSPCION RESULTS

A. General

All accessible joints identified by Bechtel as part of this reinspection

program were reinspected by AWS certified weld inspectors under the
direction of DIC and .KGt,E quality control organizations. 'Ihe reinspections
were performed to the existing welding criteria of AWS D1.1 and Bechtel
Specifications 19466-C122 and 19466-C132, with the exception that scme
inspections were performed through paint. A reinspection report was

generated for each joint indicating whether:

1) the welds on the joint were acceptable,
2) the type and extent of any deviation from AWS D1.1 and Bechtel
Specification requirements (In this case the as-built condition of all
welds on the joints was documented on the inspection report), or
3) the joint was inaccessible (i.e. embedded in concrete or obstructed by
installed equipment.)

of the 2669 joints identified for inspection 2386 joints were completely
inspected, 166 joints were partially inaccessible, and 119 joints were
totally inaccessible. All welds on 1293 joints were accepted by the
^

inspectors, while welding deviations were noted on 1993 joints. Many of the
deviation were very minor in nature, such as limited areas of lack of fusion
or undercut, minor undersize, colo lap, etc.

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E'S WCDING EVALUATION REPORT Page 7 !

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All inspection reports were forwarded to Bechtel for engineering
evaluation.

B. Sunmary of Reported Weldine Deviations

Appendix D provides a synopsis of the inspection results for each joint. In

order to accurately report the reinspector results, each straight line

segment of a weld was identified, and the reinspection results were reported
on a secynent by secnent basis. 2e neber of weld segroents on a joint which
have a particular welding deviation is recorded in the appropriate column of
Appendix D. A sunmary of the data in Appendix D is provided in this

section:
1) UnSersize
A. Weld undersized for part of length - 68 joints
( B.
,
Weld un$ersized on one leg (typically 1/16 inch or less) - 375

joints. We undersize occurred only on the return welds on 193 of

these joints.
C. Weld un$ersized full length (of weld segment) - 284 joints. We
un3ersize occurred only on the clip angle return welds on 69 of
these joints.
D.' Weld undersized due to fit-up/ root gap - 29 joints.
An engineering evaluation has identified only 5 joints (A182, A419,
A431, RA, RG39) in which the maxima calculated design stress
exceeded the allowable as the result of undersized welds. Sese 5
joints are discussed further in Sect 4on VI.B.

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 AWS WE:32N3 EVALUATION REPORT Page 8

2) Weld Defec*a
A. Overlap (typically limited to a small percentage of weld length) -

68 joints.

B. Incomplete penetration - 24 joints

C. Lack of fusion (typically limited to a small percen* age of weld

length) - 91 joints

D. Excessive reinforcement - 6 joints

E. Edge consumption (i.e. weld size in excess of E'S D1.1, Paragraph

2.7.14) - 99 joints (occurred on the return welds only on 48 of

these joints.

F. Cracks - 3 joints (all on beam to beam seat welds)

G. Gouge / grinding -14 joints
H. Slag - 9 joints
I. Porosity - 5 joints
.

J. Arc strike - 3 joints

K. Convexity - 3 joints
L. Other - 53 joints
Essentially all of the weld defects were very minor in nature. Only 1
joint (C146) had calculated design stresses that exceeded the allowable
as the result of excessive grinding. '!his joint is discussed further ir3
Section IV.B. No other repair of these defects was regaired.
3) Incorrect Configuration
A. Gap in continuous weld (typelally at nail holes provided in eW
plates to aid installation ) - 31 joints.
B. Spacing on intermittent welds - 1 joint

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AWS WELDING EVALUATION REPORT Page 9

C. Overrrun (i.e. excessive weld length) - 7'54 joints. 658 of these

joints involved overrun on the clip angle to embedded plate return
welds only.
D. Weld in wrong location /not welded per drawing (e.g. bevel vs. fillet
.

weld, etc) - 5 joints

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No joints were identified with overstress conditions as a result of

incorrect weld configuration. Overrun on the clip angle to embedded

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j plate welds was the most conmon welding deviation identified. Although
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the ideal condition would be to have the return weld extend only 1 inch
maximan from the toe of the angles, the extra weld length does not
reduce the capacity of the beam or the embedded plate to support the
design loads. No repairs were required as the result of incorrect weld
!
configuration.
4) Underrrun (i.e. insufficient weld length)
; A. Greater than 1 inch in length - 96 joints
B. I4ss than 1 inch in length - 233 joints
j An engineering evaluation has identified only 6 joints (AO, A439, A4,35,
,
A436, DD and D012) in which the maximum calcuated design stress exceeded
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the allowable as the results of weld underrun greater than 1 inch in
length. '!hese 6 joints are discussed further in Section IV.B. No over-
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stress conditions resu1 W from weld underrun less than 1 inch in
length.
.

5) Undercut
A. Greater than 1 inch in length - 26 joints
;
B. tass than 1 inch in length - 62 joints
'the identified smdercut was typically less than or equal to 1/16 inch in
depth. No overstress conditions resultad from undercut. No repairs
;, [A..
were required.
.

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AWS WELDI!G EVAWATION REPORT Page le

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6) Missing Material
A. Material change-out (e.g. shims or filler plates added, plate
instead of angle) - 21 joints
B. Missing Material - 20 joints
C. Missing Weld (segment ) - 137 joints
4
An Ehgineering evaluation has identified 69 joints ( RF, R171, R172,
1

RS10 through R869, RJ87 through RJ90, CO24 an5 C055) in which the
maxinun calculated design stress ex::eeded the allowable as the result of
missing material or welds. 60 of these joints are identical polar crane
girder radial stops. Rese 69 joints are discussed further in Section
IV. B. An additional discussion of all joints with missing material an5
welds is included in Section IV. C.
7) Inaccessible Joints
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| A. Totally inaccessible - 119 joints

<
B. Partially inaccessible - 166 joints
A discussion of in accessible joints is included in Section IV.D.

IV. JOIMI EVAWATION

A. General

All reinspection reports were forwarded to Bechtel and the as-built

condition of ea::h joint was evaluated against the allowable stresses and
, loading combinations specified in the S!CPPS Civil-Structural Design
Criteria, 19466 C-9.

Se general acceptance criteria for weld deviations from the requirements of

MfS D1.1 and Bechtel Specifications 19466-C122 and 19466-C132 west

1) All weld deviations Which resultso in a violation of the design

allowable stresses speelfied in the SNUPPS Civil-Structural Design
; Criteria 19466-C-9 were macceptable and the welds were repaired.
:

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 AWS WE? DIN 3 EVALUATION REPOIC Page il

2) Missing welds were unacceptable regardless of the stress levels in the

joint and the welds were installed unless specifically approved

otherwise by the engineer. (See Section IV. C)

3) Defects (cracks, lack of fusion, undercut, etc.) which jeopardized the
integrity of the joint were unacceptable and required repair. 'Ihe

engineer performed a case by case review of each weld inspection report

in order to identify those defects which required repair.

B. Joints khich Exceed Allowable Stresses

In the as-built condition, 81 joints had calculated weld stresses which

exceeded the allowables as defined by the SNUPPS Civil-Structural Design

Criteria 19466-C-0. All joints with calculated stresses that exceeded the
allowables had missing, (in one case as the result of excessive grinding)
undersized, or underlength welds. None of the joints were determined to
have incurred dawp as a result of the as-built condition and previous or
existing loads. None of the ' calculated stresses exceeded the ultimate
capacity of the welds. 'Ihe only required rework to these joints was the
installation of the missing, undersize or underlength welds.

The joints with calculated weld stresses that exceeded the allowables are:
1) Auxiliary Building Joint M 'Ihe top and bottom return welds between
the clip angles ard beam 763BB were underlength approximately 3 inches.
'!he maxim a design reaction is 12.2 kips, while the allowable load for
the as-built condition was 18.5 kips. '!herefore, the allowable load was
exceeded by 16 percent. 'the ultimate espacity of the as-built

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 AWS WE: DIN 3 DIALUATION REPOIC Page 12

joint was 25 kips. O ISN205683 has been dispositioned to install the

missing portion of the return welds in order to restore the original
design condition.
2) Auxiliary Building Joint A192 - 2e weld between one clip angle anS beam
763B3 was un3ersired by 1/16 inch for the entire length. In the as-

built conSition, the maxim a calculated design stress in the weld was
20.0 kips per square in:h (ksi), while the allowable weld stress is 18.6
ksi, herefore, the allowable stress was exceeded by 8 percent. We
ultimate capacity of the weld is approximately 44 ksi. n ISN20995N
has been been dispositioned to increase the weld size in order to reduce
the design stress below the allowable.

3) Auxiliary Bailding Joint A419 - te welds between the clip angle and
beam 763B7 were undersized by 1/16 inch. We return welds between the
,

clip angles anS the beam were underlength by approximately 3 1/4

inches. The maximum design reaction is 12.4 kips, while the allowable
load for the as-built condition was 6.9 kips. Werefore, the allowable
load was exceeded by 80 percent. Se ultimate capacity of the as-built
joint was 16.3 kips. p 1SN20995CW has been dispositioned to install
the underlength weld in order to restore the original design condition.
'

4) Auxiliary Building Joint A430 and A435 - We return welds between the
clip angle and beam 763B1 were underlength by approximately 3 1/4
inches. We maxima design reaction is 19.4 kips, while the allowable
.

load for the as-built condition was 19.9 kips. Werefore, the allowable
load was exceeded by 4 percent. We ultimate capacity of the as-built
joint was 23.8 kips. O 15N29995N has been dispositioned to repair
the moersized weld in order to restore the original design condition.

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 AWS WELDItG LVAI.UATION REPORT Pag? 13

5) Auxiliary Building Joint A431 - he clip angle to en6edded plate weld

was undersized by 1/16 inch for its entire length on one clip angle.
Se maximum design reaction is 12.4 kips, while the allowable load for
the as-built condition was 10.9 kips. B erefore, the allowable load was
exceeded by 14 percent, m e ultimate capacity of the as-built joint was
26 kips. N3 ISN209953i has been dispositioned to repair the undersized
weld in order to restore the original design coMition.
6) Auxiliary kilding Joint A436 - he return welds between the clip angles
and beam 76338 were un5erlength by approximately 31/4 inches. We
maxim a design reaction is 12.4 kips, while the allowable load for the
as-built conSition was 10.9 kips. Werefore, the allowable load was

exceeded by 14 percent. me ultimate capacity of the as-built joint was

26.0 kips. tcR ISN20995CW has been dispositiona$ to repair the
<

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undersize $ weld in order to restore the original design condition.
7) Reactor Building Joint RA - be weld between one of the clip angles and
beam 606B3 is undersized up to 3/16 inch. W e maxim a design reaction
is 81 kips, while the allowable load for the as-built condition was 62.6
kips. Berefore, the allowable load was exceeded by 29 percent. De
ultimate capacity of the as-built joint was 149 kips. N3t 1SN205670f
has been dispositioned to repair the smoersized weld in order to restore
the original design cor lition.
B) Reactor Building Joint RF - me weld between the pressurizer support
beam and the top support bracket at pressuriser support Detail 4 was not
installed. We welds between the beam and the bottom support bracket,
and between the bottom support bracket and the enbedded plate were
underslaed.

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AWS WEL ING EVALUAT80N REPORT Page 14

he bottom bracket welds must support the entire horizontal load with
the beam to top support bracket weld not installed. An engineering
|
; analysis has determined that the beam to bottem bracket weld was
i

adequate to support the maximum design load within allowable stresses,

however, the bottom bracket to embedded plate weld was determined to be
undersized by 9 percent. ICR 1SN20509CW has been dispositioned
to install the beam to top bracket weld in order to reduce all stresses
below the allowables.
9) Reactor Building Joint R039 - me weld between the clip angles an$ beam
;
is undersized by 1/16 inch. We maximum design reaction is 60 kips,
i

while the allowable load for the as-built condition was 50 kips.
Berefore, the allowable load was exceeded by 20 percent. De ultimate
capacity of the as-built joint was 119 kips. PCR ISN21972 has been

dispositioned to increase the weld size in order to restore the original

design conSition.
I

10) Reactor Puilding Joint R171 - he weld between the support beam and the
| top bracket was not installed at pressurizer support Detail 6 an5 the
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weld between the support beam and the bottom bracket is undersized. We
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total horizontal design load on the weld is 339 kips. Fog the as-built

condition the allowable horizontal load on the joint was 251 , kips.
.

Berefore, the allowable load was exceeded by 35 percent. We ultimate

capacity was approximately 375 kips. N3 ISN295e9CW has been
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dispositioned to install the missing beam to top bracket weld in order

to reduce all stress below design allowable.

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AWS WCD8N3 EVALUATION REPORT Page 15

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11) Reactor Building Joint R172 - he weld between the support beam an$ the
top support bracket was not installed and the weld between the support
beam and bottom support bracket was undersized at pressurizer support
Detail 8. W e total horizontal design load on the joint is 339 kips.
For the as-built condition, the allowable horizontal load on the joint
. was 286 kips. %erefore, the allowable load was exceeded by 19
percent. he ultimate capacity of the weld was approximately 426 kips.
;

, PCR 1SN205093 has been dispositioned to installed the missing beam to

top bra:ket weld in order to reduce all stresses below design
allowables.
12) Reactor Building Joints R810 through R869 -
Two of the five welds
between the polar crane girder radial stops ard the support bracket were
not installed. We maxim.rn design reaction is 450 kips, while the
allowable load for the worst case as-built condition was 307 kips.
Werefore, the allowable load was exceeded by 47 percent. We ultimate
capacity of the as-built joint was 456 kips. ICR 1SN213193 has been
i dispositioned to install the missing welds in order to restore the
original design condition.
13) Reactor Building Joints RJ87 through RJ90 - he bottom tie was not
installed at intersecting beans as required by Bechtel drawing C-
!. OS2311. A review of existing design calculations indicates that the as-
built connection is adegaate to support all design loads within
allowable stresses. Due to the installation of electrical conduit
supports the bottan tie plate cannot be installed. Drawing C-G2311 has
been revised to delete the requirements for these plate. .

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 AWS WE:DI O EVALUATION REPORT Page 16

14) Control Building Joint CO24 - me beam seat required for this joint was
not installed. We maxisrn design load on the joint is 31.0 kips. We
allowable capacity of the as-built web connection was 24.0 kips.
h refore, the allowable load was exceeded by 29 percent. We ultimate
capacity of the as-built web connection was 57.0 kV s. ICR ISN210483
has been dispositioned to installed the beam seat in order to restore
the original design condition.
15) Control Nilding Joint C055 - The beam seat reqaired for this joint was

not installed. We maximum design load on the joint is 12.7 kips. We

allowable capacity of the as-built web connection was 10.9 kips.
Berefore, the allowable load was exceeded by 17 percent. me ultimate
capacity of the as-built web connection was 26.0 kips. ER ISN21031N
has been dispositioned to installed the beam seat in order,to restore
the original design condition.
16) Control kilding Joint C146 - he weld between one of the clip angle and
the beam was groun5 out for a 12 inch length. %e maximtzn design
reaction is 130 kips, while the allowable load for the as-built
cordition was 91.5 kips. Werefore, the allowable load was exceede5 by
42 percent. We ultimate capacity of the as-built joint was 218 kips.
ICR ISN20915@ has been dispositioned to replace the missing weld
length in order to restore the original design condition.
'

17) Diesel Bulding Joint DD - 2e return welds between the clip angles and
beam 12B5 were 1/2 inch to 1 inch long instead of the reqaired 4 inches
+ 1 inch.
_ Se maximum design reaction is 265 kips, while the allowble
load for the as-built condition was 220 kips. Werefore the allowable

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 AWS WELDING EVALUATION REPORT Page 17

load was exceeded by 21 percent. me ultimate capacity of the as-built

joint was 524 kips. O 1SN20565CW has been dispositioned to install
the missing portion of the return welds in order to restore the original
design condition.
18) Diesel Building Joint Dfl2 - he return welds between the clip angles
and beam 11B1 were urx5erlength by approximately 3 1/4 inches. We
maxim 2n design reaction is 130 kips, while the allowable load for the
as-built condition was 103 kips. Berefore, the allowable load was

exceeded by 26 percent. W e ultimate capacity of the as-built joint was

245 kips. p 1SN211863 has been dispositioned to repair the

uMersized weld in order to restore the original design condition.

C. Joints with Missing Welds and Material

Tne reinspection program identified missing welds at 137 joints. 97 of
these joints were associated with three specific areas of construction:
1) polar crane girder - 60 radial stops had welds missing on the support
pla*m

2) pressurizer support beams - 6 joints had the beam to top support bracket
missing

3) beam seats - 31 joints had missing seat to beam welds

.

An engineering evaluation has determined that none of the missing welds

would have resulted in the failure of a safety related component. A
i discussion of each joint with missing welds follows:
1) Reactor Building Joints R810 through R869 - Wo of the five welds were
not installa5 on each of 60 polar crane girder radial stops. As

I -

'

. . _ _ _ . _ _ _ __ __ _ _ . _ _ ._
 7

I
AWS WEDI!G EVALUATION Page 18

discussed in Section IV.B all of these joints would have been

overstressed for the most critical design loading combination, however,
none of the joints would have failed as a result of the missing welds.
We applicable NCR's (see Appendix A) have been dispositioned to install
the missing welds in order to restore the original design margins.
2) Reactor R2ilding Joints Re, R169, R170, R171, R172 and R174 - Tne weld '

between the pressurizer support beams and the top support brackets were
not installed on all six pressurizer support beam joints. Wree of the
joints (RF, R171 an$ R172) would have been overstressed for the most |
critical design loading condition (see Section III.B), however, none of.
the joints would have failed as the result o' the missing welds. N3
ISN205093 has been dispositioned to install the welds in order to
t
reduce the stresses below design allowables.
<
.

3) Auxiliary R2ilding Joint AF - 2e weld between one of the support clip '

'
angles an$ the beam was not installed. An engineering evaluation has
determined that the existing one-sided connection was adegaate to
1
support the design loads within allowable stresses. M3 ISN20495W has '

been dispositioned to install the missing weld in order to restore the

original design condition.
*

4) ' Auxiliary Building Joints A012, A013, A023, A036, A039, A040, A041, \
,

i
A046, A058, A060, A061, A063, A064, A067, A068, A069, A070, A077, A100, '

A315, A320, A369, A385 an$ A386. Control Building Joints CO22, CO23, ,

CO27, CO28, CO29, C030, and C212 - h e connection welds between the
bottom flange of the beams an$ the beam seats were not installed. his |
weld is not designed to support design loads. Se vertical reaction of

t_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . . _ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
 AWS WE:31N3 EVALUAT30N REPORT Page 19

the beam is transfered to the beam seat through bearings between the
bottom of the flange and the top of the seat. he welds simply hold the
beam in the required location. In additional to the seated connection
all of these joints have full web connections which prevent the beam
from moving and thus there is no consequence to the crnission of the beam
to seat welds. We applicable N'R's (see Appendix A) have been
dispositioned to install the missing welds in order to restore the
original design condition.
5) Reactor Building Joint RJ83 through RJ86 -
W e welds between the
interior framing members of the contairrnent cooler support frames and
the floor framing steel were not installed. An engineering evaluation
has determined that installed welds on the exterior framing renbers were
,
adegaate to support the coolers without exceeding the allowable
stresses. We disposition of PCR ISN204943 provide $ details for the
installation of welds between the interior fram*.ng members and the floor
framing in order to restore the original design margins.
6) Auxiliary Building Joints A609 through A616 - me welds between the
clips angles an5 the support (in these cases a girder rather than an
embedded plate) were not installed. Se welds are provided to
'

terrporarily support the beams during renoval of beams on the far side of
the supporting girder. A fully bolted connection is provided to support
the beams during normal operation. ER ISN212733 has been
dispositioned to install the missing welds.
7) Reactor Building Joint R585 - me welds between the gusset plate arx5 the
C8 beam were not installed as required by the erection drawing.

<

*
 ,

AWS WELDI!G EVALUATION REIORT Page 29

However, an alternate, unsperified weld was installed Which is capable

of supporting the design load within allovable stresses. N~R ISN21235CW

has been dispositioned to install the missing weld in order to restore

the original design condition.
8) Reactor Building Joints R945 and R947 - m e welds between the clip
angles aM CB platform beams were not installed. A bolted connection
was also provided between the beams and clip angles which is capable of
supportirg the design loads within allowable stresses. ICR ISN21274 3
has been dispositioned to install the missing nids in order to restore
the original design condition.
9) Diesel Bailding Joints D001 and D002 - Tne weld between a diagonal bra:::e
gusset plate an$ the web of a beam was not installed. In addition to
- missing weld detail, there is a clip angle shop welded to the gusset
plate and field bolted to the beam that is capable to of supporting the
design load. We joint has been approved by ICR ISN29865 to use-as-is
without installing the gusset plate to beam weld.
19) Auxiliary Building Joints A633, A634 and A635 - h e welds between the
clip angles and the column were not installed. A boltal connection was
also provided between the clip angles an$ the coluno which is capable
of supporting the design loads within allowable stresses, DCR's
1SN212723, and ISN213993 have been dispostioned to install the
missing welds in order to restore the original design conditon.

Q r

a
 AWS WCDIN3 EVALUATION REPORT Page 21

11) Reactor Building Joints R991 and R992 'I5e welds between gosset plate
411PM4 and beams were not installed as reqJired by the erection
drawings. An engineering evaluation has detemined that the installed
welds were adegaate to support the design loads without exceeding the
allowable stresses. ICR ISN213233 has been dispositioned to install
the missing welds in order to restore the original design condition.
12) Auxiliary Building Joint Alli -
':he weld between the toe of a C8
channel frame and the support beam below it was not installed. '!5e

existing weld between the back of the channel and the been is adegaate
to suppsrt the channel without exceeding allowable stresses. ICR

ISN207983 has been dispositioned to install the missing welds in order

to restore the original design condition.
13) Fuel Building Joints F037 an$ F038 'Ihe welds between the flanges of a
C8 bean and er. bedded plate were not installed. An engineering
evaluation has determined that the existing welds between the C8 web
. and the embedded plate is aSegaate to support the design loads within
allowable stresses. CR ISN208833 has been dispositioned to install
the missing welds in order to restore the original design condition.
.
14) Auxiliary Building Joints A396, A412, A641 and A646
Reactot Building Joints R956 and R876
Control Building Joints C913, Cf14, C985 ard C128
Fuel Bailding Joints F996, F917, F918 and F022

(
.

--
 _ _ _ __ ___ _ _ _

AWS WELDIN3 EVALUATION REPORT Page 23

he clip angle to beam or clip angle to embed return welds were not
,

installed at these joints. An engineering evaluation has determined i

; that none of the joints would be overstressed as a result of the

, missing return welds. De applicable ICR's (see Appendix A) have been

dispositioned to install the missing welds in order to restore the
1

original design condition.

% e reinspection identified 20 joints with missing material as described

; below. An engineering evaluation has determined that the missing material

,
would not have resulted in the failure of safety eqaipment or building
t ecx,ponents. me joints with missing material are:
1) Auxiliary Building Joints A055 and A998, control Building Joints CO25,
| Ce36, C037, C949, C042, C952, Ce53, and C054 - Se been , seats for these
le connections were not installed. We beam seats were specified on
applicable American Bridge erection drawings to be installeS as regaired
by Bechtel Standard Detail 19 on Drawing C-9011. A review of the design
calculations indicated that the existiry web connections were capable of
supporting the design reactions within allowable stresses even though
|
the beam seats were not installed. We been seats have been installed
i
'
in order to restore the original design condition.
.

2) neactor Building Joint R059 - We tension plate was not installed

between the enbedded plate and beam 625B1. A review of the design
i

calculations indicates that the existing web connection is adequate to

support the vertical and axial loads. CR 15N215760f has ,been
dispositioned to install the plate in order to restore the original
design condition.
.

. !

_ _ . _ _ _ _ . - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - . _ _ _ _ - - _ _ - _ _ _ _ - _ _ - _ - - _ _ - - - - _ _ _ _ _ _ _ _ _ _
 AWS W"D8N3 EVALUATION REPJR*
.

Page 23

3) Reactor Building Joints RJ93 and RJ94 - The bottm tie was not installed
at intersecting bea s as reqaired by Bechtel drawing C-OS2311. A review
o'f existing design calculations indicates that the as-built connection
is adegaate to support all design loads within allowable stresses. Due
to the installation of electrical conduit supports the bottom tie plate
cannot be installed. Drawing C-OS2311 has been revised to delete the
reqJirements for these plate.
4) Reactor Building Joints RJ87 through R790 'Ihe lateral support brackets
for the incere instrumentation tube supports were not installed as
,

required by drawing C-OS2924 Section A. An engineering analysis by

Westinghouse Electric Corporation has indicated that the missing
brackets could result in an overstrtss con 51 tion in the instrumentation 7

tubes, towever, no failure of the tubes would have resulted frcn the
missing bracket. Westinghouse letter SNP(KG)-593 is incitaSed as an
attachment of this report. O ISN29494 3 has been dispositioned to
i

install the brackets in order to restore the original design condition. 1

i

5) Auxiliary Building Joint A628 - Only 1 of the 2 reqaired clip angles was !
installed. An engineering evaluation has determined that the installed
clip angle is adeqJate to support the design load within the allowable
.

stresses. NCR ISN212723 has been dispositioned to install the missing

clip angle in order to restore the original design condition.
6) Control k ildirn Joints C924 and C955 -
The beam seats were not
installed. As discussed in Section IV.B, the maximum calculated iesign
stress in the existing web connections would have exceeded the allowable
without the beam seats installed, however, the joints would net have
failed. WR's 1SN219480W and 1sN219310i have been dispositioned to
g
'
install the been seats in order to restore the original design
N.
condition.

u________-___________ _ _ _ _ _ _ _ _ _ _ _ - _ _ - _ _ _ . ___
 .

. AWS WE: DING LVALUATION REPORT Page 24 ,

D. Inaccessible Joints
As noted in Section III.B, 119 joints were identified by the reinspection to
t
be totally inaccessible. 59 of these joints were evaluate $ on a case by
case basis, typically where alternate load paths existed (i.e. the beam is
embedded in a concrete wall which is capable of supporting the design load
in the completed structure). In addition, some portions of the welds were
inaccessible on 166 joints. Sufficient information was available on 144 of i

these joints to enable a case by case evaluation to be performed.

Eerefore, a total of 82 joints, out of the total population of 2669
joints were identified in which a case by case evaluation of the
acceptability of the welds cerald not be determined.

,
t

me fully inspected joints may be viewed as a sample of the total population

i
.

of joints consisting of fully inspected, partially inspected and

,
uninspectable joints. Based on the above numbers a statistical evaluation
i

may be undertaken for those joints which are either totally or partially
inaccessible. It is important to observe that the sample size represents
sa::h a significant percentage of the total population that the statistic
j associated with the savle may be applied to the total population with
virtually 100 percent confidence. mis inplies that if mane percentage of
.

the inspected joints were determined to exceed allowable stresses, then

statistically this percentage may be assumed for the total population with a
a
very high confidence.

_._m_ .______m.__._ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ - _ _ _ _ _ _ _ _ _ _ . . . - _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _
 ,

ES WELDING EVALUATION REPORT -

Page 25
-

of the 2587 joints which were evaluated on a dase by case basis, only 81
joint, 3.13 percent, were identified in which the weld stresses exceed the
-
allowables. Considering{that $P or: thee joints are polar crane radial
ctops installed to one typidaly dotiil, t$ere are 21 joints in the renaining
s
population of 2527 joints, or 0.8 percent, which exceed allowable stresses.
We.uould expect the percentage of joints which excea5 the allowable stresses
in the group of inaccessible aM unevaluated joints to be approximately 0.8
hrcent, or approximately 1 joint in the group of 82 joints. Likewise, we

,
would not expect to find any joints that would fail under the design loading
,

conditions as a result of welding deviations.

V. CONCLUSION

No significant deficiencies as defined by 19CFR50.55(e) were identified as

.
the result of the reinspection aM evaluation of MS field welding of
structural and miscellaneous steel construction at Wolf Creek. All joints
i.

with calculated stresses that exceeda5 the allowables as the result of

welding deficiencies are being repaired as described in Section IV. B. i

Missing welds aM materials are being installed as describa5 in Section IV.

C.
s e

4.

Y'

% +
b4

>

,
'

%s - _ _ - . ___.
 .

Attachment to AWS Welding Evaluation Report

@
SNP( G)-503

Wes inghouse Water Rtzter " "'"5*58*5"

De:tric Corpgation Divisions nu m
PinWr Pav.eera 1523C

October 1,1984
e. J. A.. Bailey
Volf Creek Site
. KANSAS CAS & ELECTRIC COMPANY
P.O. Box 309
Burlington, g5 66839
*

SWPPS PRNECTS
Bottee Mountad Instrumentation Sucoorts Evaluation
Dear W. Bailey:
.

Westinghouse has evaluated the EMI guide tubing support deficiency repcrted by
GAI on 9-25-64 and concludes there is no potential safety concern.
Tne deficiency was described as the omission of four (4) 4x4x1/4 angle merbers
.
frnm the support loceted 32' - 2 3/4" north of the RY centerline. The ar.gles
are shown in detail A of 5echtel drawing C 052924 Rev. 4 and are labeled "by
oc er'.
The worst case faulted condition stresses with this support deficiency reach
36.6 X51 at the socket joint between the BMI tubing and the instrumentation
noz21es in the bottom head of the RY. This stress exceeds the faulted
condition allowable of 34 KSI. The stress, however, is based on a
conservative stress intensification factor (5.1.F.) of 2.1 as required by the
a;citcable ASE Code. The Succer 1963 Code Adoenda provides relaxation of the
5.I.F., depending on the actual joint geometry, in Figure NC-3673.2(b)-1. For
the applicable geonetry, the 5.I.F. is su;.5 that the stress in question
redaces to 29 KSI, and is thus within code limits. . Westinghouse has also
determined that there is no safety impact on the instrumentation nozzle or its
attachment to the Reactor Vessel. .

Therefore, Westingtiouse does not view the above described support deft:tency
as a potential safety concern. We do recommend, though, and have been advised
by GAE that the support be brought into conformance with the Bechtel design.
Very truly yours
h 0 g

[ D e' J. W. Irons Project Engineer

SMPP! Project
-

%
OCloEIS84
V/p
f -

L. R. Benson, Manage
JWI/ rec /1011d
(e@lVED 5WPPS Projects

cc: J. A. Sailey it
'

W. Goel IL
.

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

--
 ,

AWS WELDING EVALUATION REPORT

TABLE 1

MISCELLANEOUS /STRUCTtIRAL STEEL CONNECTION SUMMARY

Shop Welded Joints Field Bolted Joints Field Welded Joints Total Joints
Building Number Percent Number Percent Number
.
Percent Number Percent
Auxiliary 1500 415 1580 545 610 165 3690 1005
Reactor 2680 515 1520 295 1060 205 5260 1005

Control 350 355 380 395 260 265 990 1005

Diesel 260 405 310 485 80 125 650 1005

Fuel 90 195 110 235 280 585 480 1005
Pumphouse 20 245 30 385 30 385 80 1005

, TOTAL 4900 445 3930 355 2320 215 11150 1005

.

9
 e

AWS WELDING EVAL.ATUION REPORT

TABLE 2
STATUS OF AWS WEl. DING
INSPECTIONS AND ENGINEERING ETALUATIONS

1UTAL JOINTS JOINTS JOINTS REQUIRING ADDITIONAL JOINTS

BUILDING SIGNIFICANTLY DEFICIENT
JOINTS INSPECTED (1) EVALUATED (1) REWORK [ff"~~ TO RE REWORKED (3) JOINTS (10CFR50.55 (e))
AUXILIART 693 693 693 7 '12 0
REACTOR 1300 1300 1300 69 15 0
CONTROL 265 265 265 3 in 0
1 DIESEL
GENERATOR 98 98 98 2 2 0
FUEL 277 277 277 0 -
6
;
0

ESWS
PUMPHOUSE 36 36 36 0 0 0

'

TOTAL 2669 2669 P669 81 83 0

'

(1) TOTAL INCLUDES INACCESSIRt.E JOINTS

(2) DESIGN ALLOWADLE STRESSES ARE EXCEEDED IN THE AS-BUILT CONDITION

4

(3) DESIGN ALLOWARLE STRESSES ARE NOT EXCEEDED IN Tile AS-BilILT CONDTION.
TilESE JOINTS ARE BEING REWORKED PER KGAE MANAGEMENT DIRECTION TO
INSTALL MISSING AND UNDERLENGTil WELDS.
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- BUILDING . BECHTEL ID . VENDOR ID . APPENDIX B. P AGE | of 10 '

.============,===============.==================.=============e=============
AUXILIARY * 'C-121-00007 K6720-0-E801
AUXILIARY C-121-80010 K6720-0-E001
AUXILIARY C-121-90011 K6720-0-E003
AUXILIARY * C-121-90034 K6720-0-E103 '

AUXILIARY C-121-00037 X6720-0-E108 '

'
AUXILIARY C-121-00110 K6720-0-E109
AUXILIARY * C-121-00127 X6720-0-E111
AUX 1LIARY * C-121-00128 K6720-0-E112
AUXILIARY * C-121-00130 X6720-0-E203
AUXILIARY * C-121-00165 K6720-0-E205 '

AUXILIARY * C-121-00274 X6720-0-E403 I

AUXILIARY C-121-90494 K6720-0-E1111 ;
AUXILIARY C-121-00495 K6720-0-E1121
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AUXILIARY C-121-00496 K6720-0-E1131

AU3ILIARY C-121-00497 X672J-0-E1141 -"
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AUXILIARY C-1J:-00490 K6720-0-E1151
AUXILIARY C-121-00549 X6720-;' E802
AUXILIARY C-121-00581 K6710-0-E107 -

AUXILIARY - C-121-00617 K6710-0-E206 ~

AUXILIARY C-121-00601 K6710-0-E209 !

AUXILIARY - C-121-00627 X6710-0-E40.
AUXILIARY - C-121-00629 K6710-0-E502
AUXILIARY C-121-00682 X6710-0-E405 I
AUXILIARY C-121-V0686 K6710-0-E503
AUXILIARY C -121 -90373 Xo710-1-FU301
AUXILIARY C-121-00080 K6700-0-E803 ;

AUXILIARY C-121-00381 K6720-0-ESO4

AUXILIARY C-121-00883 K6720-0-E807 !
AUXILIARY * C-121-00912 X6710-1-E401
AUXILIARY C-121-00913 K6720-0-E701 i
AUXILIARY C-121-00933 X6720-0-E703
AUXILIARY * C-121-00934 K6720-0-E704
AUXILIARY * C-121-00961 X6710-1-FWS12 '
AUXILIARY * C-121-00962 K6710-1-FWS13
AUXILIARY C-121-00963 X6710-1-FW814
AUXILIARY C-121-00969 K6710-1-E101
AUXILIARY C-121-00970 X6710-1-E102
AUXILIARY * C-121-00971 K6710-1-E105 (
AUXILIARY ~ C C-121-00973 X6710-1-E201 t
AUXILIARY * C-121-00976 K6710-1-E202 i

AUXILIARY * C-121-00978 K6710-1-E200 f

AUXILIARY * C-121-00980 K6710-1-E211 i
AUXILIARY C-121-00982 X6710-1-E504 '
AUXILIARY * C-121-01549 K6710-1-E302
AUXILIARY * C-121-01561 X6710-1-FW815 t
AUXILIARY C-121-01562 K6710-1-FWS16
AUXILIARY i
C-121-01563 K6710-1-FWS17 i
AUXILIARY C-121-01568 K6720-0-E808
AUXILIARY C-121-01619 X6710-1-FWS18
J

* Structurally significant joints identified on drawing with asterisk.

:

"
__-_____ -_____- _
 - - - - - - - - ~--u .~rs
.. ..*

*
.
-

- . . . AUS WELDING REPORT

* BUILDING .~ BECHTEL ID VENDOR ID
. APPENDIX 8. PAGE 7
.

*============ ===============.==================.==========================:
AUXILIARY C-121-01620 K6710-1-FW819
AUXILIARY * C-121-01621 K6710-1-FW820
AUXILIARY * C-121-01622 K6710-1-FW821
AUXILIARY * C-121-01634 K6710-1-E104
AUXILIARY * C-121-01635 K6710-1-E204
AUXILIARY * C-121-01636 K6710-1-E501
AUXILIARY C-121-01681 K6710-1-FW822
AUXILIARY * C-121-01683 K6720-0-C809
AUXILIARY * C-121-01685 K6710-1-E301
AUXILIARY C-121-01691 K6710-1-FW823
AUXILIARY C-121-01692 K6710-1-FW829
AUXILIARY * C-121-01700 K6710-1-E106
AUXILIARY C-121-01701 K6710-1-E802
AUXILIARY * C-121-01773 K6710-1-FW824
AUXILIARY * C-121-01776 K6710-1-FW825
AUXILIARY C-121-01779 K6710-1-FW826
AUXILIARY * C-121-01780 K6710-1-FW827 -'~~'----

AUXILIARY C-121-01783 K6710-1-FW830

AUXILIARY * C-121-01786 K6710-1-E207
AUXILIARY - C-121-01789 K6710-1-E210
--

AUXILIARY * C-121-01790 K6720-0-E811

AUXILIARY C-121-01818 K6720-0-E812
AUXILIARY C-121-01824 K6710-1-E806 ~ - - - "

AUXILIARY * C-121-01871 K6710-1-E110

AUXILIARY C-121-01874 K6710-1-FW837
AUXILIARY * C-121-01883 K6710-1-FW838
AUXILIARY * C-121-01884 K6720X1-0-E601
AUXILIARY * C-121-01885 'K6720X1-0-E602 .

AUXILIARY * C-121-01886 K6720X1-0-FW1

AUXILIARY * C-121-01887 K6720X1-0-FW2
AUXILIARY * C-121-01929 K6710-1-E404
%UXILIARY C-121-01939 K6720X1-0-FW3
AUXILIARY C -121-01940 K6720X1-0-FW4
AUXILIARY * C-121-01945 K6720-0-FW839
AUXILIARY C-121-01947 K6720-0-E004
AUXILIARY * C-121-01976 K671-0-1-FW841
AUXILIARY C-121-01980 K6720X4-0-FW12
AUXILIARY C'-121;f0356 K6710-1-FW832
AUXILIARY * C-121-19639 K6710-1-FW833
AUXILIARY ""
C-121-19645 K6710-1-FW831
AUXILIARY * C-121-19657 K6710-1-FW834
AUXILIARY ' * C-121-19675 K6710-1-E702
AUXILIARY C-121-19725 K6710-0-E002
AUXILIARY C-121-19728 K6710-1-FW835
AUXILIARY * C-121-19731 K6710-1-E705
AUXILIARY C-121-19739 K6710-1-FW836
AUXILIARY '
C-121-12007 K6720-0-FW840
'
AUXILIARY C-121-12010 K6720-0-FW191
AUXILIARY C-121-12010 K6720X2-0-FW1
AUXILIARY * C-121-12026 K6720X3-0-E706
AUXILIARY * C-121-12027 K6720X3-0-E707
-

-.
_ ._. . . . . . - - -
 .._ _
_ - - I

.
.

- . . . AUS UCLDING REPORT

* BUILDING . BECHTEL ID . VENDOR ID .
APPENDIX B. PAGE 3
,.========= == ===============.==================.====================r.=====2
AUXILIARY C-121-12043 X6720X3-0-E708
AUXILIARY C-1.31-05412 M-412A-E201
AUXILIARY C-131-05413 M-412A-E202
AUXILIARY C-131-05482 M-3128-E194
AUXILIARY C-131-05579 M-3128-E196
AUXILIARY C-131-05725 M-3128-E199
AUXILIARY C-131-05780 M-El
AUXILIARY -
C-131-05794 50-El
AUXILIARY * C-131-05793 31-E2
AUXILIARY -
C-131-05799 31'-E3
;
. . . . . END REPORT .....

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.DATE 20 DEC S4 16:53: 47 RID 6 11 DEC S4 BECHTEL

.
e

* . . . AWS WELDING REPORT

- BUILDINO . BECHTEL ID . APPENDIX B. PAGE y.
VENDOR ID .
j
.============.===============.==================.==========================:
REACTOR * C-0X2901
REACTOR * C-0X2902
REACTOR C-0X2903
REACTOR * C-0X2904
REACTOR * C-0X2905 -
REACTOR C-0X2906
REACTOR C-0X2907
REACTOR C-0X2908
REACTOR C-0X290?
REACTOR C-0X2910
REACTOR C-0X2911
REACTOR * C-0X2912
REACTOR C-0X2913
REACTOR - C-0X2914 '-
REACTOR C-0X2715
REACTOR C-0X2916
REACTOR - C-0X2917
C-0X2918
-
REACTOR
REACTOR C-0X2919
REACTOR C-0X2920
REACTOR C-0X2921
REACTOR C-0X2922
REACTOR C-0X2923
REACTOR C-0X2924
REACTOR * C-1X2925
REACTOR C-1X2950
REACTOR C-0X5902
REACTOR C-0XS903
REACTOR C-0X3904
REACTOR C-0XS905
REACTOR C-0X3906
REACTOR C-0XS907
REACTOR C-121-DSOS1 K6724-0-E115
REACTOR C-121-08082 K6724-0-E112
REACTOR C-121-08083 K6724-0-E113
REACTOR C-121-08122 K6724-0-E116
REACTOR C-121-08302 K6724-0-E119
REACTOR * C-121-08355 K6724-0-E122
REACTOR ~W C-121-03360 K6724-0-E117
REACTOR * C-121-08361 K6724-0-E121
REACTOR * C-121-03362 K6724-0-E123
REACTOR * C-121-OS367 K6724-0-E120
REACTOR C-121-03379 K6724-0-E105A
REACTOR * C-121-03504 K6714-0-E101
REACTOR * C-121-03506 K6714-0-E192
REACTOR * C-121-08510 K6714-0-E194
(, REACTOR * C-121-03523 K6714-0-E111
REACTOR * C-121-08543 K6724-0-E124
REACTOR * C-121-03549 K6724-0-E601

_ _ _
_ _,
 -

- - - - - - u .aC
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e
* . . . AUS WELDING REPORT
* BUILDING . BECHTEL ID
. VENDOR ID . APPENDIX B , P AGE 5
.============.===============.==================.============-==============
REACTOR C-121-08562 X6724-0-E196A
REACTOR- .C-121-08572 K6714-0-E114
REACTOR * C-121-03576 X6714-0-E198
REACTOR * C-121-08577 K6714-0-E106
REACTOR C-121-03621 K6714-0-E118
REACTOR * C-121-08625 K6714-0-E110
REACTOR C-121 -03741 X6714-1-FW602
REACTOR * C-121-03752 K6724-0-E602
REACTOR - C-121-08753 X6724-0-E603
~
REACTOR - C-121-08772 K6724-0-E608
REACTOR * C-121-08773 X6724-0-E609
REACTOR * C-121-08786 K6724-0-E604
REACTOR * C-121-03787 K6724-0-E605
REACTOR C-121-08815 'K6724X2-0-FW401
REACTOR * C-121-08846 K6724-0-E606
REACTOR C-121-08847 K6724-0-E607
REACTOR C-121-OSS96 K6714-1-FW200 ~ ~~

REACTOR C-121-08897 K6714-1-FW204

REACTOR * C-121-08909 X6714-1-E105
_

REACTOR - C-121-08912 K6714-1-E107 --

REACTOR * C-121-08950 K6724-0-E501

REACTOR * C-121-08982 K6724X5-0-E610
REACTOR C-121-08997 K6724X2-0-FW2
REACTOR * C-121-08999 K6724X2-0-FW1
REACTOR * C-121-13001 X6714-1-E103
REACTOR * C-121-13017 K6724-0-FW2FS
REACTOR C-121-13052 X6724X6-0-E126
REACTOR C-121-13060 K6724X6-0-FW1
REACTOR * C-121-13069 K6724X2-0-E125
REACTOR C-121-13070 K6724X2-0-FW3
. REACTOR - C-121-13093 K6714-1-E109
REACTOR < C-121-13098 K6724X7-0-FW301
REACTOR * C-121-13099 X6724X7-0-FW302
REACTOR C-121-13119 K6724X7-0-FW303 '

REACTOR C-121-13120 K6724X7-0-FW191 a

. REACTOR C-121-13241 K6724X9-0-FW11
REACTOR C-121-13242 K6724X9-0-E611
REACTOR * C-121-1'3258 K6724X11-0-FW14
REACTOR C-121-13259 K6724X11-0-FW15
REACTOR '--* C-121-13265 K6724X11-0-FW13
REACTOR C-121-19996 K6724X10-0-FW12
REACTOR C-131-05649 M-36-E1
REACTOR C-131-05650 M-36-E2
REACTOR C-131-05651 M-36-E3
REACTOR C-131-05652 M-36-E4
REACTOR * C-131-05666 El
REACTOR C-131-05671 E2
REACTOR C-131-05672 E3
/
'
REACTOR C-131-05712 M-36-E5
REACTOR C-131-05732 M-24-El
REACTOR * C-131-05734 M-36-E6
 _

. . . ..
.

,
-
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e

, . .. AWS WELDING REPORT

e' BUILDING . BECHTEL ID . VENDOR ID . APPENDIX B . P AGE Gb !

.============.===============.==================.===========================
REACTOR * C-131-85743 E12
REACTOR " * C-131-F5759 E13
REACTOR * .C-131-95890 31-E4
REACTOR C-131-55889 M-19-E2
- . . . . . END REPORT .....
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.DATE 20 DEC S4 16:53: 47 RID 6 11 DEC S4 CECHTCL

.

*
* . . . AUS WELDING REPORT
* BUILDING ., BECHTEL ID VENDOR ID
.
APPENDIX B. PAGE 7
.
.
============.===============.==================.===========================
CONTROL C-121-91953 K6721-0-E10
CONTROL C-121-01272 K6721-0-E11
CONTROL C-121-01311 K6711-1-FW24
CONTROL C-121-81312 K6711-1-FW25
CONTROL C-121-01313 K6711-1-FW26
CONTROL C-121-01314 K6711-1-FW27
CONTROL C-121-01315 K6711-1-FW28
CONTROL C-121-01316 K6711-1-FW44
CONTROL C-121-01317 K6711-1-FW45
CONTROL C-121-01318 K6711-1-FW46
CONTROL C-121-01319 K6711-1-FW47
CONTROL C-121-91329 K6711-1-FW49
CONTROL C-121-01321 K6711-1-FW52
; CONTROL C-121-01322 K6711-1-FW53
CONTROL C-121-01323 K6711-1-FW54 - ~---

CONTROL C-121-01324 K6711-1-FW55

CONTROL C-121-01325 K6711-1-FW56
CONTROL C-121-61326 K6711-1-FW57 --

CONTROL C-121-01327 K6711-1-FW58

CONTROL C-121-01328 K6711-1-FW59
CONTROL C-121-01329 K6711-1-FW60 - ~ - " ~ '

CONTROL C-121-01330 K6711-1-FW62

CONTROL C-121-0133,1 K6711-1-FW63
CONTROL C-121-91332 K6711-1-FW65
CONTROL C-121-01333 K6711-1-FW66
CONTROL C-121-01334 K6711-1-FW77
CONTROL * C-121-01403 K6711-1-E2
CONTROL * C-121-01411 K6711-1-E3
CONTROL * C-121-01414 K6711-1-E4
CONTROL - C-121-01417 K6711-1-E5
CONTROL * C-121-01420 K6711-1-E6
CONTROL - C-121-01426 K6711-1-El
CONTROL C-121-91423 K6711-1-FW17
CONTROL C-121-61438 K6711-1-FW19
CONTROL C-121-91434 K6711-1-E9
CONTROL' * C;121-51484 K6711X1-1-E12
CONTROL * C-121-91485 K6711X1-1-E13
CONTROL * C-121-69915 K6711-1-E7
CONTROL ~ "~~ C-121-99923 .K6711-1-ES
CONTROL * C-131-85565 48-E7
CONTROL C-131-95684 M-128-E197
..... END REPORT .....
.

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 .
. _ . . -s

.DATE 20 DEC 84 16:53:47 RID 6 11 DEC 84 BECHTEL

* . . . AWS WELDING REPORT

* BUILDING . BECHTEL ID.
VENDOR ID
.
APPENDIX B . P AGE 25
.

*============.=============== ==================.===========================
DIESEL GEN. C-121-08387 K6726-0-El
DIESEL GEN. C-121-08391 K6726-0-ES
DIESEL GEN. * C-121-08831 K6716-1-E3
DIESEL GEN. * C-121-08840 K6726X2-0-E8
DIESEL GEN. * C-121-08861 K6716X3-9-E9
DIESEL GEN. * C-121-08899 K6726X1-0-E6
DIESEL GEN. * C-121-08900 K6726X1-0-E7
DIESEL GEN. * C-121-08958 K6716-1-E2
DIESEL GEN. C-121-08959 K6716-1-FW1
DIESEL GEN. * C-121-13249 K6716-1-E4
..... END REPORT .....

__ _ _

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.DATE 20 DEC S4 16:53: 47 R1D 6 11 DEC S4 BECHTEL

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* . . . AUS WELDING REPORT
* BUILDING . BECHTEL ID VENDOR ID APPENDIX B, PAGE 9 .
. .

*============.===============.==================.==========================:
_

FUEL * .C-121-85765 E4
FUEL * C-121-85813 E14
FUEL - C-121-05821 M-19-E3
, FUEL C-121-19028 K6728-0-E4
FUEL * C-121-19029 K6728-0-E5
FUEL + C-121-19030 K6728-0-E6
FUEL C-121-19032 K6723-9-ES
FUEL C-121-19066 K672SX2-0-E10
FUEL -
* C-121-19078 K672SX4-0-E10
FUEL C-131-19000 K6728-0-El
FUEL * C-131-19001 K6723-9-E2 -
FUEL * C-131-19027 K6723-9-E3
FUEL * C-131-19069 K6718-1-E7 -

..... END REPORT .....

__ __ -.

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_ - - _ . - - - - _ - - - - - - . - - - - - - _ _ - - _ _ - _ . . _ - - - - - - - _ _ - _ _ . _ _ _ _ - - _ - - - _ - _ _ - - . . - _ - . _ - - . _ - _ _ - _ _ _ - - _ . . _ _ _ _ . _ _ - _ _ . - _ _ _ _ _ . _ - - - - _ - _ _ - _ _ _ . . - - _ - -
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_ _ _ _ _ _ _ _ - _ _ _ __

- - _ _ . . . . _ . . _ . _ _ . ._
_ . . . . . . . _

( .DATE 28 DEC 84 06:45:08 RID 7 18 DEC 84 BECHTEL

e
( * FIELDFABRICATIONREbuEST
BUILDING
AWS WELDING REPORT
* . NUMBER . DATE . APPENDIX C. PAGE 1 et 8
. *================,==========,========,=====================================-
( '
~ REACTOR ~
A UXIL'IARY-- -~ -
" ~

RB0046
0556
11-26-79
'11-03-82
~
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- - -

REWCTOR ~ R B 0 f3 M I 2F 8 D - ~ " - - "-- ' ~

( AUXILIARY 0030 02-14-79
AUXILIARY 0504 08-04-82 ~
2 AUXILIARY 05'03- YS204 82~~
( ~~ AUXILIARY
- ~ ' REACTOR
~

~ 0506 08-04-82
'RB0006 09-18-79
~~'
~ ~

m REACT'OR RBT037- 08 03 8a
(. 0420 11-11-81
FUEL F0073 -
01-18-82 - ~ ~ - - - ~ - ~ - -
% REACTO~R - R'B 0'4'37-- 02 23-81 ~ -
( S'--- ~R E AC TOR ~~ REACTOR -
RB0671
RB0464
04-27-82
04-07-81
~ ~ ~ ~ ~

~ - ~ ~

~
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' ~~~' TEACTDR

-
RS1'B19-' 07#
1 3783 ~~ ~ ~
( FUEL
FUEL
F0114
F0091
03-20-84
11-10-82
RB 0919- 03-14T83 -
~ "~ -~ ~ ~ ~ " - - -~
5- REhCTOR -~ ~
( REACTOR
~ REACTOR
RB0717
RB1779
07-13-82
10-12-84
~
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0'4J22278 -
~~~ " ' ~ - ~ ~ ~ ~

REXCTOR-
T REACTOR 'RB0842 11-18-82
~~
REACTOR ~
RB0153 02-07-80
~ ~~~~~ 7 TI351- 02-06-84 ~
~ ~ ' ~- ~~~
R EhCTOR'--
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( REACTOR
REACTOR
RB0437 02.23-81
RB0360
- "~
11-18-80
- 7 EA'CTO'R-~
- ~
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RB~0035-~~12720-79~
{ REACTOR RB0135 01-24-80
ESWS ' -
6012 02-25-82
~-- DIESEL 00012~ 02 25:79 - - - -
~~
' -~~ -~

( " FUEL
0010
F0014
06-03-80
08-19-80
--'
~ ~

RB 0065-- 12:20-79 '--~

' - - - ~ ~ ~ "- ~~
'''-- REA C T O R^ -- ~
{ REACTOR RB0391 12-23-80
REACTOR RB0623 02-24-82
RB0376~ 12:08-80
-- '- " ~- ~ ~ ~ ~ --~~
REWCTOR~~
( REACTOR
AUXILIARY
RB0360 11-18-80
08-10-78 ~ ~ ~"
--- A0XI L'I AR Y N7A ~"08-15;78 - " ~ -
( AUXILIARY 0028 12-13-78
-
RADWASTE RWO937 02-24-81
T U E L ~ ~ - ' --- " ~ 'F0020 ~~10-27-80
- ~~ --

(, FUEL F0050 03-04-81

- -

AUXILIARY 0697 10-03-83

0823'~~05 19-84 -
~ - - ~ - - - ~ " ~ -- -" ~
AUXITI ARY ~
( 0791 04-28-84
AUXILIARY --
0901 08-24-84 ~~ --

0029 " 09-17-84

' ' ~'
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( DIESEL 0798 05-01-84
__ . _ _ _ _ _ _ .

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 . . . _ _ __ . .. . . . _ . _ _ _

{ * . . . l
* FIELD FABRICATION REGUEST AUS WELDING REPORT
* BUILDING- . NUMB ER .- D ATE -~ .-- ~ ~ 'AFP ENDIr C; F AGE' 2.
[ *================,==========,========,======================================
:. ESWS 0031 09-23-84 ~~- ---"- -
,. i ESUS -0028 09 17384 - "~~

ESUS 0030 09-17-84

( '" T EACTOR - - ~~~--

. RB0431 02-16-84 - - - " - ~ ~ - - " - - - "

a AUXILIKKY-
'-
0451 02 15 82--
( .; AUXILIARY
REACTOR
0452 02-23-82
RB1133 11-22-83
''
CONTROL
-
0699 '0s-21-84
( ~ REACTOR - ' ~ ~ ' ~ ~

REACTOR 'RB1112 11-14-83 -

r RB1073
^
09-13-83 ~ ~ - - - - - - - - ~~

REACTOR
.
RBDT2Y- 63 TlT83
( . REACTOR
REACTOR
-.
RB0925
RB0853
04-28-83
01-25-83 "---"

RB 0853'- 0370F83--~~ ,
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AUXILIARY 0646 05-26-83

~( 4- FUEL
~ ~

F0099 05-09-83 '" - - - - - -

REKC TOR'-- RBY97D 05-04'83

( REACTOR
REACTOR
RB0965
RB0952
04-28-83
04-18-83
- -- ~~--" ---- -

. MEAUTOR RB'095I 04Tr5:83"----

( .
'-~~ RE ACTOR
~~ R E ACTOR
RB0941
~ ~~RB0937
04-13-83
04-11-83
-
~

--

~~ ~ ~ ~ ~ - -
A0XIFIARY
-

0630 03-30-83'-
/ REACTOR RB0906 03-07-83
REACTOR hdO700 02-28-83 ' - - ' - - - ' '' --~ -

REA'CTOR "-~ ~~ RB0888- 02 10-83

( REACTOR
-~ AUXILIARY
RB0894 02-16-83
0645 05-24-83
,
--

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'

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TURBINE
RB0978 05-12-83
0491 06-03-82
-

AuYILTART - ~ ~
- ' -- ~ ~ --~
0493 - 06;16-82 - ~ '- -
( CONTROL
~~ REACTOR
0493
RB0695
06-16-82
06-07-82
~~~

~~ ~ "' --
R'E 4C T OR~~~~~ 'RB0716 07-09282' '
( RADWASTE
REACTOR
RWOO42
RB0723
07-15-82
07-19-82
REACTDR~'-"
~ - ~ ~ ~ - - - - -
.
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(
,

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-
REACTOR 07-21-82 ~ ~ ~
REACTOR RB0729 - 07-29-82 ~ ~ ~ ' ~ -
AUXIl.IARY-- -0500 08 2 02 282 - ' ~~~

{ FUEL F0109 11-14-83

AUXILIARY 0700 10-19-83
~
~
*

RB1086 09-28 18'3

~ -- -
REACTOR
( AUXILIARY
REACTOR
0703 10-17-83
RB1958 08-25-83
~~

REAC' TOR '--' -~ --- ' - ' " ~~~~---~ ~

~
-

RB 0 87 5 ~~01723283 ~ ~ ~
(, REACTOR RB1961 08-29-83 '

REACTOR RB1936 08-03-83 '

REACTOR ~ -~~-~ ~ RB 1Y54 ' 08-03-83 ~ -- -

~~" ' - - - '

( AUXILIARY 0670 07-29-83 .

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.
{ *
*
'

FIELD FABikICATION REbuEST AWS WELDING REPORT

T --~BUTEUING~- . 'NUf1BEM DATE APPENDIX C. PA
(
. .

*================.==========.========.==========================G
============
0487 05-13-82
AUXILIARY esu OT-26-82 '-~~ - --- -~

( ' AUXILIARY ~ ~ - ~
- ^^ REACT 0lr ~ -~~ '
'9436' 01-20-82
RB0606^ 01:27-82
~

~~
~ ~ ~ - ~ ~

-'

-
REACTOR RbT617- 0231~0:82 -~ - - - ~

( AUXILIARY
AUXILIARY
0471 04-14-82
0472 04-14-82
-

94-12-82-~~
^

REACTDR R80654
( .-
REACTOR
REACTOR
~~~~ ~''RB0646 08-30-82 - ~

~ ~" ---- R B 06 3 7 '03-23-82 ~ ~ ~ ' -

REWCitR RB0E39 03:23282

-" - - ~ ~

(. REACTOR RB0638 03-23-82

AUXILIARY 0458 02-25-82
e AUXILTARY N57 07:2'4 '8 2'-- - - ' ~ ~ " " " - - - - - ~

( ~~ REACTOR
' FUEL ~ ~ " ~
~ ~ ~ - ' RB0620 02-17-82 ' " - '

R0081 04-22-82 ~ ~ ~ ~

Mt. AL & UK MS0676 0 570T#8 2~ ~ " " "-~ -- ~ ' "~~

(
,

'

RADWASTE RWO903 03-27-79

4
REACTOR R6005 10-24-78
= MEACTOR H 7001 "- U7:07-78 - - --- ' - - - ~ -

( REACTOR
REACTOR"
-
R0002 09-07-78 - - '
;
i
-
RB0601 01-18-82 i
REKCTOR 'RB'06'02-' 01719283 ~ ~ ' - - ~ - - - - ~

;
'
/
AUXILIARY 0046 05-14-79
REACTOR
~ RB0618 02-16-82 ;

; (
-
_ R ENCTOR-~-- - - ~ ~ ~ -~RB O'619 02-f7-82 -~~ "' ' ~~ " ~ ~~
'
FUEL F0076 03-04-82
; .
~~ REACTOR RB0628 03-01-82 ~~
' -

RE~ ACTOR ~ - ~~~RB0616-~02 10282 - ~ ~ ~~ ~ ~ ~ " - - ~ ~

'

( FUEL F0069 10-19-81

,
6409- e9-28-81
KEWCTOR RB'0498~~06-16-81~~
~ ~ ~ ' ~ ~ ' ~ ~ - ~ ~ ~ ~

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{ REACTOR RB0482 05-21-81 ~ ~ ~ ~

< ' REACTOR RB0466 05-04-81 ~~~ ~

KADWASTE- RW9038 04 01-81 -' "~~-- '-~~ ~ '-

( REACTOR RB0446 03-10-81

REACTOR RB0446 03-03-81
REWCTOR~ RB0427~~02-19-81
- ' - '~

(
~ -

FUEL F0045 02-09-81

REACTOR 12-09-80
RB0377
REACTOR ~ ~~RB 0366~ 11 "24-80 ~ ^
- ~
~ ~ ~ ~

j { REACTOR RB0367 11-24-80

REACTOR ~~
RB0335 10-27-80
REACTOR ~~R B 0337 - ~10-29-8 0
- ~~ ~

( AUXILIARY
'

0119 12-26-79 -

j REACTOR RB0371 12-02-80

7EA CTO R' ~ ~" ~ ~- 8 8 0370 12 ~02-8 0 ~~ ~~ -~ ~ ~ ~ '" ' - - ' - - -

( REACTOR RB0373 12-03-80

REACTOR RB0022 10-16-79
-"7EACTOR~~ ~ ~~ --~ "" R B 0 0 2 0 ' 10-10-79 - '~

(, REACTOR RB0573 11-04-81 ~-

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* FIELD FABRICATION REOUEST
.

AWS WELDING REPORT

. .

* EUILDING" .- NUND ER '' . DATE~ T - ~ ' - ~ APPENDIX C. PAGE 4-

(' . *================,==========,========,=====================================
REACTPR RB0562 10-26-81
a RB0798 ~09-30-82 ~~~ ~~ - ~- ~- - -

( '7EWCTOR--
'

REACTOR RB0792 10-04-82

~~ REACTOR RB0795 10-05-82
CONTR~0L "~0550- 16:14-82 ' ~ ~ ~ ~ - - - ~ ~ ~~ ~ - - - --- - " - - ~

('
.

REACTOR RB080310-15-82
a; REACTOR RB078909-23-82 - - - - -
t, g533g9:3fr32- - --

( ~ AUXILIARY
- ~ ~ - ~
~

~ 0513 09-08-82
0022 08-23-32
RT07T 5''~~BSIl 1-~
~ - - ' ' ' ~ - - ~ ~ ~ ~
REACT 0F -S 2
( .
FUEL
REACTOR
F0090 11-02-82
R0003 10-03-78
-- KEWCTOR-
^

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( ~~ AUXILIARY
A
"
0665 07-12-83 ~ '-
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-~~ UXILIAR.Y-
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ggg4 g g ....-- _ _ _ .- .. - - _

( CORRICOR
AUXILIARY
0673
0442
00-09-83
02-02-82 -~' ~ ~ ~ " - - - ~
KEACTOR
-

RU 050 9- 66;-2 9 -81 - "-- ~ --~

( AUXILIARY
FUEL
03S4
F0043
05-12-81
02-02-81
.

~~

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/ CONTROL 0320 01-29-81

CONTROL 0209 10-22-80
CONTROL- ~-- 0288- 10-21-80
- - -- ~

( CONTROL
0280
0260
10-13-80
09-16-80
'-

A0XILIARY* - - ---
" -

- 0257' 09 10-80
( FUEL
REACTOR RB0318
F001o
09-10-80
09-03-80
- - -'~~ ~ ~~T2 3 9
- ~ ~
-~'CONTRUE 0 82 0 5 - 8 0
( ~ AUXILIARY *
0139
0122
02-07-80
01-09-80
-
-- gg97 ig_25 79 - - --

( DIESEL
AUXILIARY
0094
0066
10-10-79
08-04-79
AUXII.I~ARY - ~ ~~- ~ ~0053 06-25-79
-' -~~

( 0025
0051 06-11-79
12-04-78
_ . . . . _ . . _ _ _ - ~ ~ ~ - -
O m ~09 4 -78 ~ ~~ ~ ~ ~ - -

( AUXILIARY
CONTROL
A0082 06-29-82
C0056 07-12-83
- - - ~ ~
RB0822 042 25-83
' "-
RE'A'CTOR
( REACTOR
REACTOR
RB0822 03-23-8a
RB0929 03-31-83 '

R E ATTO R -~ ~ ~ ~ ~ ~ RB0821~~01-31-So
( REACTOR
REACTOR
RB0853 02-03-83
RB0924 03-17-83
~
REACTOR - ' - " "RB 0621"- 81231-83 ~ ~ ~

( REACTOR
. _ _ _ . _ . .
RB0924
_
09-07-83
_ _ _ . .. . . _ _ _
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. . .

AWS UELDING REPORT

e ~ BUILDING -' --- NUnBER- T- DATE'' . ''~~' APPENDIX C. PAGE' s
( '
:
*================.==========.========.================================r.====r.
REACTOR RB0924 09-06-83
..
A U KI C I A RY-- -'~ ~ -- '-~ ~' A 0 f53 0 5 - f1 83 '--- ~ --- ~ ---- ~ ~ ~ ~ ~ - - - - -

( ~ ~ REACTOR "RC1133 "1T;22-83 - - - - -

, REACTOR RB0742 08:11-82 ~

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2
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av DIESEL 60322 08-02i 79
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--
REACTOR RB0822
~
11-18-82
REACTOR ~ ~ ~ TB'0832 12702282
( REACTOR
REACTOR
1374
RB0244
04-11-84
05-05-80
''

01Tf3 53 "--
-
'~ - ~ ~ ~
m REACTOR RBO833
~~~ REACTOR 'RB1619 06-01-84
~~

( 4-~AUXILI ARY 'A0169 06-25-84

-- DTE5a 01 % e 3 - 03 8 0 - - -- -~~~ - ~ ~ - ~

( DIESEL
FUEL
0144
F6093
02-19-80
11-29-82
~
M EA CT O R-" - - RB008y 01363:30 -
- --- ~ ~ ' - ' -- -

( FUEL
FUEL
F0019 10-20-80
~ ~ - -
F0015 09-02-80 - - ' - -

--- FU E L~ F0BT3- B8' 05--80

/ FUEL F0010 07-23-80
SITE RVH0002 12-21-81
RB0271 -- 06T 10-80 ~
~
REACTOR ~ ~ ~

( REACTOR RB0272 06-10-80 -

REACTOR ~ ~ ~ -
RB0923 03-17-83
4~UX fLTARY '0555' 11-03-82- ~ ~
~ ~ ~~

( AUXILIARY
AUXILIARY
0557 11-04-82
~
' ' - ' '
0559 11-08-82
AU'<ILI ARY - 56'0--~~11211-82 -
~ ~ '

0
~~ ~ ~ ~ ' - -

( AUXILIARY
' REACTOR
0565 12-02-82
~
RB0583 12-01-81 ~~

A UXI EI A R Y"- ----- 058'4- "01-19-83" " ' '

' - - " ~ ~ ~ ~ ~ ~ - -

(' AUXILIARY
AUXILIARY
0585 01-10-83
0593 01-17-83
AUXII.I ARY ~ - - ~0744 ~01-30-84 ~ ~ ~ - " -

( REACTOR
REACTOR
RB08",7 12-21-82
RS1312 03-22-84
~~~" REACTOR ~~ ~~ RB 1652-~ 0 6 0 8-84 ~
' '~~ ~ ~

( REACTOR RB1671 06-12-84

REACTOR RB1726 06-23-84
REACTOR --~ ~ ~ ~ ~ ~ RB 1739 07-07-84 ' - - ~ ' '- -

( REACTOR RB0209 04-03-80

REACTOR
~ ~ ~ " ~
RB0191 03-24-80
RE7iCTOR RB0178' 03-13280 ~ ~ ~ ~ ~ - " ~ ~ ~ ~ ~ ~ " - " =

( REACTOR RB1259 02-15-84

RADWASTE
- ~ ~ - ~ '
RWD644 05-19-84
- ESWS' ~ 0032 10 02-89
(, REACTOR RB0227 04-22-80 '

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.{ *
* FIELD FABRICATION REQUEST
. . .

AWS WELDING REPORT

* UUALDING . r4 UMBER-- . DATE .
---
APPEf4 DIX C.- P AGE- G *

[ *================,==========,========,=====================================-
REACTOR RB0510 06-30-81 ~ --

4 _ .AUXICI.ARY ..- , . . .
STe4 11 .:7:7 9- ' ' "-- -~ ~ ~ "*
_79
__

-
. ,g79 ,
.. . . . - -
. .
.
_
0078..08-22-79 . - . ... . . . .. ---

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. 0010 0S-15-78
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0011 08-15-78
..- - ..

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( ..... END REPORT .....' -

- - . - . . - - - - - . . - .. .. . . . . . . .

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_ _ _ _ _ _ . _ . _ _ . . . _ . _ . . . _ . . . - . .
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 . . . -- .__ . - - . . .- .. .-- .
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,

AWS WEIDING REPORT '

Appendix C, Page ]
|

LIST OF NONCONFORMANCE REPORTS

1-941-C 1-9593-C 1SN3516CW

1-942-C 1-954 9-C 1SN3589C
'
1-943-C 1-9559-C 1SN3614C
1-945-C 1-9551-C 1SN3753C
1 1-947-C 1-8552-C 1NN3768C
1-948-C ISN9738C 1SN3779C
'
l-949-C 1SN9899C 1SN3784C
1-974-C 1SN9972C ISN3794C
1-082-C 1SN9992C '1SN3795C
1-983-C 1SN1956C 1SN3796C
1-984-C 1SN1957C 1SN3899C
, 1-985-C 1SN1277CW ISN3891C
1-986-C 1SN1283C ISN3892C
1-987-C 1SN1432M 1W4121C
1-999-C 1SN1486C 1SN4276C
1-994-C 1SN1549C 1SN4283C
,
1-995-C 1SN1567C 1SN4293C
1-996-C 1SN156BC 1SN4389C
1-9104-C 1SN1649C INN 4539C
1-9123-C 1SN1996C 1SN4536C
1-9124-C 1SN2961C 1SN5823C
'
1-9128-C 1SN2138C 1SN5847C
l-9136-C .lSN2154C INN 6999C
1-9139-C 1SN2228C 1SN6117C
1-9143-C 1SN2419CW ISN6299C
1-9148-C 1SN2489C 1SN6331C
1-9149-C 1NN2530C 1SN6795C
] l-9158-C 1SN2585C ISN6899C
1-9169-C 1SN2642C 1SN8312C
"
l-9166-C 1SN2647M 1SN8378C
'
1-9179-C 1SN26580 ISN8599C
l-9178-C 1SN2699C 1SN8612C
|
1-9183-C 1SN2728C 1SN8899C -
1-9189-C 1SN2793C INN 8967C
;
l-9295-C 1SN2945C 1SN9119C
'
1-9238-C 152972C 1SN94 M
l-9244-C 1SN2987C 1SN19926C
1-9255-C 1SN2992C 1SN19381PW
4

14266-C 1SN3913C 1SN19931C

1-9276-C 1SN3917C 1SN11986C
! 'l-9277-C 1SN3939C 1SNll282C
,
1-9335-C 1SN3041C ISNil592C
I
1-9338-C -ISN3111C 1SNil689C
1-9339-C 1SN3115C 1SN11986C
i 1-9349-C INN 3132C 1SN12199C
i 1-9345-C 1SN3139C 1SN12517C
i 1-9355-C 1SN320CW ISN13289C
1-9385-C 1SN3255C 1SN15220MW
1-9423-C 1SN3261C 1SN15352C
1-8433-C 1SN3385C 1SN15685PW
1-9434-C 1SN3386C 1SN15723CW
1-9439-C 1SN3475C 1SN16728CW
1-9445-C - 1SN3481C 1SN16988CW
.
1-9446-C 1SN3483C ISN19864C

l .

- -.- -. - - - _ , _ - - - , , - - _ ._ .- - , , , , __ ,_ ,, - - __ __ - .. _.,, - --., - -

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*
. . AUXILIARY OUILDING F894532
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. AUXILIARY BUILDING F#94532
y 0~~ . . . AWtrWELDING REPDRT7 APPENDIX DT PAGE''.f ---
4.' CJOINT. TYPE US . WD . ' . IC . UR , UC . MM . IJ GN -s
'oc..........,~....'.............=@.........................................................................mear...
A B . C D.A, 9 C D E F G H I J K L.A B C D.A 8 .A 8 .A B C.A
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"| *WD-A: DEFECT LENGTH IS 3/8 m

it. o . . .' r - ' ~ - - ' ~ ~ ' -' - - - - - - - - - ' ~ - ' - - - - ~ - - - - -
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. . . . . . , -_ . . . . . . . _ . . . . - . . . - . . - . . . . _ . - . . _ , . . - -
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"'.| o'fwl-CINO WELDS PRESENT DN WEST CLIP ANGLE TD BEAM q
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eUS-A:DNE LEO IS UNDERSIZED FOR APPROXIMATELY 5810F THE TOTAL LENGTH
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F994532
' o . AWS WELDINO REPORT APPENDIX D. PAGE F
. '
. :q
OJ US UR . UC . MM IJ WD IC f
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eUS-A:DNE LEO IS UNDERSIZED FOR APPROXIMATELY 13% OF THE TOTAL LENGTH . ___ _ . ... -. . . . . . - . . .

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; [WO-C: DEFECT LENGTH IS 1/16 I IJ-8: LOCATED IN DLOCHWALL
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- enn-C: SEAT TO SEAR WELDS ARE MISSTNG 8 US-C:DNE WELD WAS REJECTED BASED ON VISUAL INSPECTION
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WD IC UR . UC . MM
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eUS-A:0NE LEO IS UNDERSIZED FOR APPROXIMATELY 19% OF THE TOTAL LEHOTHs M-A: FILLER PLATE WAS INSTALLED g
-o - 7 -. . ..
_ _ . . . , _ . . _ _ . . . _ _ . _ . . . . _ , . . _ __
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O ; CWO-C: DEFECT LENGTH IS 1/4

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AS46 F u1 1 1 6 e2
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' (US-A:0NE LEO IS UNDERSIZED FOR PART OF THE LENGTH s M-C: SEAT 70 BEAM WELDS ARE MISSING --- -- - " - ' - - - - - - - - - - -

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"' cWD-C: DEFECT LENGTH IS 5/8
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' CWO-C: DEFECT LENGTH IS APPROX. 1/4 : WD-A: DEFECT LENGTTH IS APPROX. 4-3/8 9
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. sWO-C: DEFECT LENGTH IS 1/4 m
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AWS KLDING REPORT APPENDIX 0 PAGE I
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i '~GIJ-8: LIMITED ACCESS-APPEAR TO MfET MINIMUM REOUIREMENTS

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' eWD-C: DEFECT LENGTH IS 1/4 MAXIMUM i WD-F: DEFECT LENGTH IS 3/4 8 IJ-R: LIMITED ACCESS-VISUALLY OM-
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O!J-3:CANNOT BE MASURED DtfC TD EDGE CONSUMPTION. DUT APPEARS 04
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I.! eWD-G: GOUGES DUE TO CONCRETE REMOVAL DEEPER THAN 1/8 (3 PLACES) & GRINDING (5 PLACES) - - - - -

N OIJ-3:CANNOT BE MFASURED DUE TO EDGE CONSUMPTION AND/OR GRINDINO-SIZE IS VISUALLY OM 9

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8 P4 4 1 e i e1 m
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4 i .
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SEAT TO EM8ED(TOP) & SEAT TO BEAM WELDS ARE MISSING-2 PLACES EACH ..._ _ _ ._____, . _ _ . . . . _ . . _ ._ _ .

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 -

AWS WELDING REPORT

Appendix C, Pcge $ ,

LIST OF FIELD CHANGE REQUEST

1-0860-C i

1-0901-C
1-0917-C i
1-0928-C
1-0957-C
1-0974-C
1-0993-C
1-1007-C
1-1434-C
1-1440-C
1-1590-C
.

to

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'
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L
 Bechtel Power Corporation
Eng neers - Constructors ,

P O Box 42 g'l
New Strawn. Kansas 66839

Dece:ber 25, 198t.

Mr. Gary L. Touts

Construction Manager
Wolf Creek Generating Station
Kansa s Gas and Electric Company
Post Office Box 309
Burlington, Kansas 66839

BLKES- 1364
SNUPPS Project
Bechtel Job 10466-003
Files: 0266.2
Inspection of Painted Welds

Reference 1: BLKES-1348
Dear Gary:

As previously stated on Page 2 ef the Attachment on Reference 1,

we are now able to furnish the number of uncoated welds.
" Visual reinspection of 1090 uncoated welds in the
structural steel at WCCS has, in fact,shown no
evidence of weld cracking or porosity, and only .

107 cases of minor undercut."

Should you have any questions, please contact me.
Sincerely,

*
/
C. M. Herbst
Asst. Proj . . Engineer
CMH/ds
cc: M. Johnson
J. Harvey
R. Brown
J. Bailey

.
 . .

. .
.

Bechtel Power Corporation

- - . ? -
En;>ee s - C: r~ue:: s
P O. E0= :2
Ne* S a..n. sa ras 65539
Mr. Gary L. Fouts
Construction Manager i;0V 05 Td4
Wolf Creek Generating Station 'D
Kansas Gas and Electric Ccmpany C g # '/
Post Office Box 309 t'
UOl/ e -

Burlingten, Kansas 66839

'Oh
:,, ', - rpy
,
, *'s r.
. ..

BLKES- 13 '.S
SNUPPS Project
Bechtel Jeb 10466-003
Files: 0266.2
,
Insceetion of Painted Velds
Attachment: Visual Inspection of
Painted Tillet Welds
tear Mr. Fouts:
!
'

Sursuant to KO&E's request, the Bechtel Engineering position for Visual

.nsp?ction of painted welds in accordance with AUS D1.1 is attachec.
.

Should you have any questions, please contact me.

. Sincerely a
s
# #
\. . -

. N /
'. : _ ;
, ~-
. N. C. M. Herbst
-

?- Assistant Project E.gineer

i ' ,
's '
,

Y }'/
.

CMHNP/lb'.,f i N '
.
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cc:
' * '
\<'.x'
,N jh',/ ,7',g -
M. Joh'nson w/1 , ,'. ' > '1
, s/*
'-

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J. Harley u/1' .

.N. ' %. s,,!

< ..s /' ',.~
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'*// ' ' '/ \v' / ,I ' -

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R. Brown w/1 .
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J. Failey w/1 ' */ ' '

'N' '. 's '
-

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.tt,cr,.nt :: sua:-:2;;
, Page * tf 2

T VISUAL I?!S8ECTION CF DA!'!TES 7'LLET *-TLOS

Summary of Bechtel's Position

With the exception of a number of attributes, fillet velds wnich have been
coated with up to 4 mils of primer and in sene cases, up to an additional 10
mils of topcoat can be visually inspected to the Na'S 01.1 acceptance ,
'

criteria. Those attributes which cannot be fully evaluated are of little or i

no concern on the structural steel at WCGS.

Evaluation of Physical Characteristics

The following characteristics can be fully evaluated to the design require-

ments and AWS D1.1 acceptance criteria with the primer and, in sone cases,
a topcoat applied:

- Weld presence and location

-
Weld length
-
Weld size, both leg length and throat thickness
-
Weld profile, including convexity and concavity
-
Fusion between weld metal and base metal
- Overlap
-
Cross-section of weld craters
-
Coarse undercut
-
Larce porosity

The presence of the coatings should not in any way detract frem measuring,
with adequate accuracy, any of these characteristics.
.

Evaluation of Metalurgically Induced characteristics

The following characteristics are more difficult to evaluate and messure in

the presence of the coatings, and in some cases may not be visible at all:
-
Neld cracking
-
Fine porosity
- - Tignt undercut

The application of priner and top coat may partially or full'y obscure these
attributes, all of which are largely dependent on the "netallurgical"
;
characteristics of the base materials being joined, the welding filler
materials being used, and the ability of the welders performing the work.

N O OM ~
+@ &% %g4M@ y S WE. 9 O O8 ..
-

'

. o 'atec- e- te v_::E -;..

'tre I cf 2
.

The base naterial used for all the structu-s! : teel at Uelf Creen is AST1
A35. This mateni.al is a Icw-carbon, hignly.weldaole Steel, and is, by far,
the most commonl?'used structural steel within tr.e U.S. Its cc position and
strength are highly compatible with those of tne welding natcrials, Type
E7018 electredes, used to jein the steel: that ic, there is no cennetation
of " dis-similar" caterials, which can frequently lead to netallurgically
*nduced welding problems.

Weld cracking is frequently caused by high carton and alloying element

content of the base material or welding materials, or by high non-metallic
element content, such as sulphur. Neither A35 nor E701S have any of these
adverse compositions.

The compatibility between the ASTM A35 steel and the type E7018 welding
electrodes results in sound, crack- and porosity-free welds, provided a
number of basic precautions are taken. These precautions incluce proper
fit-up of weld joints, absence of restraint during welding, application of
preheat for thicker members, and use of approprtate welding parameters. All
these items are described or defined in the welding procedure specifications
required by AWS D1.1, and used by the constructor. 3echtel has reviewed and
accepted these welding procedures as being suitacle for the work at Wolf
Creek.

Porosity can be caused by poor welding electrode control and issue. Type
E7013 electrodes contain a " low-hydrogen" coating, wnich tends to absorb
moisture during storage, which in turn can give rise to porosity during
welding. Great emphasis is placed, therefore, on the correct storage and
issue precedures for this type of welding electroce. They are stored in
heated evens and issued in limited quantities, and unused electrodes are
carefully reheated or baked prior to reissue. These precautiens have been
standard for many years now, and through their use, coupled with use of the
proper welding parameters, porosity is not a concern.
The presence or absence of undercut along fill.et weld edges is dependent en
the base caterial, welding process and materials, welding parameters and
welder ability. The first three of these criteria have been addressed in
the discussion on cracking and porosity, and for the base materials, welding
process and naterials and welding parameters used at Wolf Creek weuld not
lead to weld undercut in themselves. However, the formation of undercut
during welding is dependent to a large degree on welder ability. The
cerrect combination of travel speed, current, are length, electrede angle,
weave, electrode si:e, etc., are all inportant in preventing undercut. The
welder training and certification pregram used by the constructor, along
with the qualification tests required by AWS D1.1, are all designed to
provide the welders with the ability to control these attributes.
Throughout past inspections, and current inspections on uncoated welds,
cracking, porosity and undercut have not been identified as generic
preolens, which, if they occur, tend to be widespread. Visual reinspection
of flater) uncoated welds in the structural steel at WCGS has, in fact,
shown no evidence of weld cracking or porosity, and only (later) cases of
minor undercut. We contend, therefore, that the lack of ability to identify
[< _ these attributes on coated welds should not be considered detrimental to the
reinspection program, since there is no reason to believe that they may be
present. The reinspection program should continue to identify these con-
Cerns that nay have some effect on the design capability of the structures.
.

d W $
 .

*
.e.. .in ,,, ,,,,
ATTAC pf ,q -
_

'
A
. ~ . . . _ . .
- I NT E Rp F.F.I C E CORRESPCNDENCE

To: G L Fouts :-0;FLh.C E4-765 2 - 03433-003 -

new: J A Eailey
DAtE: Nove:-ber 13, 1984
suBatcT: Inspection of Painted Welds
REF: 1) BLKES-1348

NPE is in concurrance with the Bechtel position stated in the

referenced letter ab:ve. -

L E
h..H/JAsailey: dab
a

cc - M L Johnson (MS3-01)
J Fletcher
C M Herbst
R W Grant
.
C M Sprout CG3-31)
N W Headley

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 ._ _ - - - - . . - -_ _ _

*
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.

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.
, .
=
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O n. e. :. 2. ,

of the plant.
L .Inlems
o thTI~ sa'fe ty ' p ecb addition,
. the g r : n ci n - itself may cause
.

III.
U::0ERC'!T PROVISIC::S CF AWS
::1.1
; The third
'
cut. pechlem regarding welding pertains
Early
current editions
issue has of
a AW3 D1.1 prenibited undercut tc welf under-
res tric tion on and the
whichwelded
the is based on the
member. directi n of the p rincithe depth of undercut
pal stress
Th es e rules are impossible to follow, in
because undercut
Inspectors do not can net be elimina ted completely and the t

performing
sions inspections. knew the direction of primary stress when
1
have
staff, but been discussed with members of AW3The problem -

'

because these men are reluctan t 01.1 tecnnical i

| reluctance only means thatthere havetobeen

revise thea document
no major industry c =pl
nts.
are not enforced, or as This
;
the provisions of the document
j
permitted
siens are waived by the designers. by AW3
* The 01.1, the
minimum w provi-
cc: allowed by AWS Dl.1 (0.01 inch) eld under-
,
the restriction is ridiculcus. cannot be measured, so
;
Section III, ::E-4 4 2 4 ( c ) , allcws .

1/32 inch undercu . Cesica- <

en this prevision. Inspectors havewith

ers have not had a problem beenthis provision, and the
;j t

aable to make adequ t

'

e evaluatiens haced '

A problem arises
,

( and insistAS:2
rejected on no undercutwhen
at a l'l . ::RC Inscect:rs
Some become
Inspectors have c
i
.
D1.1buildings.
and requirements which were written pris true:
marily for ural welds o
'

because it sas 1/64One ::RC Inspector rejected a weld undercebridg

.

,
inchrepairs
This leads to more weld deeper thanispermitted by Code.
which
;
.
a safety concern.
IV.
E::C3CACHME! T Oli MI iI:!U:1 THICT.! 233
>
,

'
* There are cases where
-

thickness
items requirements
being inspected.may not be metIn spec to rs have noted that minim
for local areas of
*

the
either
to by undercut or grinding.These local thin areas may be caused
j
,
restore minimum The resultant weld repairs
accepting the area on the basis of engineeringthicknes
The
,
an
evalua tion.
ties. A5::E
The C:de philcsoph/
design engineer of design alicws
4
spots by showing that the localthe
can oitan justify discentinui-
shallow -

, diameter
cpening.
ities than
Also the Code allow dofdiameterloca
e
the AS::E Code allows an
unrei.nforded
l area -

!
j
the allowable stress.to have a,n incroaced primary stressarea
! s. , of up to 1101 of '

i
g ' When the design engineer uses these
, ,,
>

i
e
.

_ _ _ _ _ - - '-
 1

k
L E HIG H U NIV E R SIT Y .
Bewenes Pennsyivania 18315
-

, fritz Engineering Laboratory

-
e.oo#s is
December 10. 1954 '

Mr. Richard Ivy *

Kansas Gas and Electric Co pany

P.O. Box 208 '
Wichita, Kansas 67201 ;

Dear Mr. Ivy: '

Re: Structural Steel Welds at <

Wolf Creek Generating Station

We have reviewed the problems associated with the structural velds in the
structures at the Wolf Creek Cenerating Station. Dr. Slutter was on the site
on November 1 and 2,1984 to observe firsthand so=e of the veld deviations. the
method of inspection, inspection records, and problems encountered in completion
of the inspection program. The problems encountered at this site are not unlike
structural welding problems that we have seen at other nuclear power plants.
The problems at Wolf Creek are perhaps more frustrating but less serious than
similar problems at other sites. The approach being used )y Bechtel as sun =a-
rized in " Weld Deviation Evaluation Methodology" dated Nove=ber 26, 1984 has
also been reviewed. .

The exa inatien of the welds in this reinspection progra= is very thorough,
as evidenced by the documentation on every connection. The thoroughness of the
inspection has revealed so=e problems that require evaluation frc= a structural
analysis point of view and a much larger number of instances where deviations
from AWS D 1.1 - 1975 are reported that do not constitute structural deficien-
cies.
fro: It appears from the latest su==ary of inspection and evaluation received
Bechtel (dated November 27, 1984) that no significantly deficient joints
have been found.

We have the following co==ents on the various categories of problems that

have been found in the reinspection:

1. Missinz Welds

Oovicusly the missing welds should be replaced if they are needed

to resist design loads.
Some of these welds such as the beam to
beam seat welds may not be required, and replacement should not
be necessary. Where they are inaccessible and cannot be replaced,
an appropriate analysis of the other load paths should be
provided.
*

!
.

. -

Mosearch in CevW Enginesting one metates messe .

_
 Mr. Richard Ivv , ,
Dece= der 10, lir; '

Page 2

2. Undersize. Uneeual Lee, and Underlength Welds

The approach that is being used to evaluate these types of condi-

tions using the smallest veld dimension is very conservative.
Welds that are no = ore than 1/16 in, undersize will have adequate
strength on the basis of the latest code recoc=encations. The
allowable stresses being used by Bechtel frc= the Seventh Edition
AISC prcvide a conservative basis for evaluation.
3. Oversize and Overlencth Welds

These deviations are not generally a probles to be concerned

about.
There are so e instances where the additional a: cunt of
weld causes the connection to provide more restraint than in-
tended.
welding. The original design actually specified this additional
In these structures the additional weld cetal should
not cause problems.
deformation can resultEnd rotation and the resulting connection
in cracking of the welds if the additional
weld increases the bending stiffness of the connection and
decreases cuctility. ,

4
Cracked Welds 3etween Beam and Beam Seat

These cracks resulted from rotation of the end of the beam as

concrete
The slabs
cracking were
dees notpoured and additional dead load was placed.
indicate a ceficiency in the cennection
since the weld is not needed. The cracked welds that were
detected were
the me:cers probably
being undersize because of the rolled edges of
joined.

5.
Return Velds That Are Overleneth But Undersize
The purpose of this weld is to produce a proper termination for
the ver:1 cal weld. It is not necessary that it meets AWS 1.1 -
1975 size require:ents, since it
The
acded lengen can increase capacity in so=e instances.is not
The pri-
needed structura
Lary cojetttve of end returns is to minimize prying and distortion
at the root of tne pri=ary weld.
6.
Lack of Tusien and Undercut

These problems
handled are very few in number and are being satisfactorily
in the analysis.

.
 . .- . - , __. . _ . _ .- -- ~ _ - - -_-

'
.

Mr. Richard Ivv ,

Decenber 10, 15II' '
~ ,
' ~
;

!
Page 3 '
:
'
l

7. Beat Seat Missing

'
i

; These may not be needed but an analysis of each one is being race.
i it is assumed that seats will be provided if needed. ;
*

|
S. Fit-Ce Cao with Undersize Weld
i
;

! This is a rare occurrence considering structures involved. Proper

1 analysis of this is being made by Bechtel.
1

i. . Inaccessible Welds
4
i

; Since there are no significant structural deficiencies a:eng the

j exposed velds
cessible welds are
inspected,
similar, it is reasonable to assume that the inac- ,

'
i
'
4
The general proble: ,

!
!
of weld size should be considered in terms of the
i ,
where the AISC allowable stresses are applicable. expected statistical ,

i
Fig. e showing the statistical variation cf the 1/t in. , 3/8 in. , and 1/2 inEnclosed are F
velds used to develop the AWS and AISC specification provisions. .

These curves
j
The variatien of weld capacity thatshow :ne deviation in weld sizes that a
resulted fro = the AWS-AISC fillet veld
} the test sa:ple. study in 1966 vas in part due to the variation in weld size that existed w
4
exist with all welds.These were normal production welds, and similar deviations will
j
strength bcsed on no=inal weld size. Figure
It
19.3 in Structural Steel Design shows the shea
}
the variation in capacity is based on the veld size variationis clear that part of the reason
' .
l

When
unless it a weld is found to be undersize by measurement, it is not significant
, falls below the range indicated by the curves. The AWS Specification i

i does not address the problem of deviations, and disposition of undersize welds
j must
chat be done using the type of analysis that Bechtel has proposed. The fact
'

they are using actual veld sizes in calculations is conservative , since

1

j the specifications
uncersize. used the lower bound of the test data which included weld

i
weldsWeld site deviations on the return welds does notrequire analysis.
are not These
some additional strength does resultintended to increase the strength of the connec
from the addition of these welds. The
)' main function of return welds is to increase the ultimate strength of the struc-
ture by delaying and tearing of the veld and improving the ductility of th e
connection.
large enough to provide a satisfactory veld termination.These welds n
,

'
,

i t i
*
\ r

i.

'
!
4 .

_ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ . _ _ _ _ _ - - - - _ _ - _ _ _ - - _ - __ .- __ -_ _ -_--_._ _. _ _ - - _ _ _ . - . _ _ _ _
 Mr. Richarc Ivv , ~
rece:cer 10. 1531 ~

Page 4

The analysis work being dene by Bechtel is basec en elastic design w :h

reference to :he Seventh Edition of the AISC Manual cf Stee; Ccnstruc::ca.
This apprcach is conserva:ive ec= pared to the ul: 1: ate strength metnoc ava:1-
able 1: the Eighth Edition and the curren: approaca used in LRFD design as
given in Lead and Resistance Fac:or Desien Criteria for Cennectors a. Cne of
the provisicas of the earlier specification that is verv conservative and not
applicable to weld capacity is the allewacle stress for base etal in snear
given as F = 0.4 F,.
v y This 11:1: state was arbitrarily adepted in 1969 anc is
not related in any way to weld capacity. This is only new being corrected in
the A15C Specifica: ions. The attached copy of Table J .3 shows the proper
limit state conditions that are used in the LRTD Specifica:icn. Steps are now
underway to change the allowable stress provisiens for shear on the weld leg
to 0.3 Fu in place of the value 0.4 T . Typical increases in allowable loads
y
for eccentric cennectiens that one can expect to result f ce using the ultimate
strength analysis outlined in the Eighth Edition of tne AISC Manual can be seen
by cc paring the results given in Table III pn page 4-31. With a weld length
of 11.5 in., the C-shaped weld and the outstanding angle vertical welds are
similar to the welded exa:ple shown on page 661 of cne secenc ecition of
Structural Steel Desien. The ulti= ate strength analysis of the clip angle to
plate velds provides an 81 increase in lead. The C-snaped welds of the clip
.

angles :o bea:
seb
strength methed.
are permitted to carry lit ore 1:ad using the ulti ate
This can also be seen by ce= caring the standard angle cennee-
tion leads in the Seventh and Eighth Edi: 1cns of the AISC Panual.

The A!SC previsions fer the design of this type of connection are very
ecnservat ve even when one uses the ultica:e streng:h methec. The =ini=ue
facter of safety for a connection designed by the ultimate strength =ethod is
given as 3.33 cr. page 4-74 of the Eighth Edition of the AISC Manual. The
asual factc; cf safety in weld design for single load vec: cts is 2.33. The
more conservative design for this type of connecticn reccgni:es that minor
will occur.sucn
deviations as found in the connections at Wolf Creek Cenerating Statien
These deviations are not unce en, and this is recognized by the
AISC provisiens.
fillet welds are used.In particular, the weld size variati:ns are :ypical where
recognizes :..a: The higher factor of safety in use f:r eccentric joints
c:ner deviations are likely.
We de ne: :elieve the: a structural people: exists with the Wolf Creek
welcs once
Nove:cer 27,:.e obvious problet of =1ssing welds has been corrected. in the
1954
to overstress of 1620 joints evaluatec. summary, Bechtel reports only 17 joints requiring rewo
This is a very low percentage in
view cf the conservative apprcach being used in the analysis. A less conserva-
tive approach sign: result in an even s= aller nu:ber of joints requiring rework .

* Load and Resistance _ Tactor 9esien Criteria for _ Connectors, by J. W. Fisher,

T. V. Gala:cos, G. L. Kulak, and M. K. Ravindra, Journal of the Structural
,
Division ASCE, Vol.104, No. ST9, Septe=ber 1978.

'
_ _ _ _ _ - _ _ - _ - _ _ _ _ _ _ _ - _ _ _ - _ _ _ - _ _ _ - _ . .-___ _ _ _ _ _ _ _ . _ _ _
 .!r. Richard Iv&
'
* -

Dece=ber 10, 1954

Page 5

In any event we feel that Eechtel's approach in considering the inspection re-
ports and their subsequent analysis is adequate anc sufficiently censervative
for the type of structures and the type of connections involved. The overall
quality of the welds based on the inspection data and observations that we have
=ade exceeds the require =ents for structural welding for this type cf
construction.

We would be pleased to excmine ether Bechtel dispositions unen they are

availaole. We agree with the procedure being used.
Sincerely you s,

f !\
QhV %( L
\
'

Joht '4. Fisher \

Professor of Civil Engineering

Co-C airman, Frit: Engineering Laboratory
,
,',
j / ~|/, .
. 's 2 T?t ~. , s t A:
Roger 'G. Slutter
Professor of Civil En;ineering
Director Operations Civision

"
.a'F : RGS : ra g

Entlesures

cc: J. A. Bailey #

i
.

m _ _ _ _ . - . . _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . - _ _ _ _ _ _ _ _ _ _ . _ _ _
 -.

i
Secc. ::. Welds
Tacte .'2. 3
Cesien St emein er weies
Types of welc anc --

Material * '
Stress Resistance Ncminal
Fact 0r e Recurrec ne8c l
;
strengtn strer.gtQ
F
p
g Or , levet~ ''
,

Complete penetration Greeve weld '

,

; Tension nCrmal to
' effective area " Matching" wel: ce !
used . >
Compression normal to t

, effective area Base 0.50 weld metal with a *

F. strengtn level *

Tension or C0mpression equal to or less

. Darallel to axis of weld inan "matCning" ?
may be used -
I
Shear on effective area Base 0.90 I
0.60F
r}.
'

weld elect. 0.80

!

*) 0.60FhX
] Partial Penetration Groove welds
.t, Compression normal to
d effective area wele metal with a i

Base' strengin level ecual

O 90 F i
.h' Tension or c=mpression Y to or less tnan . !

; parallel to axis of weic " matching" weld

'
'

..
metal may te usec -

; Shear carallel to axis Base'

i pf w elc O.75 0.60F
welc elect. 0.75
0.60F{XX '

' Tension ncemal to Base'

? effective area O.90 i F
weld Electrece 0.30 ! 0260F
.,| %- Fillet welcs
EXX ' '

'I
s '- '
Stress en effective area Base'
. O.75 0.60F
N weld elect. 0.75 welo metal with a
0.60F3 strength level ecual
;
Tension er c:mpression Base' to or less t*'an
igarallel to axis of weld O.90 F I'
" matching" welo
metal may me usec
Plug or Slot Welds '
t

Shear parallel to faving Base' O.75 *

surfaces (en effective 0.60F Weld metal with a

area)
weld elect. 0.75 0.60F" strength level ecual
i to or less than
"matening" weld
metal may te usec
'
'For
D definition of effective area, see Section J2 .

C For " matching" weld metal, see Table 4.1.1, AWS D1.1.
3

.
,

. Weld metal one strengtn level stronger.thane s" ofmatching"

built-up
.

o members, such as flange to web connections, may be designea withoute regard to

tensile or compressive stress in these elements parallel to the axis of th
e welds.
The design of connected material is governed by J4

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JOURNAL 0F THE 's z
o.s u.. ..s.,e.., . . shes s., ens,3, ., s. c
e. t i,,*e.g . e u
me, we egb, <.me.e.ec% e. ,.,,,, e .f s.,c, <e.. ... .
. s
STRUCTURAL DIVISION N
a
f as.aeen=a Jew =.#. v.4 s. No 2. Arv .1971 rr 31 4 '3l p
to m e..nde e. p K . end cetemhos. T v . t eeJ end Res.seeeee e ace.w Devsn (* .I
sieet." Jew
'

of ene 5,..er- s tw . AsCt., vs. trbe. No 5to. rea, r pe, I,OAD AND RFSISTANor. FAcIOR Dr. SIGN I
lenns, s,pe , e,fs, pp een 8417 y
11 Stones, a H , enJ Isomcit. 6 0. Is . "I le awat 5ssength of Sseet Concrete Compas*e CRITFRIA FOR CONNECTORS * N
Brems." Jew.et ./ ear se..cew # twm . AsCt, vol 91. No S i!. F#on- repes
42'd. AP' I'*1 rr 78 9' By Jolie W. $lsince,' heoalete V. Galesebes.' Fettees, Asfr
51 Spr. feen.eef.e abr Is use.
e febnter.en ned frecreen of St.ueru.el$seeffer 9=.IJmte. Geoffrey E. Molek.' and Af eye, andre k* Re' led **.* *

Amenten Insedute of 5ecel Constroesn.a.1978 femben, A$rE &,

8) "Sacet Seesctuees foe B U.ags-1 wn e 5 eees ikvgn." 05 4 See derd tre i 8814 ,

ComeJ.en 5:enderJs Assoues na. ReeJale. Onsano CaneJa. Esec .1974 J

'

leveoevenoes '
l
9
Design ersterie based on the l oad and Resistence rutor Dcugn ll Rilip
approeth must include e arcetment of comnections This sepost will fotus .m [
denlopment of the criterie accessary for the prmopelfestenmg elements ( cl.ts,Q
h gh sitength imles, and ordinary imisst and well include ellensensumsthe
of
'
hp
opphtstion of these elements in common types of jo.nts Conopoenon mell I.c ,

made = sib scsults schreved using wasting stress Jeugn p

-i
As developed in Ref 11. ihe i RI'D meth =1(en be syntheurcJ es 4
6
;
4 R. # >. G..
... ID
-p
The left hand side of I'<g r
i is the ressstens e of the memt.cr or stimeme IR, O
is the noenenal resneence and 4. as a "resistence f actor") while the sight 1.en.l
%
sk!c gives the effeds of the load on the niember or sesuteure Conudenng,
for esemple, only deed Iced and lite losJ rq l =ool.1 he weissen $
;

) + n. >. e _ . v. e,_ {
o,
j en which
0,,,, and Q,_ ere the meen deed and hoe land effeces. ecspec tively. p.
and y, and y, are the coercsp.mdeng loed facenes The prmeepet purpose of
!
this papee is to develop espresnons for she parameters e and n en I ql {
i ,

Nose - thscussion open unaJ f ebruary I 6919 Seposese des ann ns sh..uld be subm.sseJ }
|
fee the enJ.,n.wel repers en th.s symg= seeni
lo estead the sh.s.es dese pee .noneh. /
'

e enseen sequest enese he f. led m.sh the Id ent of Technwel Publuste.as. AM t- Ibe j
.

;
popes as part of the copye.ghsed Joernal of the Sonettwel Dewmen. Fem eeJmas of she g
Ameneen Saucty of Cowd I ng seest. Vcl 104. Na $19. Series her,1979 M eesse r.re
f
.
was subm.tted fee review fee pose.Me pubiwet.on en usy 11. 1978
* Tes
berhecage,
regeensed
lil at the Desebre 16 fil l975. AM l' Anneal 4 covenema A Ferred*ca.
betJ |
P
' Prof of Cie I ages . I"nor f ears i eb I ebigh Ifoi, . Beiblebene. Pe
'Peof and rhme.Ee, I mars inert . Wesh nes. S t . s. e .
, se.
j
__ . _. _ _ __. _. .
 _ _ _ _ _ _ _ _ _ _ _ _ - - _ _ _ - _ _ _
_ - _

_s

1828
Sf PTIMitta 1913 i

De development =]I e based on the use of first-ceder probabihstic methods

513 Sig
LCAD CISISTANCE FACTOft .73
v
'' The rundamentat tequirementi for s =cil *lesigncJ connection con be consedered
.

Welde.-The ocid types used for structurel purposes are primanly she groove
welJ and the Giles weM In the case of groove =cids, she forces acceng see T
j e
usuelly lensile ce compsessive. Tests have shown that complete pencoresion
1. Adequase strength-It is generally considered good p,ectice the
that gronve =elJs of the same thic kness as Ihe connected pert are cepoble of developeng
j
connectmas be some.hst stronger then the parts being joined Thus, d te fun the fun carecity of that part. Since is is norenal to use weld metal that is
shoukt occur. it witl tehe place in the members sether then in the connections
et Icost as strong as the base metal this means that the psoperties of the base
thereby ensuring that emple earning (e g . lerge deflectrons)
t
=diuse.
' secede fed
enetel edi govern the design hus when complete penetration groove welds !g
2. Adequate Ductility- Care must 14 Islen in proporteening the elemente
ese und, design con be based on she properties and behavior of the membes '

will result.inOf
of the connection to ensure that ductate behavioe,smh =hith the connection is being mode.
cou se
undesisable phenomens as buckhng of plate elements, britsle tract see. Ismelter
he uNmese strength of fellet acids subjected to sheer (the usual cow) is N
'

testing. med eaccisive local distortion must be evoeded. Provision of dependent

adequate ut.on the sesength of the welJ metet and the detecteon of the ap
ductdely =di mean that the structure containing the connection ein have
load cepecif y I.e pesellel to the direction of the load le "hmgit'inhnel"
1he eclJ sney
l
foe dasMrtion before fedure sad mill eHow for the redistnbution
The of loads
(Ulet weld). teensverse to she directinen of the load (e "erensverse" filletk =ci .
'

provision of adequate ductility is a requirement geocrolly less welldefine-I esor et any angle in bet =cen Regardless of the onensation she melds fed en
understood thee that of adequate strength- sheer, elihough the plane of rupture varies. All esperimental studees have shown
3. Economy- As for au stnicsural components,is le desireNe that connectionsshot loogitudmal fillet we1Je provide lower strength but higher ductility then
he economical of snetenal and be as simple as possiNe in fabrication. transverse fillet = elds (l.2.7). Smce in comples joints it is not el=sys possible
,,

9
so define the d rectma of loading on the =eid and smcc the longitudinet fillet *

le moshing stress design, specifications (11) customarily specify allo =eNe = cms provede she lo=es imund to weld strength, they =di be used h{re to h
steesses and give rules negarding buchhng iroNems and the hke. Alibough not provide the basis foe devan recommendaticas lhe results can shen be opphed '
accessarily obvious, most allowsNe stresses for festening elements and most in general to filles welJs =ethout reference so the dereciion of loadens f
rules for prefertioning connections are, is fact, based on ultienste stsength Esely tests on lo= carbon steels connected by manuel arc hmgitudmal fillet
consideratioes "Tredit.oner* design of connections is much closer to the I R f p =ekts showed that the ultimate sheer strength on she minimum shroat eree
approach thee seest users of these specificateons perhaps reshre. was 65%-35% of the sensde strength of the deposited material (4.6.12) These
,
eenly studies also showed that sheer yickI ng =es not critical en fdles welJs N'
Cauenanon or Coeuscsoe Dvesee mou= =ece because the meterialstrain-hardened without large overalldeformetions occiarneig '

nus, the yield point of fillet welds is not considered a s'anifecent resemeter
He loed factors, w and the resistence factor. 4. in Eq I depend upon More recent tests on s wide range of steels connected with **meschmg**
%
i
electrodes have provided date on strength andits verisinhty (2.3.g,9) tror many
o **sefety indea." p, that is obtained by cohbrosion to esistma standard designs p
of these tests, date =cre not obtained on the tensile stern:th of the deposited
(ll)_ hus, et to intended then successful past practice =di be the starting pmnt ej
fos LRI-D. For beams and columns, it has been found that a value of (t = =cM metal, only the sheer strengths were obtemed ) Bhufgets gives results for
3 O provides a good estimate of the schebdity inherent en current design. This 127 semples of weM metal for =hich she menemum specificJ 8cnsde 58'ength
is 62 ksi (unpunished) The mean sensde strength value. (e.)_. =es u n tsi, j
value has been taken also es the basis for E RfD cnterie for all other types the standard devission, e,,,
of structural sacrobers in view of the desirshihty thei connections have a higher =es 2 56 n se, and she coefficent of veristion, V. . ,
=es 0 019. For a semple of 118 specimens of E70 electrode =cid metallmenemum
degvet of rehehihty then the members they join, the sefety indes (I for connections )
aboteld be somewhat larger than this value of 3 0. specified teosde strengtb 72 ksi) Blodgets determined (v l. - 74 9 6ss a.,
i - 2 67 hsi, sad V,, = 0 036 Ifnpubbshed studies by Nash and flofer for the
o

ne cabbestine procedure used here is the same as that fono=ed for beams
same category gave (v.). = 86 g tsi e., = 9 08 ksi, and ( = 0 20 with
h;
and columes (II). Is wiB be carried out for various combinations of dead and aire of 40 Blodgett also obtemed date from tests on =clJ metal
a semple
.

love load and =di cover weIJs, high strength bohs. and ordinary imits.
De safety endes it is der.ned (II) es made =seh I'BO, fi90, and IIII0 electrodes. Table I summarises eII of the does
y
from Blodgett's report. It is worth noting that Bhufgets also obtemed results 4 1
le for F.70 electrode weM metal shot =cre higher then those hsted and composable
0, to she values found by Nash end llotta for a semple of 12s specimens made
O * Q y , p'. -
-

- (II
,
is eksch Jt, and p, are the mean values of the resistence end the load effect.
and V, end V,ere the corresponding coerrecients of venetion Detaded definitions
of these quenteises can be obtemed feoro Ref.18.
using E7024 and E7024 electrodes (minimum specified ecosile strenath 72 t sel,
Blodgett obtained values (v ). - 85.4 ksi, w, - 4 77 isi. anJ q = 0 056. g
IIntil more date are evadable, it seems reasonable so use she lo=ct Imund q
sesults listed in Table I as the basis of the formulation herem the value of
the ratio of the estuel tensile strength of =cht metal to ses mmemum specified
g
ten,de strength =dt be tenen as 105 mesh a coefficent of venetoon of 0 04
 0
1410 Sf PI(MBE31978
S39
) Ti
.i19 (CAXtStSTENCE T ACTOR '
at
nis will be consider:d to apply to cl.clectrimle classifications being considered. 1
i e . E60 through I 110
Fig I shows e distribution of the ratio of Gilet eclJ shear strength to =cIJ
The coefGeient of varieeion of the scussence, Ve , acquired for the s..luti.m
of Iag ) es deGncJ es (11) f -
j

electroJe sensde strength for a semple of II) specimens The = eld sheer sneenaih, d * an' d*O W
q
v,. is that for the appropriate matcNng electrode using the values ileu ril.ed
herein. These Jase provale she follo*ms results. (,,1, O e4, .,, in ohnh the coeffkients of variation on the righs hand side of she equation !p
o in. e nl
f., = 0 10 represens she uncertaineses en meienal strength, febeksiion, and a " professional"
g,,,,,,,c, pet,;,,1 ,7 g
g
e weta Se' east''
TABLE I.-fler e The wenstmn m the professional assumptions reflect the accuracy with =Nr h 9
the forces acting on she fasteners see eshmeted The conce determination of
--- .--- -_. . . . . - - . .. these forces is highly comples and they are usually ass;gned accoeding to e 4
specie.c at.on
tene.se e due sde strucsure, the principles of the lo=ct bound theorem of plaster, y are
sens te ueen costs.c no si no f
suess in vehd thus, as no enor is me.le in statics and =clJ meterial is proved ed to
sens te Stenderd of / s pec.f.e e .

Electrode neps p., sempt. st ese devierson.

scuss the forces enigned, she joent will be saf e. There is, therefme, no varial diry Q
vee.es.on. tion tea-
geoup seguees each of the professional assumptions the esogned, statecelly correct forces =di be ' '
e.re t v ,1, .., s, s.t * s'' " .
reusicJ Accordmgly, the term V,in Eq 5 is ses et sera
('l til (1) 18) (M (4 til b
E6nto, f 60tl.
E6027
Vanesson in fabricetma reflects the venetson of the =cid length anil e,hroat
sNdness from shose assumed in the design At she present time, there are
j
42 127 84 0 2 16 0 019 th y
E.7014. F 70lt 72 lit 74 9 2 67 0 016
not enough deve svedel'le to obtem V, qisenestatively. A value V, a 013 will
4t4
T8088 4 80 816 87 9 4 14 0:49 I 10 he assumed for fillet melds. This emphes that there is e 50% probability it at .

Esots X to 16 000 2 4 12 0 041 8 II the actual sheer area will be within 1801L of the eres assumed 1Ns es behewed N
_ $ b_ - . - - :- ''I I
-
b= - - -
-- N s-
,,p,,g,,,,,,,,,,,,,,,,p,;,,
ne coefficient of venesion of the material strength from the steinensi deve
p
T
evadet,lc Iov Gilet =cIJ strength is
y, y, j,
. . en - **
e - e s. V',.**-+ = (0.10)' . (0 (M)' = 0 0116 FI w
so s. .e n. T,,, r
e
Also needed for the celibration is she =clJ sire required by the 1978 Amern en
Institute of Steel Construction (AISC) Specification (III Usmg Pers 2 of she b
.
__~ Specincetion, she design cntenon for a load combmesmo of deed end hve foe.1 (3
P

is N
**
1. 7 A w 0 ) r, ,, = I 7 e (D, e L., )
-

2 -
-
(7)
en which 4 - the cross-sectional esce thsough the throat of the meIJ. D, .

_
, - the code value of deaJ load, f.., = code hve load venue es reduced for ,
8
' erce, and e es en influence coefGcieni transinemma los<1 intenuty en member
, _p*r* .C '' t .
_.

" __ " 2._ _ _

~
12
' force | Note thee the load factor (17) appears on both sides of I'<l 7. she
[
"
''
result obeeined here using Part 2 of she Specifeceseon are sdenseret to thes =hu h
Q
;;- g would have been obseincJ using Part I, ellomahte seres, alcugn. of thee seene d
y
specifecation | The mean ressstence of a fillet =ct.1 des gncJ enen.ima En the
,,o ...e...ne t, .t A St...e S r.. . .. fI.e... l. 7. .. S r.en..t. ; i m AiSc Sr -iGcetic. is creIore
e
The sheer strength to tensile strength reaso and its coefGcient of varietism 8 " A I'.I "
c ( D. * l )( v. ). - 9 c( , e f... I tRI
Iq
=dt be used to eteleste the safety moes.11 The mean sheer strength of Gilet O17 ***
welJs can be espressed as i and slic conesponJms coefGcsens of veristion is f
3 ,

f. f. '
m hi
(,,) ={ . '| | .

L e, J ., ( 7, , , ) .
I r, , , - O s e u f Os r. , . . tel
r . v r:, . r' - vo ciis . n om - o ins e
I

Substitution cf R.,(Fq 8). Ve(Fq 9), P., and V,(Ref II) men the especsuen |

i
--
.

1812 Strif Mala ISPs 53 ;19 IDA3 fitSISTINCI F ACTOR ,1

.or the safety indes D (Eq 1) con now he performed for o vceeety of desi. ,d
and lave load intensities and for vertous values of the eributary eres Table
7Atti 2 -Selety lades p fee High Serength Bolse end fettet Weide 2 hsts values of p for the basic Code live-loed value of L, = 50 psi and for
dead land sateesities of 50 psf. 75 psf. and 100 psf and for tribiesery esees
=r=---------1-=,-----=r=-u eengma froen 200 sq fe-I,0fc sq fe. A plot of p ver.us tributary esca es shown
-

. m - -

Deed
'* * # ,
in l eg 2 for D, = 50 pif. Esemining the Inhulated values, et is spresent shot
.' for the whole domain of variables does not change much, she sense bems
**'
, Sese s,sade p from ? = 4 20 to 6 = 4 98. |The safety inden has also been esamened for
pee A490 I *~ " ** * " "" *
4 .n A325 A32% A490 A125 i A490 *

seusee sque,. F,ates bolve t> ate s tiotes tioits holes botes
- 75 psf s fl = 510 and for L, = 100 psi et as 31 = 3 77 |
foot sees e,.ed, sens.o. se ..on .he e, shee, s,.co o. ,,,c e liigb5trength Boles.- A relatively lesge amount of data concerning the strength
it) (2) (3) Ist op ist it) Its (1) th*'*(8''"8'<s of h.gh. strength bolts are evadable. T he results are scattered
SO 2tn 4 20 4 si 4 74 1 st 1 21 e en I 12
throughout a large number of seferences but these have been =cIl sesmn) need
ern 4 44 12s $ 1s 6 16 5 77 31s 1 44
in a publicatoose sponsored by the Research Council on flolted and R eted
171 4 11 1 19 1 Il 6 10 1 70 1 de i 12 Structural Joints and this will be the principal refescoce celed an ehes sectice
an0 4 16 1 SB 1 72 4 49 4 11 I el I et III
1.cno 4 70 1 31 4 09 6 91 6 41 1 78 3 13 D8'cef Tention -lhe mean sesistence of a high strength bolt in direct tension
75 2'n 4 11 1 10 $ 62 4 61 6 01 8 19 I 46 as
eno 4 73 3 96 6 24 7 10 6 68 0 70 8 Se 4
g 3
720 4 SO 1 71 6 00 6 ft 6 19 8 47 I 11 g ,j "= | j* 7*
s.am ''
300 2f10
4 67
4 il
S o2
1 99
64,
4 29
7 :9
7 il
6 71
6 66
l ie
8 68
1 41
8 11
( r. n '

ann 4 91 6 41 4 39 7 17 7 17 I 70 1 64 in which a, = the ultimate tensile strength of the bolts, T, = the specified
6fM 4 82 6 14 6 86 7 12 7 11 8 60 t 11 minintern tensde strength; and A, = the tensde stress esce of she teilt. The
750 46s 6 Il 6 61 7 11 4 94 e 16 8 42 following date ese eveifeble (5) (n,/T ). = I 20 for A125 bolts and 107 for
I. ore 4 B0 6 le 4 56 7 17 7 21 I 64 s 18 A490 bolts V.,/F, = 0 07 for A125 holts and 0 02 for A490 bolts.
't en loed is $0 g i tes es case, it will be assumed that V, = 0 (es for fillet =cids) and that V, = 0 05 g
_ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ __. . ... _ .._ ._ __ _ _ . . - -
(reflecting the good control characteristics of bois manufacturing) la sildisson, I
she eres of the bolt A,, corresponding to the nominal diameter =dt be 'esed
*~ This is shout 75% of the tensde stress area for bolt sites commonly used en
, , , ,
e a m e ..= o structoset week. Using these dete, for A125 Imles:
e am w
******"'***
R., = 0 90 A, T : V. - 0 09 . (IIe)
e for A490 bolts: R., = 0 80 A, f,; V = 0 OS (I I f> )
' #
-

The term A, con be obtained frooi the 1978 AISC 5pecirk stion =here I 7(.4, T )
I, f 1'e -
- o c iD. t > -
s -
-
,
J A, = - ( D, + L., ) . . (12)
F.

$Z en which T, - the ellowohle sensile stress es gisen in the Specific seson

The sesistance terms of I'q Il con now be =ritten es. for A125 bolts
'

T*
e - > - - - - R. = 0 90 - c ( p, + L )
e see eme y,
s, =, a. s e, t e,r >
(11)
F
,to. 2 - Sete,, des , vs.t.us - e f- ^4* l-iir
A_=0 y <<D.. v
In general terms, T q Il can be espeessed es

'
.

__

me-_ _ _ - _ _ _ . _______h
1432 stPflunf o t17s SIS ;I9 LOA 3 RIS STAPdCf FACTO 8t .1
.or the safety indes D (I'q 1) can now be pe formed foe o voiety of drei. A
and I ve lood intensitics and for various welues of the siihutary esco Tehle
7Astt 2 --seten,ladee p t= m he st. as'h sense .ad rmet weide 2 hsis elves of p for the bas.c cale live losa value of L, 50 pst and fo,
deeJ Iced enteesicies of 50 pst, 75 pst, and 100 psf and for seitmeery esees
___
.==-=:-.--------=-=-----:r- --
, = -- - senging from 200 s,y it.I,0no sq ft. A plot of 31 versus erihetery esce is shown
Deed ;, g es 2 for D, = 50 psf. fisemining the tehulated welues, se is apperces that
nood. .
31 for the whole domesa of variablo does not change much, the range being
,"' Selevy sade. p (som p = 4 20 to p = 4 98. [The safety inden has also been esamined for
pee I '" " * * " " " * " " * * *
4 .a A325 A490 A 325 4490 A)2% A490 *

swe.e ewwe teet bosse amtes botis tetts botes tmse,

" O" * I* N N '' O * !
foot teos sde seas.no sea s.on shew shew t,.co t..es m liigh Seveegab Boles.- A seletively longe amount of data concerning the strength
I'l (Il (1) 181 ISI 168 (7) Isl (1, characterestecs of high-strength bolts are eve Isble. 'The ecsults are scattered
10 2te) 4 20 4 et 4 74 "E ' 'I' "" ' '''"#" "* * #""' '"'"
1 e6 1 21 1 46 e 12
40 4 44 12s 11 6 16 1 77 l is 44
in a pubi cation sponsored by the Research Council on fiolted and Reveted
171 4 Il 1 19 12) 6 10 1 70 I 46 I 12 Serwtural Joints and this will be she principal refe ence ceted in this section
to e st S ta 1 72 6 69 6 11 1 61 l es (3)
8 onri 4 70 1 at 6 01 69? 6 41 I TI se U8'etr Tenison -The mean vesistence of a high strength Imit in direct Iennon
71 2res 4 11 S to 1 62 6 el 6 01 I 19 I 46 as
en 4 ft 1 96 6 24 7 to a 68 8 70 1 16 .

720 4 10 S TI 6 01 6 es I 47 '-
6 19 1 11
g* ,
10r0 4 67 6 fil 6 48 7 19 6 71 l 38 I 41 ( r, j , A * T* ',(10)
trn 2fc 4 fl 1 99 6 29 7 81 6 64 I 6e 1 11
enn 49s 6 48 6 e9 7 17 7 ff 1 78 1 64 in whish e, - abe ultimate tensile strength of the bolts. T = the specified
onO 4 82 6 14 6 se 7 12 7 11 I 6e i 11 minimore tensile strength; and A, = the tensile stress esce of the imit. The
710 4 68 6 11 6 61 7 11 6 94 I 16 I 42 following date are available (5) (e,/F,). = 1.20 foe A325 teles and I of for
I.orn 4 so 6 18 6% 7 17 7 28 8 64 I SI A490 bolts, V.,/F, = 0 07 for A325 bolts and 0 02 for A490 bolts.
*t s.e lead es 30 psf foe en cases It will be assumed shot V, = 0 (as for fillet =cids) and shot V, = 0 05 |
____a___________ _ _ _ . . _ . _ _.. .__._ _ _ _ _ _ _ - -
(reficcting the good control chorecteristics of Imle snenefactormg) In addismn. I
the ares e,f the bolt A,. corresponding to she nominel dismeses =ill be 'esed
~
, , , _ This is almut 75% of the tensile stress esce for imit aires commonly used en
e ame : ~ ...as i structural woek. Using these date, for A125 letts:
e .m s
* ***'*"'' *""
R. = 0 90 A, T ; V. - 0 09 (IIe)
e for A490lmits: R. - 0 0 0 A, T,; V. = 0 05 (IIH
' 7 e Tbc term A,can be obeeined from the 1978 AISC Specirk stson where 17f 4, f.)
f, = I . 7 c ( D, * L., ) or
~
i _ ,
J A, = - (D, + L ) (32)
1

$U in which T, = the allowshic sensile stress es gesen in the Specifkeinon

The resistance terms of I'q li can now be writsen es. for A125 holes.
'

T
e - - a a R., = 0 90 *- c ( D, e L.,)
e see wee f,
7.m. , a. ee, s. eis >
(l1)
F
I ' ^# I*U " #=0m c(D,* L,)
r:0. 2 -seteer Indee see verleve Ceaneesere
la general seems. I'q 81 con he espresse.1 es
.

_N_
. ,

: '" + _ _ . _ _ ---____-h '

 p
143a
Sil'It utstit Isle sts SIS
'e, A, f. 10AD C t 5sSI ANCE IACIO] sl5 t
A. = l c (D, e L., ) (, 1 fy 1
k f. A, f. (34, g, , j _*._ } |
f a* %
-.
} ) J. { c g p, , g 3, :.'l
-

gg93
L o, ) . \ f, J . L F, )
The safesy indes it (I q la can now lie detesmmed for hiah sisengih to.it,
acting an tenseon As noted for the case of lagh strength tmhs in tenson, the spece6ed mmimum
)$
lhe salues of G. and l', are derancJ m itet. II, hde A, sensile serengili will be taken as 120 kn for A325 tmiss and ISO ksi for A490 [}p,
is seven by I q 41 os 44 and V, toy l q ll.1he seccafied mmi nom sensde khs lhe pesmissible shear sisesses according so the 1976 Rescasch Counut
soength. F,. fos Alli tmhs up to I in in diameter is 120 kse aml 150 ksi~

on Riveted and flohed Structural 2oints Speufkation and the 1978 AISC
,

for A490 khs up to l-l/2 in in diameter lhe sinawable Icasde suess. T,, (,
Specificahon are 30 ksi and 21 ksi fue A125 bolts (no thseeds en a shear planc
as 44 ksi for A325 lehs and 54 kse for A490 khs. s -[
and thscads intesceptar, a shen planc, te.t<chwely), with the correspemdeng N
Table 18 ses the salves of p detesmmed for this case anJ they ese also shown
figuses of 40 kse and 28 ksi for A490 tmhs. the ratios of these shear stresses
in Fig 2 for the partuutas case of D, = L, = 50 psf. For A325 Whs, the ese approaimsicly the same as ll c stio helecen the gross tmle area and one
6
safety anJen varies (som 4 88 to 6 42 se.d fos A490 kits et ras.ges from 4 74
ao 6 95. 8'k'a lh'ough the root of the thseaJJ gmstion of a kh Ihus, she safejy enden,
d
p, for the two cases =d' tic nearfy the same. ''
}j
SAcer -lhe mean resniem e of a taps strength be.it acems und-r a fosce 'd
tending so shear is thsough a sight causs section is The vakees of Il for iss4strengih Whs loaded in shear are geven m lable si
2 and art shown en l'eg 2 tur she case of D, = 1.,, = 50 psf. Oves the range .I
es: mined, p vanes (som 5 86 to 7 58 for A125 khs and Isom 5 21 to 7 Il
R. = A, r,m I
g s,, ), g p; ), .
(IS) f r A490 idse it is mocth noting that the safety inden for high.assength bolla h.
loaded in ahear es signaricantly higher than ihas for filles eclJs. .s
j,
in = hu h v, = the shear strea.gth, e, = she eensde sirength of the tmli, r, Tnestene -liigh strentah boles may t e used in joints where se is desnet,lc -
^
= the specificJ minimum sensde sinength of ibt boh seisterial, m = the nu=*e that shp not occur under she wosking loads. The conse.bution provided by one
tut: to the total shp sesistance is ~

of shear planes in she josas, anJ A, - Le cross necennat area of she kh. $
'
he stainsual dets avadable for the satio of kla sheer sesength to kla sensde E " "II. I- ( T ). . -

sesength are O) (,, /w,) = 0 625 and .

(20) L
V., /e, = 0 05) These are arphcable
in which m = the number of shp g lancs, A, es a slip creffitiene sellecting she I
for bosh A325 snJ A490 bhs. The data to be used for the esino of telt tensde
,
strength to specified minimurn sensde strength are the same as given pseviausIF type and condstma of the faying susface, and T, - she tismpeng force psovided d
for botas in senseon and ase diffesens fut the =a grades of fasteness. Thus- by the tmit. A gomi deal of information is known about she shp toelliuent \
for A125 bohs- and the clamping force and sheer disinhunons (5? . d
The mean value of the clamping fosce and sts dnenhueson depend up m the 3
A* = 0 625 x ! 2 A . T* = = 0 75 A, f* m ; V, e 0 10 strength of the bois and upon the method used fos instalianon (a shbeated wsenth
(16o) j
and for A490 Whs: or turn.of-nut) la cacher methal, the clamping forte is to be a minimum aff ,

0 70 mimes the specified minimum sensde airengsh of the kis mesesial, F., smies j
D. = 0 625 x ! o f x A T,m = 0 67 A, F, m, l', = 0 of
(161. )
the tensde area of the imh, A,. IJsing the data for Imhs inssaticJ hy she turn.of sms .

method (5): $
Is a fashion sawAa.-so the development of liq 12, the kh shear esca sequiscJ I
| 20
by the 1978 AISC Specifica mn can be deocloped as
i T.L * I 20 x 0 70 F. x A, = 0 98 A. F. . Olt
[
c
A,=- (p, , L )
F, m (17) m = his te 120/10) is the estio of she mean sesnsle sesength e4 all Al25 Imles
so she mean sensde sisength of the pastu ulas lot of b..l;s uma asi el.csc seses p[;
-.
in = huh F = the allowable shear sesess gisenin she Spcofg sma lhe sew. tam e (tmah as composed so T,) 1he coeffiuens of vesistmn a essesp.mdmg to I q ?
teams of Ih 16 can now bc wrissen es. for A325 Imiss- " "* "' '"' "''"8 ** * * * " ' ' * " ' " # " "" "' '
y actual (lampmg fasce to that specified ($ 20). 0 0F as she sanasmn in the rtuo g
D. = 0 75 ' c(D s L., I 120/101, and 0 05 as the assumcJ vanatmn due so fahnterion uncessamises
F. l~os A490 tmhs ensselled by the suon of nun method, she capreuson equivalen f
g , ,, ,,,, ,, g q y g ,, g3 4
f.
oc for A49U buhs' A. = 0 67 r ( D, a L,, ) I U1
. ( T,) = 1. 26 x 0 70 f, x -- A, - O lit. A, r, (22)
I 10
In general terms. I q 18 can be especssed in the form
with a coefficient of varianon equal to o 10
.
 .
.

e436 SEPit Milt 219 78 Sig Sig IOAMESISTANCE FACTO'l 837 '

he .. , cocificient oblemed feom o simple of 312 specimns of A7, A16.-
A440, and I E 17 and Fe 52 (Fusopean) seccis is 0 ))6 with a coefficient of
vanation of 0 07 (5) Simdas data are avadable for a number of oaher cases
For esemple, gne tlassed A514 steel has a shp coefficient of 0 318 with a
coefficient of vanation of 0 04.
lhe value of the slip sesessence capressed by Fq 20 can now le further
c:ses, fillet wilds end high-streIgeh tmhs. Ahhough se would be mors ecoA. acal
in teams of material used, Iwo values of p woulJ ancecase the design complesity.
f or ehe serviceabihty seate Il = 15 =di be uscJ liased on the cases esamincJ.
shes represents a seasonelle value.
-

flessamointion or Rassa:Ance Fanos

quani Ged Considering hohs instaticJ by she surn of nut method and stects suth
as A36 =sth clean mill scale, for A125 Imits:
The sesistance factor,4 (Eq.1), can be capsessed as (13)
f, = 0 3 3 m A. F,; V, = 0 24
(2)al R. '
and for A490 bohs. f, = 0 29 m .4, f.; l', = 0 24 + = -- c a p (-a (l V. ) IpI
(236 ) R. f
The 1973 AISC Specification presents the requisements foi inction-type
connections in terms of an allowable sheer sesess (even though the tmhs see in which R. = she mean resistance; R, = the nominal resissance as esgressed j
by the design esitesia, and a is a numencal facios equal so 0 55 (11) 1he serrns |
not actually acting in shear)
p and V, have been defincJ previously. The sections followmg =di establish
F. A, m = c (D, , L,, ) g43 the values of the resistance factor for the various fastener condelions. .

.' filles Welds.-lhe nominal resistance of a Gilet weld in shear is customardy .

Solving fos m and using a value of 0 75 for the ratio of sensile stress area taken as 0 6 simes the speciGed minimum sensde sesength of the deposited weld -

to gross kit area, A,/A,, the strength terms in Eq 2) become, for A325 metal 'this is based on an assumption that she fillet weld is in putg shear E
bohs:
'
and that the discostion energy theory describes the condition of plastic ibw. [
F. (Ilic"cance"numberis t / dos 0 577.) Calling ehe throse nsce of the weld,'
A ..the
f, = 0 2 5 c(D,+ L I '
-

nominal resistance is then -

>

y (25) R,-06f,,,A, On)

or los A490 bohs. P, = 0 22 c ( D, + L,, )
TI.c mean resistance of the weld is
la general terms. Eq 25 cais bc wnsten as #= " d I' I '

y* As destnbed in the development of the safety inden for Giles =clJs. Il -

P. = H,). ( T.I. - - - c (D, + L., ) 06)
A, F.
The specified minimum sens le sinengths. F., are again 120 ksi, for A325
khs and ISO ksa for A490 bohs. The values given by the AISC SpecaGcation
for F, are 17 5 kse for A325 bol.s and 22 ksi for A490 bohs. The values of
the safesy inJea, p, for joenas of A36 (or semdas) seect with clean mdl scale
faying surfaces and using either A325 os A490 bolts installed by the surn-of-nut
neesbod are tabulated en Table 2. A plot of values for the case of D =L
= 50 psf is shown in Fig 2. Over the sange enemmed, the safety indes varies
froni i 46 to I.73 for A325 bohs and from I 32 to I 64 fos A490 tmhs.
As espected, the values of the safety indes are low for bolted, friction-type
connections as compared so the other cases conudered. This is because the
consequences of failuse of a (nction type bohed connection ese less severe
than the fadure of high.steength bolts in shear or sension or of fillet welJs
is shear. A sepasste value of the safety endes should be estabhshed for each
of the serviceabdity hanie slaics (bolts in friction-eype connecisons) and strength
limit states (bolts in tenuon os shear and fillet welds)-
The value of fl = 4.5 =di be selected for the strengib hmit state. This reflects
quite accurately the values obtained for Giles welds. encept for some cases
of high hve. to dead load satios, and =di be conservative for high-strength
bolts. It would be en order lo select two diffesent values of Il for these two
4 5. (v.). - 0 88 f,,,, and V, = 019. Substituima of these values and the
capressions given by Eqs. 23 and 29 into the espression los the sesistante
factor (Eq 27) anres a value 4 = O R
. liigh;stsengsb Bells: 'Itealoa.-lhe nominal resistance of a high steength imit
m tension as O)
p* . 3, r, , , ,
(10)
and the mean resistance, as given casher, is R. = 120 A,f, los A125 Imhs
and R. - 107 A.F. for A490 bohs. Fos these two fasteners, it was found
that V, = 0 09 fos A125 bolts and V, = 0 05 for A490 tmhs Again using
( p = 4.5, it can be determined from Eq 27 that 4 = 0 9f for A125 bhs an
tension and e = 0 94 for A490 lmha nn eension.
Illab Strength Boles: Sheae.-The nominal resistance of a high sseengih bolt
in sheer is (5)
A* = 0'625 A* F* . . . .
(38)
and she mean resistance, as tieveloped in i q.16, is R. - 0 75 A,f,m for
A325 bohs and R. - 0 67 A T,m for A490 bolts The values of F, ocse
found to be 0.10 for A325 toits and 0 07 for A490 t ohs Using a value of
p = 4 5, she resissance factos (Eq 27) is 4 = 0 94 for A325 bohs and 4 =
0 39 for A490 toits.
I

~c' _ . , _ _ _ _ _
.- ,
 , - . e

telt StPt(M (2 1818 518 $18 *

LCAO CISIST ANCE F ACTOft 8438
litsh Sasragsh Boles: Vomtrleed Shene and lesslue.- Fos a f astenes sub3 ctied
to imah tensson and shcas, she following sclassonsbp has I.cen sceommended for beams, columns, and other main struclusal componenes (11 = .. the
(5)- use of y, = 8.1. y, = l.l. and y, - | 4 has been sccinnmended for use in
S* + (0 6 T)* ' 410 6.4, V,)*
the I RI D format (II) Whde y, = y, = 1.1 woulJ saill be appsopriate for
'" ''"8"''' *f t''''"*''' a value f 1, = l.2 should probably t,c c hosen *k@
(12)
los f asteness sa is <sson eype connecesons and ,r, = I 6 shoulJ be used for all
,

an h t h S is the factosed shcas imtc. T is the facemed sensale luete, and othes fasseiness flowever, sashes than using diffesens load factoss for theic 3
As 1
sepsesenes cHher the imit asca through the shank os thsough the root of cases, the effets of the different p factoss can t.c impnscJ on the value of '
the thecads, depending upon she actual location of the f adute suitate_ /'
4 to I.e used for the category described in lat le 3 as " Connections- All
lhe resistance factos. 4. can be estabbshed from Others." shss means that 8)
3. i
A. IR..,i f s, i 109 (109 r. D. + l.39 c, L )
/s
A.
=( -
| {
A A, / ,, 5 F, / .
-
l
03) .- 1.1 (l I c, D. * I 4 r, D. ) . . . kl
4 A , f.1)(1.14 c ,D.,* 1.59 c,L .)
,
(10) Q
V,'
and Vi = V[-2 e
-
V,' s V[ (14!
1he estio on the lefe hand side of tNs inequahty varies only from 0 86 to .; .
* * 0 90 as the hve load so dead load cifect (r, f. /r ,D.) goes isom 2 to 0 25
ia =hich A..,/ A,ss abe saRo of ahe caperimental sesength eo she nominal strengib
ne cossesponJmg venenon for she categosy "Connecamns- l'escuen** ss from f,l
I 18 to 1.12 over the same range. Smce the vassaoun is not large su eseher p
acceedmg so the antencen equaison (Eq. 32 with 4 = 10) ne statistical case. is is recommended that the sesistance factor. 4. be moJilied for connecuons
dein for the satio are ( A,,,/ A.) = 105 and Vg / A, = 010. Using these as follows. 4 = 0 88 4 when p = 4 5 and 4 = 1.15 4 when p - I.S.
data and the previously developed infosmaisou. V, = 0. V, = 0 05. (e,/F,l., *
= I 20 or 107 for A125 or A490 Niss, and ( V., /V,) = 0 07 os 0 02 for A125 TAttE 3 -Load Factore for Varioua Safety nadas Values
or A490 bohs, e can be determined usmg Eq 27 as 0 91 for A325 bolts and
0 85 for A490 bolas
litsh-Streegik Belts: Fekstoe.-lhe nominst faictional ecsistance provsJed by
g o,g ,,go,, ,
*
the clamping actaoa of one bgh-stres.gth bolt is * "d*' ' '
h
A, = ne 4,(A, x 0.1 F,) . .
{;
(15) p ,3 o p ,,,a,,,,, ,, ,, in ,

and she mean resistances and coefficients of variation are as given by Eq 0*'3"***"'"''' """'I '" '" '" #
21. ne value of V, was found to be 0 24 for txHh fassences. Ilsing thesc 0 * # ' "** *"'"" U '" *" * ") E_-!U-
data and the value p = I.5. the resistance factor is found from Eq 27 to
_
--
- 'Y.
'
be e = 1.15 for A325 bolts and 4 = 101 for A490 holes. In leib esses, in
has bees assumed that the bohs ase installed by the tusa-of nut method and 1he modified sesestance factors for she various cases considered are thesefore. #
that the faying surfaces are in the clean mdl scale condisson. for filles welJs: 4 - 0 88 x 0 9) = 0 32. l'or Nah sese.igih imles-
Medined Restata ce f aceae.-ne use of t.o ddfesent values of the safe:Y
1. Tension A325 4 - 0 38 x 0 97 = 0 85 and A490 4 = 0 818 x 0 94 &
f[
inden (p = 3 for snembers and p = 4 5 or 15 for fassences) introduces some
.
.

o gg.
$
operational ddficulties that muss bc resolved Westing Fq 2 in terms of the 6
dead and lave load intensities. D. and L.: 2 Shear: A325 4 = 0 88 x 0 94 = 0 81 and A490 4 = 0 88 x 0 89 = 0 78 $
) leniina and shcas; A125 4 - 0 88 x 0 91 - U 80 and A4wn 4 - O as
4A,2'ya(r,y,D. +c,y,L.) (16) x 0 85 - U 75
c
4 I siction joints A325 4 = | 85 x i 15 = 112 and A4wl 4 - I 15 x
,

'
is whkh 1, = the load factos repsesenting uncertaisines sa the analysas. Fsoin
Ref. II: 101 = I .16.

y,= cap (ap V,)

y
.
(37) Clessly, it is desirabic to reduce the numicr of values so be used for she
-

v. = 1 * a p V V1 + V'. resistance factor to a mminium.18 as necernmended that 4 = 0 601 c uscJ ,

08)
ya * 1 + * @ Y V +V 4r
fos all cases involving the strength firnit state, i e fillet =clJs. and Ngh assength
bolas an sensson, shear, os comtaned senssoa and shear and ehes 4 = 115 be f
?
(19)
used for ahe serviccahhty famis state, a e , shp sessssant somes usma h gh strength
Using the values V. = 0 04. V, = 0 04. V, = 0 20. V, = 011. anJ V, r h
bolts. He value selected for the strenath hmet stoic as some*has unconsesvata=c i

0 05 (Ref. 5) the load factors y can be estabhshed for the three values of for A490 high sesength tmles an shear and fos A490 boles an combencJ senseon
p nese ese sabulated in Table 3.
and shcas. It should be secalled. however. that the 'alac of the saic8r saJe*
*
'N i
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
 t .

144v '

Strit M8EQ 1973 9,.

519 ST9
fl = 4 4 LOAMESISTANCE fACTOft 1441
ea constavetive los all cacs invoiring high-st Insth imits. The value
4 = l.15 selected for the serviteabshey temst siete is information
conservative. necessary for the developmens is also presented 1he worn shows
seflecieng S'
tbc fact that bolts =di not eloeys be anstalled by the susn of nut method that current design values for different connectors psovede subssensselly dif fesent '
.
levels of schebdity.
3,..
IIetanee Cos =ecion Peosisene
ac,,,,ge...,,,,, *
j(
Slip-Reelsteese Cesentloes: Obeeb faa Serength. -Whenit as censidesed neces- !!
The work that resulted in Ibis paper was sponsored by the Amesican Iron
sary that conacceed parts not shp into beenna under sesvice toeds, the connection N
*di be designed as a (siction-type joint using she cnteria alseedy developed
and Steel lassitute ( AISI)-Committees of Structural Secci Producers and Steel p
,
for abas case. It muss be recognised, however, that such a design doesPlese
notPsoducers en AISI Project 16) " Load I actor Design of Secci Buddings." y
The membess of the Advisory Task Force 1. M. Wes 6birment. W. C.
mulosnatically ensure that the critene essablished for a I. coring type connection J
liensell (Engiacering Supervisor). I., s. Beedle, C. A. Cornell. E. II. Ueylor.
willaiso be mes Thestfore. if the seswiceability limit state (shplis being esernined q
.

the sticogsb
be checked. limit store (both shear steength and bearing capacity) must also
J. A. Odligen. I. M llooper. W. A. Mdet. Jr.. C. W. Pennhem, and,1 Wintes, o
have been most helpful with sheer encousagemens and advice.
Oseleary Boses.-Il has been customary in the past to apply the some design
Aeremose.-Renassacas
cules to ordinary bolts (American Soucey for Tesiang and Meterials (ASTM)
A307) as those speciGed fos high-strength bolts (ASIM A325 and
. VesyA490) t
I limiles. 8_ 3. and Kutet. G L . "Steength of fillet WetJs es e I'vessace of perusen
httle data about the strengen of osdinary bohs are available and it is therefose g
*I L'*d,"
w,fsmg J,wn.f. We J ag Reeconh Comesd. WI 14. No 3. May,1978
8; commended that abe same procedure be followcJ, i.e.. she LRI'D procedures ' )
2 bP
developed for high strength bolts be considesed vehd also for ordinary bolts. wt ):* l
j,wug ,f $, ret. 5. and Kut h. G 1. . **Fecenstw !!y I medcJ WelJed Cesautenes."
Of course, ordinary bolts should not be prescnbed for frweion-type connections 5,,,,erwa n,uses. A5CE. vol 93. No. 515. hoc regws 8874. May.
t972.pp 909 lisal
saace Ibc level of Ibeir
probably highly variable.
clamping force is both uncertain as to magnitude and 3 l'e**. 8 E.. and Ketet. O t~. "We Jed Conseeseces under Combened Shur and f
Moment." Je=al */ 8he 5"we'**8 D"'''** ASCE. vo l 100. No 5 I4. reoc rarve
Bette-Beartag Capseley of Cosmetted Mete lat.-The bearing capacity of she |
cosaccted matenal immediately adjacent to a bolt is a design problem usually
a[[,, #' *

:3 ,,,,ws pubinhed letoemessos. Appendia p." Regest

asociated with tbc fastener. Sanctly speaking, it should be assigned to the og Weld panel og it.e 5ecel 5:encewes Reseenh Commisier, ikpeniscat of Sucece
and ladusirial Reseesc h. London. I agtsed.1910
enember but it = 11 continue bere to be refeted to she fastener. 5 iishes. I W., and 5 eeek. I at A . C=dde se Desla s C,#rerse fee seisc4 g 4 As escJ
The nominal resistance se ber.nns has been established as (5) #*'"". Iob8 WdeF and Soes. Inc.. We M. N L. M
i

C. = aa F, s 3i J r* .
6
I sumise. F. R. "ne Sasength of Aes Weided Joisia." hace JJage. Inesieve ma of f
. i
,
*
g43, Cevil rassacers. tendoe. TagleaJ. Yet 211.1910.pp 322-121
7 la i
in which r, = the specificJ minimum sensele strength of the plate materiel- iggins. T. R , and been. F. R . "rsoposeJ sesesses fav i dice WetJe se BudJems
,
Cemsaruction," artissag fee.<=st. WI 47. No 10. Oct . 49ts, p 429 5.
af = the bole diameter; e = the end distance of the boh; and a = the governing
a Holta. H. M and Kutek. O L.. "ll'sh Sisength polis and WetJe em I ced Shesing
pleie sbichness (ibe thinner of the two thicknesses in a leP Joint or she least 3 ' * ""* ' "" "*" ~

of the sum of the thicknesses of the two outer phes or the thickness of the lleMee.Comede.Sepe.100
cacloacd 9. Khamme. C. K., "$sseagth of Ions f allet WelJs " shesis sucsensed so Neve Scosse
1.5. ply in a bute joint). Eq. 48 as opphcable as long as e/d as not less
i
ibao lecheecal College. as ilekfe e. ranade. an 19a9. as passeel fe f8 alismess of the seqvuemente
.
The following statistical data eclate to E for the degere of Messes of I agiscenes.
9 41 (5)' Number of tests = 27*- " "** "* * *
sesso of mese test to psedicted values = 0 99, and coef6cient of vanelson * "*#""s
De,.gn lo "Connectanes " Aesterch
.
Aer*'s of#e
. Deparissene J)I agmeesus.
Caval
0.II. With respect to r,. the following date are availebte (la):Ratio of sneen Wesfiegion time,essity 5 R ome. Me . May. Im I

|
to speciGeJ ultimese tensde sesength = 1.10 and coefGcient of variation = 0 II. i t . R e vadie. M K . .d Gatasab-e. T v . "t **d a nd 8 e sa'**" 8 ** '"' De* ** f*'
Frome 1.bese dele. P. = 0.16. Usang liq 27 and the valine in4=5. 4 - 0 99
.

58e el." Ja*ra*' */ '4e J''*e'"'*' D'''''** ^ 5Cli D' 388 " * 3 3 '' "'"' '' P''
x 1.10 esp (~ 0 55 x 4 5 x 0.16) = 013 .'.j''8 ' ' t

Q,',[ ,$3s, I [[tJ.sg commissiec." Ameness We J=g 8mes=. lHl.

Modifying this to account for the use of the higher safety inden. 4 = 0 gg Bj "specificas . f e she Desige, rebewaims. and I:seensaa of sie.uws: Sint ter f
x 0.13 = 0 64. s udd.ags." Amene*= 1**'d"'c *f 5'rel C'*"'"'"*** N'* Y*'* " Y * "''
n . spu.f.cas foe Sir.coment fosase fleing A51M A335 ** A490 8"8's." Reennh |
I
$usseeams see Concsuasons Coment es Es*cied seJ Bolsed Strucesset immes of she tagiensing I eveJaisos. BH6
!

;
A
This paper develops the cominal resissance terni and sesistence factee for
escb of the commonly asscJ connectors an structural secci
t
lhe slatestical
*

!* il
 _ - - . . - - -_. . _ = _ _ _ _ ._ .. _ .___

hY l

%
.

[ '

4 s

i A rt.19.3) RESULTS OF TESTS OF WELDS

. . - H3
f T The increased use of high strength steels and th: need to refer to them in
spec:5 cation prousions resulted in further studies on h!!et welded connec-
tions." *
S:nce fillet welds may be made with electrodes whese mechan::al
properties are not equal to those of the base metal, the study esaluated the
induence
weld. of type of e!ectrode, size of $llet weld type of steel, and type of I
All test specimens were designed to failin the welds, esen though the
; mechanical properties of the weld metal exceeded those of the base metal.
; The study indicated that when longitudinal 6!!et welds were made with
electrodes that " matched" the connected steel, the weld strength saned
from
19.3.
60 to $5 per cent of the electrode tensile strength as illustrated in Fig.
The study indicated that the failure plane generally was at an angle i

'
,

o top i
'

.
'

!
.
~
O to r y
|
p |

5 .[ 9 |
r T -
-
,

._;
,
CMw
4
3:i,: 1
s ,. .. g, e ,.. g
*
e s e s:.e rm e e . ee c ,

/
<
0 43 - .

1i a r. e . . .. ., c,.u ..
-"
i ::3
-Li- -

~ 1:5
%.
-

ac
tese Ae4
! v.tme t60
436
(70 eaal ;*14
a
tro ';to
h:
Fig.19.3 Shear strength of longitudinal fille: M.
metal, welds with matched base 8'

,
less than 45' to the plane of a leg. Thus. use of the minimum throat thick- .

ness is conservati$e.

, Since weld metal may be deposited on base metal with different mechanical k.;- '

Es
properties, combinations of strong base metal with weaker weld metals and *
' uce-sersa were also esaluated." *
The results are summanzed in Fig.19 4. _

!
This rescaled that the effect of dilution upon weld strength was not great. _

Where plate bendine is not a problem. tests of welds subjected to combined .

bending and shear have indicated a varvin5 factor of safety against weld El =
failure.
The results of tests on sertical weld groups are plotted in Fig.19.5.
As the ratio of eccentncity to weld length (e/L) varies from 0.06 to 2.4, the
.

. ;
L.d

-v

l
$ _ _ _ _ _ _ ____. ___ _ ___ _ _ _._
 s- -

...
.- -
.. . .
* .
. . -
z
.
0009 61 <

C' ; REDY, . HERBERT, GIBBONS

~

L.
S ASSOGIATES,ING.
August 11, 1983
.

000-083-139
, ..

7
,

Subject:
.
Weld Evaluations .

increases
of and
this paper delays at a number of nuclProblems as
.g unnecessary cost
The subject ear si te s.
observations given are based onprimarily deals with the inspection ofThe
we .

one particular site. performed at acnumber

o n s t r.u
of cnuclear
t i o n activities
sites andbeing
are no
related to any
The subject welding is ,

Welding Society (AWS)

(Section III) for for structural weldingunder the auspices of b
supports. and the ASMI Code
( l.
The areas of concern are fourfold: welding of pressure

2. Continuous measurement of fillet welds:

Grinding of all fillet and butt welds;
3.
Undercut provisions of AUS Dl.1; and ,
4.
A.
Encroachment on minimum thickness.
.
I will addres.
.
s these areas individually.
I.

-
CONTINUOUS MEASUREMENT OF FILLET WELOS
. Both AWS Dl.1 and
have in
been requirements for minimum si:ed fillet
exis tence for many years. e
w ldthe ASMEe
-
(at s which have
least until three - or four yea rs During these many years,
ago),
ment of each inch of welding.qua Inspectors
tely. evalua ade-
ted fillet
s cal measure- -

Several years ago this

free fillet weld gages changed when a supplier furnish 6d
. nuclear plant sites. to QA/QC Inspectors at
~

several
p specified minimum we.1dstated measuring each inch of fi
s
-
length of weld. verify tha t t h*e -
siae wasbeen
What had previously met correctly
for the continuous
under-
.

..

*"
.
J'103 ALSRIGHT WAY e
LOS GATOS. Cat imama nu-- ..

.-.
 ..
'; ' ' '
. -
-
.
.
.
0000-c I
.
.

stood by Inspectors to be a
( uneeceptablit Co" some Inspectors. visual judgment was suddenly
undersized welds were fcund in minor leral areas,Not surprisin
Non-Confor=a nce , Re po rts and many
reviewed and accepted were written. If the Designer
minimumthe Inspector might object on the basisthese local conditiens a
were not met. sizes that the specified
or other experienced Inspectors said the discrepanciesIf were
acceptable, the Ins
or intimidated.some Inspectors stated they were being harassed
This condition has
extreme
(1,000)
when URC In s pe c torsrecently progressed to a more sericus
fillet welds and foundexamined
only one about one thousand
The
long particular veld (1/2 inch fillet) tha t was undersi:ed.
and was only 1/32 inch undersi:e.was only four inches
ally censidered by the NRC as a major discrepancy, and ,The weld was initi-
f ur ther consideration after
have indicatedwas re-evaluated
existed. as minor
ment
would no problem Good judg- .

. ,

Because QA/QC
undersi:e welds, Inspectors do n o t wan t
reinspection the tendency new is for the NRC to find'any
programs. them to initiate
costly and
have tolddoes
me not add to overall plantThis is safety.
extremely time consuming
, Of
ingcourse,
for perfection is physically impossiblethey intend to ..
perf ection in weld size, but in look- ,

some ofwith
ating, the other more critical
the result that aspects they shculd be evalthe
u-
.
performed. inadequate inspections will be
One acceptable
s
to evaluate filletway for an
welds experienced,
is as follows:
*
qualified Inspector .

,
*
s ,, .
. . _ Review the weld procedure,
-
*

*
Review and evaluate the' welder's perfor:ance .

Based on-this
weld passes required to achievein f o rmation, ' determine
,

*
the required weld
size specified on the appropriate drawings.
; '
:
*
. Visually examine
,

.
basis
of of sample
the weld
.
deposit. measurements, determinecythe
There is no
or the of
length AW5 filletDl.~1
welds.Standard to continuously meas ure .
-

' the fu11c_

from mini =um si:e fillets as documented in ASME.Both ASME
NC/ND-4427) -

In fact, and - paragraphs 8.15.1. 7 and 9 NS-4 4 2 7 (and

,

' Code to there -is no requirement' in any s. 25.1.7 of 'AWS DL.1.

! k.. 7 tructural or
continuous ly measure ' for minimum A S P. 5 ' ' o
dimensions
,
1 i
\

emmeesaneume .66
e

.
 -

.
< .
.
'

(
-
. .
,
l
i
,
O D 09: i . .
i

. material.
(
Thickness checks are not
of surface of structural beams,fw each ' for
inch of ine'
each sur .

ness of pressure piping. or for mininum wall thick

There are minor imperfecticas
Because of this, the AS:E Code in every man-made object built
or 3 depending on imposes a safety factor of
, These safety factors arethe design and intended use of the item. .

and minor imperfections.provided to

Therefore, account for unknown
ins
on a random sample basis to determine nc=pections can be made
detriment to safety. inal si zes with nc
I
It can be consertatively
tions, estimated that
unnecessary repairs, increased the cost of reins
unwarranted delays can cost close to S100 million pere.and
sitd
There
inspection on nuclear ccmponents.are usually five or six (a minim
levels of
level of review) When the NRC (as the last
levels more
require of inspection _ becc=e
repairs to be made. more demanding and c equently
of concern can be more easily evaluated. welds
, the true areasa
sive repair welds of ten tend to ha rm In addition, exces-
,
structures. It is known rather than help the
the cause of cracking problems.that some repair welds have been
N.
.
II.
GRI :DI ;G OF ALL FILL 7.T .'diD EUTO WEL::S
There seems
s industry which requires thatto be an-unnecessary practice develop
ground n the
to
.
fillet and butt welds should be
not aelimina te all of
ripples
eitheror to make
Dl. 1 flush surfaces .
"
-
This is"NB-4424
III. requirement AWS
states (and NX-4424) of or AS:E Section
that "as-welded" conditions are permittedSection III specifically
any possible
as long as
tions, are not masked.def ects, as shown by non-destructive
which a-
ex
would mask defects,
Section III prohibits coarse ripples
,
-
Manyeven but does
Inspectors are insisting that not prohibit all ripples.
ate ordinary ripples whichwelds do be ground to elimin-
*

effect on weld quality. not have any adverse

,

safety concerns.Insis tence on grinding welds could result

Specifically, it can in other potential
ing . and unneces s a ry repair welds.
cult result in overgrind-
Itatalso
in-service inspection.to locate butt weldstime, makes
a la such
ter as it diffi-
during i
' The
"a s-weld ed" condition has ' no
the ripples ~~

defects) but do not mask the detection'ofimpact

! ..

on safety (prov
( unacc ep table
grinding velds significantly. increases'
i @i i
the cost
-

O GN 9 WW G . E'
g g g, e se # ##.
 . - - .

.
*
.' .
*'
. .. .
.
. .
.
.
. ( .

00M 51 ,

o::. the plant. .In addi icn,

L other sa.,ety. prchlems.
. the g:; n d1n 7 ts+1f may cause
i

..
IAA. (J. ...:
,. .c,. ,w....
P.n.O..
<.,.S C .a.. C e nas
. . . . , , ,
...

The third
cut. problem reg 2rding welding pertains
Early editions to weld under-
current issue has of
a AWS 01.1 prchibited underc ut and the
which is based
the welded on the directicn of the p rincipalres triction o
member.
because undercut can notTh es e rules are impossible stress i n
Inspectors do not to follow,
be elimina ted completely and the
performing inspections.know the direction of primary stress when
sions The problem caused by these provi-
staff, but
becausehave been
these mendiscussed
are reluctan twith members ofechnical
AWS D1 .

reluctance only meansthere have been to

no revise the document
major industry ec=plai
nts.
are not enforced, orthat
as the This
provis ion s of the document
permitted by ANS 01.1, the provi-
siens are waived by the designers. '

cut allowed by AWS Dl.1 (0.01 inch) The minimum weld under-
the restriction is ridiculcus. canno: be measured, so
Sec tion III. NS-4424(c), allows .

ers have not had a problem 1/32 inch undercut. Design-

on this prevision. Inspectors have this
with been provision,
able to naheanc the-
adequat
e evaluaticns baced
A problem arises
and insistA Son
rejected ". E. no undercutwhen
at a l'l . N?.C
SomeInscectcrs
Inspectors beccme
have
.
Dl.1 buildings.
and requirements which were written ps tructural
rimarily for welds on th
'

because it was 1/64One NRC Inspector rejected a weld undercutbrid

inchrepairs
This leads to more Weld ~ deeper
whichthan permitted by Code.
.
is a safety ccncern.
IV.
ENCP.CACHMENT ON MINIMUM THICT. NESS
,
There are cases where
-
thickness
items requirements
being inspected.may not be metInspec tors have noted that minimu
'

either for lccal areas of the

by undercut ors grinding.These local thin areas
'

to may be caused
.

.
restore minimum The resultant weld repairs
accepting the area on the basis of engineerinthickness
,

than can
.The g evalua tion.
ties. ASME
_The Code
designphilceophy
engineer of desien allows
local disecntinui-
.

can oitan justify

~

spots by showing that

'

the shallow -

i
diameterAlso,
opening. than the Code allowed diametethe
r of an localin'area
ities to have an the ASME Code allows unrei.nforced
increased primary stressareas around discontinu .
the allowable stress.
y . of up to 1101 of
When the design engineer uses thes e
I
m

i ht ,

: -
.

, , , , , . 3 ,, _ - . , , . - . . - , . - . ,1,-,
 _ __
_ _ _ _ _ _ _ - _ _ _ _ _ - - - - _ --

,
, ...
. -
.
.., *
, ..
.

. .
, !
D D Cs
4. .-
.

'
evaluaticgs
murn t s a r e m,tp
et aand
ccep t local condi t i e n s ,
Un f or tuna tely, unnecessary weld the Code require
tions, some Inspectors refuse t:
repsirs
ac:ect
are avcide:
approved the engineering resolutioneven whenors
thehav
AEME A .

In the .

problem, p rexcept
e c e d i for
n g areas of \

sis welding concern,

is placed on the wrong criteriathe repair welding which is caused whth .
sometoNRC
ment Inspectors and Investigators are nThe NRC is involved becaus
be exercised. -

In ot allcwing good judg-

general, the ASME ,

understood
when NRC inand
vesproperly
ti ga tors controlled weldAu thorized Nuclear Inspectors
(ANI) have
.

accepted by the ANI, inspections.

>
criticize However,
|

! which he previously knew to be acceptablthe

e.
criticism
to reject weldsforces th
This welding -

guidance
the should be given
acceptance to NRC Inspectorsinspection
cant
enough that more prob
cost, criteria a
tiae isin both time and money, nd me thods of inspecting welds.and industry
apprcpriatunacceptable. for continuing to inspect The
, foranminu-
a decua cy. e for determining signi fi can tThe industry needs inspection cr
( ocram problems and
meaning:.ul inspections and substantially,Cencentrating
repairs.
ere
o
reduce unnecessary weld

*
* SUGGCSTIONS
Meetings and
,

'
participation; Seminars with both industry and NRC
'
Technical
try and HRC personnel; papers on the subject by prominent
* indus-
.
Training courses
and Standards;
.

*
on use and understanding of Ccdes
NRC support for
.
allow " qualified" prof essionalclarifying
engineering Codes
and Standards to
judgments. encineers to make
for " qualification".)
* (Endorce'ASME/ ANSI N626 3 .

NBC Infcrmation Notices;

~

*
Schedule .

,*
le=s as identified by either groupNRC-Industry
other p' rob- Forum .

*- - ,. ,
.

3 /*
/
,

in .

9 -
@D ''

F
--

e _-
- _ _ - _ - _ _ _ _ _- . - -

f
1

ASSESS!ENT OF DIC PROCFx:

_ .. -
' z
SECTION I

A.
In relation to Quality Program breakdown in DIC AkS D.1.1 Welding
KG&E has co'nducted
an assessment of the programmatic aspects of the
piping, hanger, mechanical, electrical and civil disciplines to ascertain
adequacy of the programs instituted.
The assessment has concluded that a satisfactory level of confidence exist
to assure compliance to 10CTR50, ANSI N45.2, FSAR, Design and Procedural
Requirements.

The following general aspects of the Construction Program at Wolf Creek

Generating
program andStation provide adequare assurance of the completeness of the
its implementation.
1. Activities are controlled by written
(Administration, Work and Quality). These construction procedures
procedures are developed
to provide
FSAR a method to document and implement work to ccmply with
conmitments, including applicable requirements of
specifications, codes, and the
standards and include appropriate
requirements of 10CTR50 and ANSI N45.2. These procedures are
revised as necessary
procedures / revisions to provide program enhancements and a ll- i
, are reviewed by Dlc Construction Engineering, i
Quality Engineering, Quality Assurance, Quality Inspection, KG&E !
* Construction and Quality Assurance Organizations. Redundancy of the
review serves to identify possible errors or emissions. and dis- |
j
continuities
ation. would be identified and resolved, prior to implement- 1

2.
A major program enhancement review was conducted by DIC in early
1982.
This program was initiated to provide a critical review ano
identify areas in which the Program could be improved to assure
completeness and provide fcr effective implementation. As a result,
new procedures
revised to were
achieve developed
improved
and many procedures were extensively
control of ongoing
activities. construction
For those areas containing ineffective or incorrect
program controls, an evaluation of past performance was conducted
and corrective action taken as necessary.
3. All s.ork and inspection activities
and KC&E QA organizations. are routinely audited by both DIC.
AS!E Code Applications The - Aathorized Nuclear Inspector for
provides
supplemental surveillances.
Periodic audits are
and AS?E auditors. also provided by DIC corporate personnel, NRC.
A ga in , redundant auditing programs provide added
assurance of implemention of the Construction Program.

In- addition to these audits and surveillances various external

auditing agencies such as INPO, and Construction Self Appraisal
(CSA) have conducted extensive Program evaluations to determine the
effectiveness of the Program and its implementation.
I.,
-

in addition to the above, sections II, III and IV also illustrate and emphasize
the Quality
struction . Programs of the project and to provide confidence in the con-
effort.
I

~-
 |
|

. Section II
, .. .

The below listed areas of discipline depict the enhancements that have been
performed over the life of the project to assure constructaen acceptability and
program commitment acceptability.
A Pipe. Manger Mechanical Disciplines

The DIC Programs established . for ASME, ANSI B31.1 Critical and Special
Scope piping and hangers provide assurance of their adequacy as follows:
1. Traveler packages are issued prior to work activities. Prior to
release, travelers are reviewed and approved by both Construction
Engineering and Quality Engineering to assure that all work and
documentation requirements are included and adequately addressed.
2. Quality Hold Points are established in the traveler documentation
precluding work to process beyond desagnated
inspection / verifications.
Quality

3.
Documents included in the traveler are entered on an -andex to assure
that documentation
adequate control. is not lost or removed from the traveler without
j
!. .
Traveler
activities
packages are in the work areas to assure ongoing work
are conducted
assignments. in accordance with established work
5. Traveler package documentation undergoes
i

an
in-depth. final review by
Engineering prior to transmittal to the Combined Review Group (CRG)
for final review.
Va rious program snadequactes have been identified, addressed, and resolved
through audits, nonconformance reports, Stop Work Actions, or Corrective Action
Reports, which provides additional assurance of program adequacy.
.

B Electrical Discipline

The
and Electrical discipline was evaluated to determine programmat:c adequacy
controls established to assure compliance with requirements.
following is a synopsis of the evaluation: ;

',
1.
All
-ork
electrical installations are performeo by the direction of a f

j
assignment issued by engineering. The work ~ assignment is' t
issued to perform any required work to support a system or buildino
turnover.
The system or building scope is used by Construction, ,

j
Quality, CRG and Startup to assure that.all work'necessary for=the
system :s completed. ;

The
-

scope of the system or !

building includes the cables,.
terminations, equipment, raceways and supports required for the
' operation of the system or -building per the current approved i
;
design.
(. 'i
Enkineering - initiates the appropriate work assignments ' for
mplementation of
the work .in-'accordance with the applicable
#

-procedures.
.

-
 ,

!
!

The work assignment specifically identifying the work to be

pe r fo?in'd
being : is i s's
issued to
ue'd *- t o the c ra'it for implementation sith a copy
Quality Inspection
vertfacatten and
for
documentation of the installaticn. After completion of the worx, 1
,

Quality Inspection transmits the Quality enecklists and supporting

documention to CRG for final review. ,

2. \

In July of 1981 DIC discovered concerns relative to the inspection

and documention
IE areas.of the anchor bolts installed for electrical supports
.

'
in Class
The concern was addressed to Bechtel via SCR i'
ISN 3476 C for an A/E evaluation to determine an alternate means of
verifying the integrity of the installed anchors. Bechtel sas aole
to formulate
an alternate means of verifying the anchor bolts inte-
grity by supplying alternate torque values for specific details used '
for electrical supports. With this alternate means of verifying the
i
anchor installation DIC was able to accept the anchor installation
without removing the installed support. !
1

3.
In August of 1982 DIC encountered problems concerning the available
documentation and missing documentation for the welds cf electrical
supports installed prior to August of 1982. After identification of
the problem via NCR ISN 20073 EW, DIC revised its work and quality
procedures to require inspection / reinspection of all raceway supports
in Class IE buildings and Class IE supports in non-class IE-
buildings to assure that all the necessary inspections nad been
performed.
,.
'
After the implementation of the new procedures, Eechtel
was requested to perform an independent survey to determine the-
acceptacility
August 12, 1962.of the welds for II/I supports installed prior to ;

Based on the results of Bechtel's survey, it was

concluded that welds for II/I supports installed prior to August 12,
1982 no longer require inspection. Their engineering evaluation f

resulted
the in adeuuate
deletion confidence in the installed welds to allow for
of weld inspection. The . inspection requirements for
Class IE supports was not involved . in the survey and continues to
require a complete weld inspection. This program, at the present
time, is 99'; complete.
4
DIC
18 suspended low voltage cable testing and terminations on itarch
1983 - f or failure to comply with IEEE-422-1977 and was documented
by NCR ISN-9486-E a t the -request of Electrical Engineerint. As a
result of this
Inspectors NCR, Dlc terminations engineers, craft a r.d quality.
were retrained as to the intent of
Extensive IEEE-422-1977.
as to the research was performed to -identify and document all cables
validity of the tests performed. This resulted in two '

auditional ''CR s (ISN 12484-E and I

ISN 13893-E) and procedural

revisions to establish more stringent test controls. ;
'

5. DIC Electrical, in May of 1983,

identified concerns via NCR
ISN 11287-E relattve
electrical supports. to ehe material installed for special scope II/I
It had been found that special scope II/I |
electrical supports were installed using non-traceable, non "Q"
material.
(' In close coordination with KG&E and the Design A/E,
. extensive field inspections and research was performed to provide
the A/E with sufficient information . to allow them to perform an
engineering evaluation and determine if the subject material can be
used as installed.
3

_ _ _ _ - _ _ . - - - - - - - - - - __ _ _ _ _ _ . - . - - - - -
 Electrical Disci g ne con't) ..

'
The A/E's evaluation resulteo in a "USE AS IS" disposition.
In addition, DIC revised its work and quality procedures to provide
sufficient material control and vertftcation to assure tne in-
stallation of qualified support material.

6. In April of 1984 DIC electrical discovered concerns relative to the

breakdown of the unique identification requirements for electrical
supports. DIC Electrical initiated CAR l-E-0039 to document these
concerns. Extensive research and corrective action was implemented
to correct and resolve these items. Implementation of the
resolutions for CAR l-E-0039 has been completed.
7. In April of 1984, DIC identified a generic concern on the
method / accuracy of maximum allowable sidewall pressure OlASP)
* '

permitted during the cable pulling process. This was addressed on

NCR ISN 17440E for resolution. The A/E's evaluation resulted in a
"l'SE AS IS" disposition.
S. In the process of performing final inspection on raceway, a
deviation form the "1" separation criteria was identified on KG&E
CAR-15. This item was documented on NCR ISN-20443-E and
dispositioned in compliance with the applicable procedures. Work is
presently being implemented to bring this into compliance.
In addition to Daniels pe rf o rmir.g the installations to their approved
procedures additional credibility ir added to this by acceptable start-up and
pre-operational testing performed by the KG&E organization.
C Civil Discipline

The Civil Discipline was evaluated in the major areas of Civil activities to
determine the adequacy of the program and established controls. The
following is a synopsis of the evaluation by area.
1. Concrete and Materials Testing

The possibility of the use of defective materials is minimized by a

system of testing, at specified intervals, to assure acceptability.
Tert frequencies are maintsin through the use of logs, as for raw
materials and designated " test loads", as for concrete placements.
Deficient materials / products have been identified and resolved
through the Nonconformance Program.
2. Steel Coatings

Steel Ccating activities began at Wolf Creek without the Daniel

procedure WP-V-100 being approved by KG&E. As a result, a third
party evaluation was performed. Results provided conclusive
f evidence of sa tisfactory performance and acceptance by Bechtel and
'\ the NRC. Inspection programs have _ assured' that acceptable.

4'

l.
 1

'
.

certified materials were u*t!tzed in e.ica approved

techa. sue. coat:ncs
of subsequentInspection
layers ofrelease
ccattncismaterials.
also requirec pror te q M ica:t.sn
failed to detect any adverse trends 2n tnis area.E n e rr.c l avitts have
3.
Concreti and Grout Placements

Concrete and Grout Pre-Placement checklists are utilized by Quality

to assure all
Locations of prerequisites are completed prior
embeds and installed matertal
to placement. ,

documented. are verified and

Concrete and Grout Placement Cards are utili ed to
assure interface of various
release for placement craft and Quality disciplines prior to
activities.
These documents become part of
the pour package, are reviewed by CRG and are retained as a QA
record.

4 Cadwelding/Rebar

Placement and acceptability of placement of rebar and cadwelds is

controlled through the use of marked-up as-built drawings. Cadwelds
are produced by certified
craftsmen whose qualifications
verified by Quality prior to cadwelding. Cadweld recertificationare
is
performed
Foremen andatQuality
intervals controlled through logs maintained by the
inspectors.

Assurance of acceptable rebar and cadseld placement is also '.erifted

prior to concrete placement througn ecmpletion cf the Ccncrete
Pre-Placement checklist.
I
5. Soils k
6

i
1
The soils program also shows problem preventive mechanisms in the
form of pis~ cement prerequisites and logs. .before fill may be [
placed, the foundation must be ;
approved by the Geotechnical Engineer
and that approval must be vertfied by QC, At this point the QCI !
initiates a log (Lift. Thickness Log / Daily inspectien - Report) as a ;
!
means to track compaction / moisture test frequencies.
as described, With controls
improper placement and inspection are minimized. !
Errors are readily-evident during review of logs. '

'
6. ;
Core Drilled Penetrations
.,

location, elevattoa, and size

:
are vertfied by Quality, Cut rebar in
i
the penetrpions
concrete are
placement noted and documentation filed by the appiscabl e
number. Cut reca r
!
placements is t racked
in specific
concrete
I

nonconformance.
5y ' Civil Engineering to preclude
;
three: Rhou t All core drilling has ' been performed- by one crew
i the. power black and would assure
resulta. consistency oi
{' .irea. 92 significant
Piping hscrepancies have been identified in this
pla' cement
,

; and sealing operations .31so require

iertrication of penetration location and acceptability .

:h
;
.

1
5

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

7.
Post Applied Plates /Expansicn Anchors
' __

Proceifures and Quality checklists provide

nonconforming installations. hold points -n:ch preclude
Ve n f i ca t i ons include bolt length and
size, concrete
pattern,' surface
location and surrounding area, sa:e of plate, bolt
of installation,
'
Location and bolt torque.
acceptability
performed is further
by other vertised when attachment to plates
disciplines. is
Acceptabilit'/ of expans:on anchors
' is performed
criteria. solely by Civil Quality to assure uniform knowledge
activity resulting program
Several audits have been performed on this
in program enhancements
electrical installations per NCR ISN 3476C. and a retrofit of
At KG&E's request
an investigation was initiated by DIC to determine
the retrievability
applied plates. of installation documentation associated with post
KG&E provided a
{
Mil-Std statistical sampling plan based on
b 105D, which
accepta'ility established the sample size and AQL to determine
.
'
of the total population., The results of the
investigation were well within the
established . acceptability level.
B.
Structural Steel Bolting

Drawings
inspection are
and used by Quality personnel in ef forts to status their
acceptance. As connections are inspected
;

accepted a and-
{ inspector. drawing is highlighted, initialed and dated by the
;
When all connections per an evaluatacn are finished an
'

Erection Checklist is completed for that elevation. The drawing is

1
i attached and retained as a QA record.
;

!
In~ addition, connections that
are disassembled subsequent to
inspection must. be brought to the attention of QC via written
notificatien.
;.
At that
-ritten notification time QC maintain status of tne jetnt.
is placed The
j is ~ annotated ' accordingly. in a suspense file and/or the drawing
Both are used as gutek reference before
turning over documentation to Document Control.
'

Structural steel
holting has been further addressed on DIC CAR l-C-0026.
i 9.
! Structural Steel Welding-
The
completion of acceptable retraining on April 1,
' 1951 emphasized
to a11 welding inspectors, including those inspecting AkS weld s, the
Aimportance of assuring welds . satisfy established acceptance criter
*
100*. weld reinspection was ia.
initiated at this time on ASME, B31.1.
Critical, Spec 2al Scope.' Component Supports, liowever, structural
;

steel welds were not included in this reinspection ef fort and were
L
subsequently addressed on DIC CAR-1-W-0029 (NCR ISN-103SI-PV) for
fillet- welds and .DIC CAR-1-V-0031 for missing MSSWRs. Further
investigation necessitated the KG&E CAR 19 evaluation erfort .

Ik

+ ~ -, = y a e ,, ,, y - ,, .,. - - - . , , ,
 The %;1 ding of es tructural steel at
'a e l : Creek Nuclear Plant was
-
essentially complete as of April ! ;951. April 1. :931 ts a
significant date in the htstory et tne '-olf Jreek Project ta that it
signified the date when all retraintr.:; ei D!C Weldant Inspect:rs was
completed for fillet weld inspectten (Ref. E!C CAR |-W-00: 91
Subsequsnt to April 1,
1981 ~ all fillet selds installec in A5':E anc
Special Scope applications were reinspected in strict compilance
with Design requirements. The reinspection was the result of
significant deviations' from acceptance criterta on >upport selds
accepted prior to April 1, 1981.

Section III ADDITIONAL !!EASL'RES OF CONTIDENCE

A. The following are additional actions that have taken place to assure that
.a satisfactory level of confidence exists to assure compliance to 10CTR50,
ANSI N;5.2, FSAR, Design and Procedural requirements.
The initiation of the KG&E Construction / Start-up Walkdown Group has elven
KG&E an added level of confidence in the Quality of the Daniel inspection
program. This walkdown was performed by KG&E personnel a t ter rec e ivin:;
notification from Daniel that the hardware installations vere complete and
accepted by DIC Quality. This 'valkdown was performed usine tne DIC
installation traveler design documents for pipe supports. All c.t h e r
inspections were performed using the A/E design . drawings and detatis.
This verification was performed by inspecting for the attributes detined
by the A/E as key quality characteristics. Inspections were performed on
Pipe, Pipe supports, !!echanical Equipment. Electrical Te rminaticns , iiVAC .
Civil and Electrical Room and Area Turnovers. Upon ecmpletion .si thew
walkdowns, discrepancies were identified to Daniel and were nanaled in
accordance with approved applicable procedures. Reworr.s associated witn
any of these discrepancies were also inspected by the 'walkdown group.
While these walkdowns have identified discrepancies they have also served
to strengthen the program by making the construction organizattens aware
of weaknesses. No major generic problems have been identtiied . durine
these walkdowns.

The effecitveness of this walkdown can by shown through the additional

walkdown that has been performed by KG&E QA. A summarization of the
purpose and results of QA's walkdown can be f ound in Section III;C letter
KQCLKQ-54-111 dated 11/27/84
S. In adhtton to- the KGLE Construction kalkdown .the 79-1+
walkdown _has been performed by 13echt el Power Corporation. This
walkdown was performed to assure - that final installations within the
stress bouncaries analyzed by the' A/E for N-5 scope were installed to the
A/E design -- reyut rements .Valkdowns were performed using destan drawincs
and . details. ' Discrepancies found were documented and either reworked ar
received a "Cse As Is" disposition by the A/E. During the 19-14 walk.1A n
there were no major. discrepanctes 'adentified that were generic in nature.
C. See attached letter KQCLKQ-84-111'

7
 D.
A review of Daniel and KG&E generated CARS was performed to determine if a
Quality 3ssurance prociems existed as were nsted in KC&E CAR 19. ny
Excluding the two DIC CAR's (29 & 31) that are associated with KG&I CAR
19, there were no other CAR's that had significant problems pertaining to
Daniel's inspection and documentation that were not properly closed out
through installation inspections and /or documentation reviews.
See
attached letter KQULKQV-64-456 for review of KG&E generated CARS .
E. Inspections by the NRC have been
disciplines.
These include the following as a mintmum, conducted in all the major constru
o
Electrical installation and Terminations
o
Mechanical supports for Pipe, Electrical and HVAC
o
Mechanical installations including bolting
o
Civil (Concrete and Coatings)
o Material Control
o Traceability
o
Nondestructive Testing
o
Personnel Qualifications (Welder and Quality Personnel)
< o
Procedure Reviews (All Disciplines)
Although some inspections by the NRC have
have been resolved through their noted program - inadequacies , these
nonconformance program. violation _ reporting system or the DIC
Areas of concern
continually made recognized by
KG&E aware of potential problem
the NRC have
requirements and project commitments. areas, regularatory
benefiet i to the Quality Assurance Program
All these items
here at collectively have been
our ove: 411 program. WCGS and have strengthened

F.
4 Construction
Co rpo ra tion. Self Assessment- (CSA) was performed by the Delian
of The
construction at basic objective of the CSA was to evaluate the adequacy
the site.
A sampling of construction hardware was
selected frem.the following disciplines:
o
o Electrical and Instrument Construction
o Mechanical Construction
o Velding and Nondestructive Examination
o Civil
3: and Structural Construction
o 4terial Traceability and Maintenance-
o
Quality Control Effectiveness
Quality Assurance and Engineering Change Control

t
 !
,

The prima ry er all conclusion frem the CSA c: fort is :nat, based cn the
hardware and d6cumentation reviewed. Volf Creek construction workmansnap and
inspection practices appear _ equal-to and. in some
standards. areas, better than industry
The hardware and documentation revtew
of installed and ' quality control accepted hardware. included.detatied inspecticns
the hardware, together with the The size and diversity of
each- item inspected, provided substantial number of attributes examined for
constructed -- i n accordance reasonable
with design
assurance
and
that kolf Creek is(
requirements. installation procedure
documented on a CSA concern /closeform.
outDiscrepancies which were detected durtng th

(
9 '
 I

#C e m IIPP 900 1 0F
SEC7!!N !!! C

-- | ---
I NT E,R O F FIC E CORRESPONDENCE
-

A
'IO: R. M. Grant, Director O.:ality K0CI.RQ 84-111
FBOt:
G. W. -Reeves, Saoerintendent OJality Control h@ m'
DE: November 27, 1984

SEEJECT: KG&E OA Walkdown Surveillance Procram

This correspondence is to s=rnarize the pur;:ase and results of the KG&E CA

WalMown Surveillance Prograa.

In December,1982, the EG&E CA Surveillance Section peformed a hardware and

doctinentation review of the second mechanical systen to be turned-over fran
the Constructor
System (BN) . (DIC) to KG&E. We syste:n was the Refueling Water Storace
The problens identified suggested that neither DIC nor KG&E
were sufficiently aware of the status of incatplete work, nonconformances
and doctrnentation at the time of turnover.
Se tac used the results of the "BN" surveillance as the prirury basis for
enforcement action ard civil penalty. In res;cnse to the tGC, KGLE ~

c
forrnitted
systentoturnovers.
an enhanced hardware
Additionally, walk $own
in ouder and continued
to assure doct:nentation review effort
cornpliance,
turnover. KG&E comitted to KG&E QA surveillance coverase of each system
this NRC cormtittment.The KGLE GA WalMown Surveillance Group was formed to satisfy i

Primarily, the CA Walkdown Surveillance effort monitored the effectiveness

of the KGLE Construction Walkdown program.
This was accm plished utilizing
a team of O' inspection personnel hired specifically for this purpose - each
person hired had been certified by a previous employer.
Se QA walkdown team was divided into three disciplines; electrical,
piping /HVAC, and hanger / instrumentation.
At the time of each safety related
system turnover, each group would walkdown a portion of the systen - about
20% of the hardware / documentation w>uld usually be checked. Attachment 1
identifies each
Surveillance safety-related
Report (s) . system and the corresponding OA Walkdown
Instructions and checklists were develooed which
identified the attributes to be checked during the walkdown surveillances .

Findings fr:n each walkdown surveillance were compared to the systen

exception list and the results of the KG&E Construction Walkdown. %= most
significant findings ware normally found to have been previously identified;
those
of items not quality
a significant identified were typically variods and minor - not indicative
program breakdown.
Quality Program Violations
(QFV's) were issed
were identified. ', hen specific, inclementation or programmatic weaknesses
IC&E Construction turnover efforts.These QW's
Attachment 2 depicts the served
ntrnber ofas constructive
, QFV's issued
surveillance to KG&E Construction as a result of the QA walkdown
effort.
,
misissued
OFV's; only one OPV was chart detonstrates the effectiveness of these
after tbvember,1983.

.
 -

KG&E CA*a E M 3 S M I U U
, . .
.

Overall, the KG&E OA walMm su i

{;r,]ffn n
turnover /walMm progra to e
incomplete work; nonconformances, ,}{E}{e*
L s.a f
d mentation at the ti e of turrover.

GG/rw

*e

I
 . :- ? -
Attachment 1
?*;e 1 of 6
EL!r."RICAL DISCIPLINE
.

System
Surveillance
_ Retort 2. Systen Surveillance
Re:nrt !b
NG S-675
SA NE
S-676, S-748 S-750
BL KJ S-775, S-797
S-677, S-783 EN
RL-1 5-678, S-747 S-776, S-777
RP-2 AC-2 S-779
S-685 PJ
RP-1 S-686 S-780
GF-4 PK
S-711 S-761
KA GF-3 S-796
S-712, S-774
EG- LE
S-713, S-745 S-822
GE BN
S-714, S-751 S-828
NK AL S-829
S-716
GK S-717
FC-1 S-719, S-753
NE
S-719, S-800
DC-1 S-727, S-755 .
JE S-728, S-752
S3
S-730
GD S-731, S-759
( BM
S-733
E3-1 S-739, S-754
AS
S-740
EF-1 S-741
EM-1 S-742, S-320
EM-2
S-742
BG-1
S-744
BG-2 S-744
GL
S-746, S-823

v --
 Attacnment I
, . Pre 3 of 6
'
F#.C DISCIPL!hT

Surveillance
System p,3aart yg,

GD S-695
G." S-736, S-914
GL S-759
GK S-763
GG S-782
GN01 S-896
GT S-897
GK g ggg
GP S-901

.
 . . _ -
._ _ _ .

, , .
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-

Attachment 1
Pre 2 Of 6
PIPING DISCIPLINE
'
.

Svstem Surveillance I
1

Reoort No. Svstem Surveillance I

Feoort No.
_

AL -

S-666 !
AB-1 H3-1
S-673, S-702 HK
S-1001
KA
S-674 S-1003
EN ,
S-684 j
AE
S-689
BM
S-690 i
BL
S-701 i
EG
S-749
EF-1 S-757
'
BG-1 S-766, S-961
BG-2 S-766, S-997
BC-1
FC-1
S-768, S-900, S-1007 '
S-769
JE S-722, S-1004 .
EM-2
S-785
HB-1
S-786 .
EM-1
S-806
U
E3
S-816
S-821
.
KJ
SJ
S-837
S-838
EF-2
S-844
EP
GM S-854
S-884
,
BG-3
i
GP S-886
S-901
EN-1
S-913
,

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. _ _ _ _ - _ . _- - _ - - _ - - - - _ -- - _-_ _ - _ - ._ _ -_ _
 - - ..-. .. _ _ _ - - . _ . . .. - . . . . . .- . . - - - . . _ . . - . . .

.,

. ---- " **
' * Attac.w nt 1
.4;e 4 of 6

PETMNICAL ,

,
i
EQUIP *.DO DISCIPLU;E (Pefomed by . ur.a/hWC Group)

Syste
Surveillance
Retort m.

S-813
EJ S-815 ,

KE-1 S-317 )
; B3 s-833
i Gi-1 S-841
AL S-942
BN
S-846
GF-4 s-914 '

EC
S-928
EF-2 s-943
G S-999
@ S-1002
EP
S-1005
GL -
c_1014
.

t
4

i
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!.

e.

te
.

i
9

___m,____ ____ _ _ _ _ _-- - - .----- - - - - - - - - - - - - - - - - - - - ^ " - - ^ ^ ' ~ ~ - ^ - - ~ ~

 --

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A::20. ten: 1
Pre 6 of 5
INSUE.T CATION DISCIPLINT
.

System Surveillance
Pe:crt !b.
AL
AS-1
S-696, S-910
B3
5-697, S-881
EM
S-698
EF
S-699
PC-1
S-720
BN
S-721, S-942, S-452
B3 S-722
KJ S-852
JE S-883, S-916
KA
S-883, S-931
GS S-883, S-931
GK S-1141
GN S-942, S-952
GG S-952, S-1024
EC S-952
-
EN S-974
EP 5-974
/ AE S-1024
C S-1155
BG S-1155
GT S-1156
HB S-1141
SJ S-1141
S-1141

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AIA :0'E*.T TO SECT ::: ::: D |
-.. ..,,... ...,

', ---
_,
1NTEROFFICE CORRESPONDENCE

'lV: W.J. Rudolph II

i
K3C Qi 94-456
FRCM:
7.W. Malecki 7 M
DATE: Novemoer 26, 1984 i
j
SN: Feview of KGLE Generated Corrective Action Recuest I
i

In support of KO&E CAR No. 19,

CAR's. I have reviesed all of the KC&E initiat.d *

The general review was conducted to determine if any of the CAR's

were similar in nature to the Quality Assurance problems as noted by KG&E 7
CAR No. 19. CAR No. 19 noted inadequacies in insoection and doct nentation- !

by Daniels.
This review will determine if other CAR's pose any significant
proolems as far as insoection oy Daniels. I.isted below are the CAR's
reviesed and the results of the review.
'

CAR No. SUBJECT

,

SITE IS C
!
1 Orawirgs out of revision t
!:o Imcact |
2 |
Storage vault does not contain the proper No Imcac
*

enviro =. ental controls 6

&

3 ::o security procedures .. , ._

. ~ ... .ca ... i
,
-

t,
4
Colf Alloy not providing the correct d:yerentation No Irpact
for various fittings |
v {
5 Internal pipe cleanliness ::o Impact
6 Internal pipe cleanliness ::o I pact
,
7 Internal Pipe cleanliness '
.
i:o I act
8
Inadeqc. ate document control on obsolete docrents !:o != pact
and enange infor.ation not controlled and translated
into travelers-
9
Ceficiencies in the mechanical / welding surveillance ::o Impact
program, surveillances not being perferned as
prescribed

13
CE not reviewing travelers for accuracy No Impact
11 Not issued
N/A
12

( Work Pequest not properly processed, temporary

modification log used in correctly and nonconfor-
mance reports not properly initiated, tracked and
No Impact

closed.
-

'

.
.
l
,
,
.
N'M.F.W 84-456
h;e 2
k . t -+ *

13 Permanancy of corrective action

No :mpact
14
Insulation centractors tampering with pice supports :o I:cact
15 .Minimtra separation violated
No I. pact
16
Inadequate doctraentatien and doctrnentation review
No :mpact
17
, Inadequate review, processing and doe.:nentati:n
pertaining to h3 E Work Request No Imoact
~

18
T
Start-up Field Reports not being properly processed No Impact
<
19
. Miscellaneous Structural Steel Welding (L'S-Dl.1)
(This is the subject of the CAR Review) N/A

20
Lack of p:ocedural compliance for start-up and No Impact
operations activities
I
In strr.acy, other than CAR No.19, 4

to Daniels inspection and doc.:nentation were noted by tne reviewno other sig! .
f
74H/sjs
' (' . 1
RESPCNSE RECUIRfD: YES BY:

10 'X
,

f
.

k..
#
>

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e

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.

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,

i
i
THIS SECTION OF THE AFFENDIN IS A LISTING OF ALL SUPPORTIVE AND INVESTIGATORY :

i,
DOCO:ENTS UTILIZED I' PREPARATION OF THE 1GLE CAR-19 FINAL REPORT. THE VOLU'!E
OF THESE COLLECTIVE ODCL'!ENTS PROHIBITS THEIR INCLUSION IN THE EODY OF THE FINAL I
REPORT. THESE DOC'.::ENTS HAVE EEEN TRANS.'!ITTED TO i:G&E QUALITY ASSURANCE AND ARE
. .7 AIL'i2LE AT Ti!AT LOCATION.
!
,

h
!
i
>

I
.

i
L.
o

.
h
'
16. DIC Quality Engineering interview re-
f sults with:46 Qualitt WeIding inspec '
tors - Corrective Action Ic IV ?indings/ Corrective Act: ens
17. c

Information from other utilities /A-E's

on inspection of welds - Corrective
Action Id IV Tindings/ Corrective Actiens
18. Letter ELEES-13'B, C. Herbst to G. Tou:s, I
of 11/5/84 - Corrective Action Id IV Findings / Corrective Actions j
19. Letter RNPLKWC 84-065 J. Bailey to G.
:
I

Touts, of 11/13/84 - Corrective Action Id IV. Findings / Corrective Actions

, ;

20. DIC Comparison of ANSI N45.2.6 require- 1

ments, 1973 vs. 1978 - Corrective j

Action If IV. Tindings/ Corrective Actions
4

21. Mapper printouts of statistical data

compiled frem reinspections - Corrective
Action if IV. Findings / Corrective Actions
22. DIC. Quality Engineering analyses of rein-
spection data - Corrective Action 2a IV. Tindings/Correc:ive Acti1ns-
23. Design Change Notice C0011 Rev. 7 of
'23/78 - Corrective Action 2a IV. Tindings/Correc:ive acticns
24 Drawing C0011, Rev. 12, detail 10 and
note.14 - Corrective Action 3a. IV. TindingsiCorrective 1.ctions
25. N'CR ISN 20509CW on Pressurizer Supports -
Corrective Action 3a. IV. Findings / Corrective Actions
26. NCR's ISN 21308CW, ISN 21309C'.',11SN
.# 21310CV, ISN 21311CV on the Polar Crane
' girder radial stops - Corrective Action
3a'
- IV. Findings / Corrective Actions
27. .American Bridge drawing E117 detailing
Polar Crane girder radial' stops -
Corrective Acticn 3a !V. Findings / Corrective Acticns
28. P awing C-OS2963 detailing Polar Crane ~

girder radial stops. -Corrective Action

'3a s
IV. Findings / Corrective Actions
29. Drawings GOS2919, GOS2924 and C121-8773-
03-on Incore Tubing Supports - Corrective
Action 3a
IV.
.
_

Findings / Corrective Actions

.

30. NCR ISN 21273CV on missing channel clip

welds'- Corrective Action.3a
h- IV. Findings / Corrective:" tions
.

.
 _
.-

31. SCR ISN 20495CW on investigation of

/
missing welf dnspected by R. Smith - ''

Corrective Action 4a IV.

32.
Findin s.Corroc:ive Actions
NCR ISN 20796CW on investigation of
missing veld inspected by V. Barb -
Corrective Action La IV. Find:ngs/Corrn:tive Ac:: cts
33. KGLE Surveillance Report S -372 -
Corrective Action 5a IV. Findings /Correc:ive Actions
34
Summary Report for Corrective Action la IV. Fir. din;s/ Correct :ve Actions
35.
Summary Report for Corrective Action Ib IV. Findings / Correct:ve Actions
36.
Summary Report for Corrective Action Ic IV. I
Findings /Cerrective Acr. ions
37.
Summary Report for Corrective Action Id IV. Findings / Corrective Actions
35.
Summary Report for Corrective Action le IV. Findings / Corrective Actions
i 39.
Summary Report for Corrective Action If IV. Findings / Corrective Actions
40.
Summary Report for Corrective Action 2a IV. Findings / Corrective Actions
41.
Summary Report for Corrective Action 3a IV. i
Findings / Corrective Ac : ens
( 42.
Summary Report for Corrective Action 4a
?

IV. Findings / Corrective Act: ens

43.
Summary Report for Corrective Action 5a IV. Findings /Cerrective Actions
44
DIC Program Assessment Report 1. s
Executive Summary, '

II.
V.
Introduction. :
Conclusions
45.
DIC Corrective Action' Report.I-EW-0046 I.
t
Executive Summary
46.
Completed Corrective Action. Schedules
-for CAR-19 !

47. Listing of all DIC NCR's generated

.

durin; CAR-19 activities

.

|
:{
L
~ ~ ~ ~ + - - - - - - - - ~ - ---~~.,___,n_ _ , , _ , , _ , , , _ , , , , _ _ _ _ _ _ , , _

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k UNITED STATES
{ NUCLEAR REGULATORY COMMISSION
,
,y,-/ U.S. NRe"'amta o c ass
OFPICE op
emsteorrens h NOV 19 g g 4Q m , n s.s
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Hi iit loris'

Iht at t .n in J si. . un.t P. t s weri

req asted b- Mr H . , e r- 4 1 ) j 15, n 4 .
We t r ted *
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d1J < o tr < ~ < thrcugh is vou t l e.s r
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, s NUCLEAR REGULATORY COMMISSION
9',7 ALLE2ATION DATA FORM
instructons on rSverse $sde

RECEIVING OFFICE
Docket Number (if applicable)
1. Facility (ies) Involved: (Namel
m more than 3. or rf
genenc. wnte GENERIC)
[f)/) x > z< v v 0 5o oo </ f z
'

O R L I U A.T o d j AO6AS

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2. Functional Areals) Involved:
(check approonate bonies) i operations onsite health and safety
Y construction offsite health and safety
'

safeguards emergency preparedness , ;

other tspecity) -

3. Description: 14|( I A)l4 | j |Tl i IV I El | | | | | | | | | I I I | | | | |

(Lwrut to 100 cha acterst gggggjgg j

lIIIIIII IIIIIIIIII II III III |

l at y l- 1914l- lol6121 I i l | IIIIIIIIIIII |

4. Source of Allegation:
(Check appropnate box) _
contractor employee security guard
__ licensee employee news media _

NRC employee private citizen

_ organization tspecifyl
_
other tspecityi

MM DD YY
5. Date Allegation Received:
I I I 9 9 il
6. Name of Individual triest two initi.i end is.: namen k.Il. N1f k
Receiving Allegation:

7. Office: *

O I- RIt1
ACTION OFFICE
.

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9. FTS Telephone Number: ,

10. Status: |

ICheck one) - Open if followup actions are pending or in progress j

Closed, if followup actions are completed

MM DD YY
11. Date Closed: hk
W le
12. Ren. arks: | | | | j | j j | | ; | | | | | | | | ; ;
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3. Ass. ''Q '' J & &. w,fsJy /A,/A pir

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Q4-84-052

Two QC DIC Inspectors that claimed to have inspected welds

Reinspection revealed these_two welds did not exist _
RE! . NRC Reg 4 Inspection 84-22 dated 26 Oct 84 (pg 7. Para 3, line 4)
KG&E response CAR 19 DEC 84 *

Have NRC Accepted????? (5% power lic.)

PLAN

Interview two welders

Did you ever do it before?
,

Did anyone order you to make false inspection?

How did it happen?
BACKGROUND

CAR 19 identified 2 missing welds during reinspection. Weld inspection records

existed

Internal invastia,ation = HUMAN ERROR

Missing h 7% -mape.p#eAM M
W21d A InspectordEEEk inspected between 800-1000 structual steel welds (one error)
Beam connection very similar (same bldg coordinates) as steel directly below
Telecon interview = cause unknown / neg info

Missing [W'&"
Wald B Inspector sammh inexperienced (only 6 structual steel welds inspected)
confusion entering Joint numbers on MSSWR

related drawing found to be unclear and lacking clear designation of connection'

.

Feb 27,85 Public Meeting Between NRC and KG&E

Bill Rudolph (KG&E QA) "The missing welds, the missing material also
represented a QA program breakdown" (Pg.66)

Berra (DIC VP OPS) admitts discovery of missing welds (Pgs. 97 + 105)

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- - - - - - - - - - --
._______ __ _ _ _ _ _ _ _ _ _ _ _- - _ - .

.
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Conversation between R. K. Herr and Dick Denise on March 18, 1985: ;

1. NRC required KG&E to rainspect 100% of miscellaneous structural steel i

welding records (MSSWR). ~ ~

A. During reinspection, 91% of the welds were totally accessible.

6% were partially accessible.
3% were not accessible.
2. The blueprints (drawing), referred to in 4-84-026 regarding the fuel
handling building, were included in the 1001 reinspection.
3. The missing MSSWR for safety-related welds amounted to 1,509 out of
6,816. Region IV NRC is satisfied that the reinspection included the ;
welds of the 1,509 records that were missing. '

A. NRC Region IV inspection report 84-22, dated October 26, 1984,

identified the missing weld records and the missing welds that were
erroneously reported as being visually inspected. '

C B. K6*r e
KG&E answered report 84-22 with a, Corrective Action v s(rCAR)
No. 19 = d T L. 31.
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NRC, although KG&E identified the missing welds and the missing
MSSWRs, did not accept their resolutionjnd required the 100%
reinspection.
or edgy 3 /
4. On November 21, 1984, NRC forwarded to KG&E escallated enforcement action
amounting to a civil penalty of $75,000 for " failure to inspect" and
" failure to take corrective action,';(according to the Division Director,
NRC Region IV, KG&E did not preside o.. adequate ..=r iv 6M2 "ich
resulted in a possible inte pretation that KG&E failed ot maintain
records, even though the N v
maintain those records had not requirement, Nfor KG&E (Daniel) to
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28 of 33

Applicable drawings were reviewed for similarities in beam numbers, floor

layout and beams at similar locations in an attempt to further identify
possible sources of confusion. As a result of the investigations conducted
only two (2) cases were identified where inspection documentation existed for
_welds not in s t e l i e d --
-

The first case is the installation of bene No. 524E2 and its connection
to an embed in the Auxiliary Building. All available informatica indicates
that DIC Quality Inspector W made a human error when documenting the
g/ inspection of this beam connection. A review of the drawings shows that the
beam configuration and floor layout in the area (elevator shaft and equipment
hatch) directly beneath the beam connection in question are very similar. In

#' ,Q
y'
/
addition, the beam below beam 524B2 connects at the same buzicing coordi-
nates.

It is possible that Inspector W could have been one elevation beneath

where he should have been when inspecting the connection. Out of the
h
V
multiple welds inspected by Inspector W this problem occurred only once.
actions which would result in other conclusions had occurred, it would be
If
-

reasonable to assume that they would have occurred repeatedly. Inspector W's
signature appears on over eight hundred (800) MSSWR's. Each MSSWR could
document multiple weld inspections, therefore, inspector W very likely
inspected over one thousand (1,000) structural steel welds, with the result
that this type of problem occurred once. A telephone conversation between
Inspector W and DIC management personnel concerning this incident revealed no
information that Inspector W could offer, since he could not recall the
specific connection from the more than eight hundred (800) he inspected. The
root cause conclusion in this case is human error.
The second case is the installation of beam No. 95BS to an embed in tl.-
Centrol Building. All evailable information suggests that DIC Qualit;
Inspector X made a human error when documenting the inspection of this beam
.:sr connection. The _MSSWR documenting this connection shows Inspector X's
M sonfusion in that he entered the joint numbe_r incorrectly when filling out
this portioa of the MSSWR, then lined through, initialed and dated his error,
and entered what he thought was a corr m entry. Drawing K6711-XI-I-E13
6
details this connection, but is unclear in that it does not designate the
connection number for the beam clip to embed weld, and only lists the beam
[, ( seat number (91M1).
Further research revealed that Inspector X completed one hundred
eighty-three (183) MSSWR s during his tenure on site, but only six (6) o f_
these MSSWR's were related to structural steel weld inspections. This is
indicative that Inspector X was possibly confused by the details on the
erection drawing. It is probable that Inspector X attempted to document the
welds attaching the beam clips to beam 95B5, since no retrievable MSSVR is on
file for these welds. These circumstances are documented on nonconformance
report ISN 20798CW for disposition and resolution. The root cause conclusion
in this case is human error.

Finding #5 of CAR-19 stated, " Objective evidence that the mechanical and )
structural inspection / documentation problems identified in KG&E QA Surveil- I

lance Report S-372 were rectified has not been provided." I

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CAE /7 i/03
Th2 aissing aids id:ntificd for instel iens involving eth2r
miscellaneous materials and welds missing are of a smaller quantity.
Thorough investigation revealed the root cause of these missing welds to be
due to a lack of formal follow-up and inadequate statuses of completed work
and the subsequent completion of unfinished work. The missing welds on the
Incore tubing supports revealed that all investigatory information supports
the hypothesis that these missing welds were not installed due to oversite.
The four lateral support brackets, two at each of the vertical angle supports
(Incore tubing supports) located 32' 2 3/4" north of the Reactor Center
-

Line and 4' 10" east and west (one each direction) of Reactor Center Line on
Drawing GOS2919 were added by revision to drawing GOS2924 after the supports
had been presumed completed.

Nonconformance report ISN 21273CW documents missing welds on channel

clips to beam attachments. The channels that American Bridge Drawing
#C121-10675 shows welded to a beam web along A2 at Elevation 2042' are bolted
instead. The channel clips are bolted to the web using the same bolts as
removable beams on the opposite side of the web. Research found that the
installation of the ch annel and removable beam was late in the construction
sequence of this area, also. Since the channel clips and removable beam clips
are bolted through a beam web with the same bolts, the channel clip
attachment welds were probably assumed to be unnecessary by the construction
personnel responsible for installation. -

If the removable beams nad been disconnected for the purpose of

construction, it would have become necessary to weld the channel clips to the
bea= web at that time. The beams and channel in question were installed late
in the construction sequence of the area, removal of the beams never became
mandatory, the welds were not a recognized priority and were never installed
as required. The root cause of these missing welds is due to DIC error _in
assuming the bolted connections were acceptable rather than the recuired
yeles- In the miscellaneous group, investigations revealed that welds or
material found missing were those welds or materials that would not impede
construction progress related to that connection.

Finding I #4 o CAR-19 stated, "One (1) weld was documented as having been
inspected wh in reality the weld was not maae. We f . NCR ISN 20495CV)."_
Corrective Action 4a)
" Investigate the concern to determine the root cause of the error.
Immediately notify KG&E Quality Assurance if any other problems of this
nature are identified. Document the investigative actions. The notification
of KG&E QA shall not preclude the issuance of an NCR."
The results of the CAR-19 inspection -effort were tracked and each case
where a missing weld or miss ing material was identified was researched
thoroughly by DIC Engineering to determine whether documentation existed
pertinent to the installation of the missing veld / material. Miscellaneous
Structural Steel Weld Records (MSSWR's) were reviewed to determine if a trend
or pattern existed. Nonconformance reports identifying missing welds were
compared to MSSWR's te determine if there were repetitive occurrences.
'-

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3. Welding of Structural Steel

During a review of QA/QC and Quality First personr.cl qualific6tions and
subsequent interviews, the NRC inspector became aware of potential
problems with corrective action reports CAR 29 and 31. The NRC inspector
subsequently obtained copies of the two documents. CAR l-W-0029
(initiated on March 22,1983) states, in part', " Subsequently to the
issuance of . CAR l-W-0019, quality has instituted a random reinspection of
(Yg h
-

accessible structural steel fillet welds in 6110 buildings. It has been

determined by the results of this reinspection that an_unac_ceAtable
-percentage of these welds are deficient in the auxiliary, control, and
~ fuel buildings." Attacheir documentation revealed that in the auxiliary
building, (Q welds were inspected with 33 being rejected. In the control ,
and fuel buildings, 50 welds were inspe7c ed with 43 rejected, and 53
inspected with 35 rejections, respectively. Revision 2 to CAR 1-W-0029 .

stated in the disposition that the defective welds would be transferred to

a Nonconformance Report (NCR). The NRC inspector obtained a copy of NCR
ISN 10381PW which was used as the vehicle to carry out the direction
provided by CAR 1-W-0029. It appears that DIC Project Welding Engineering
[ gC1
o I personnel again reinspected the welds to more clearly define the nature
and extent of the defects on a weld-by-weld basis. A majority of the
defective welds were categorized as having * cosmetic" defects. The D1C
reconnended disposition was use-as-is for welds identified containing
" cosmetic" defects. The NCR states that " cosmetic" defects include arc
strikes, convexity, cold roll (understood to be synonymous with overlap),
porosity, and acceptable amounts of undercut. The NRC inspector noted
with respect to these defects that overlap is prohibited by the governing
AWS DI.1-75 Code and specific acceptance criteria for the other defects
are also defined by this Code. The engineer accepted the D1C
recocraendation stating, "This disposition is based on the understanding
that the cosmetic defects outlined . . . of this NCR do not constitute
violations of AWS DI.1-75." A written-in note labeled "5NUPPS cornent"
states that DIC had confirmed the engineer's understanding. NCR ISN
10381PW was completed as indicateo aboVE or. August 30, 1953.
'
On August 16, 1983, DIC personnel issued CAR l-C-03S1 which indicattd that

' [[b
L
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L approximatEly 16.4 percent of the miscellaneous structur61 steel wcidino
_ records for *r welding could not be located. After corresponding back
and forth, u n and the engineer concluded that it was acceptable for some
amount of these records to be missing, provided that the quality inspection
,

prograr. was accept Qb e Senior licensee QA management expressed to the

NRC inspector that the program had obviously been fully successful since
|
very few welds had been found to require repair after a substantial
reinspection effort associated with CAR 29. The NRC inspector expressed
concern wi'th this approach to resolution and suggested that the licensee
! reevaluate their position.

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On September 11, 1984, the licensee, in conjunction with senior DIC

manag:nent personnel, maJe a presentation to the NRC Task Force Director
and other NRC staff personnel, including the NRC inspector. The
presentation was aimed at the 0]C effort to provide adequate records of
inspection of the structural welds. This ef f ort involved the inspection
at that point in time of 319 weld joints in the reactor building for which
there appeared to be no records. Of these,.48 were found to not meet
code / design original
requirements. Several had been reanalyzed by the
engineer and found to provide adequate structural strength and were deemed
to be "use-as-is."
The NRC Task Force Director and the NRC inspector met with the KG&E
Project Director on September 14, 1984. The NRC personnel informed the
project director that the NRC position was that NCR ISN 10381PW had not
been properly disposition _ed and that, therefore, the underlying premise
'for the closure of CARS (29 innd /jhwas faulty. The NRC personnel stated *

that it appeared that the quality status of the majority of all structural
steel welds was at best indeterminate. The project director proposed to
have the engineer identify a group of structural members with the highest
design loads or the lowest design strength safety margin and to have these
joints inspected. The NRC personnel indicated that might be one possible
approach to resolution of the matter.
During the week of September 17, 1984, a reinspection of the identified
structural members with the highest design loads or the lowest design
strength safety margin was initiated. The reinspection identified a
number of welds which do not meet drawing requirements. This information
was presented to the NRC staff during a meeting conducted on September 25,
1964. In an effort to confirm certain of the identified cond'itions, the
NRC inspector accompanied DIC welding inspectors into the reactor building
to observe specific, identified weld joints. This observation confitned
the welding inspectors' findings; e.g., welds that are undersized and of
insufficient length, lack of fusion, and missing welds.

The rissino welds are f rom the same location in each of six pressurizer
_

support connections. Certain of the other welds in the pressurizer

support connections were undersized and of insufficient length. Drawing
No. C-05 2904 shows that various length 5/8-inch welds are required in 14
specific locations. Four locations required a 5/8-inch fillet weld of
8 inches in length. The actual welds in two of the locations measured
between 3/8-inch and 1/2-inch by 5 inches in length, and 1/2-inch by
3 inches in length. The missing welds and the undersized, insufficient
length welds are_ clearly not in compliance with the requirements of the
draeing or AWS Dl.1-75.FThe initial weld inspection records for these
~
~

. connections could not be loca_ted.

The NRC inspector accompanied two DIC welding inspectors for reinspection
of nine structural steel connections in the auxiliary building. Drawing
i

I
 - _ _ _ _ _ _ .
-- . .

O O
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-7-

No. K6720, applicable to these connections, shows 12 weld locations per

connection with certain of the welds requiring returns. Reinspection of
the welds and returns involved provided the following sumarized data:
Missing welds 2
_ ,

_
Welds with insufficient length 9

Undersized welds 6
_

-
Undersize welds with insufficient length 2

Overlength returns 44
_
'

Undersize returns 25
_

Undersize returns with insufficient length I

_

The NRC inspector requested the initial weld inspection records for these
welds and returns in the 9 reinspected connections. As of September 28,
1984, the only inspection records that were located pertained to 10 welds
and 6 returns in one connection, and 6 welds and 4 returns in each of 3
other connections. These records did not indicate that the welds were
anything other than acceptable. The licensee infonned the NRC inspector
of a situation where one inspection record for connection 524B2, clearly
indicated by an attached sketch, the existence of the a weld that
reinspection found not to exist. This problem will be followed up in
conjunction with the other structural steel problems.
The NRC inspector made a comparison between thc existing initial
inspection records and the results of the reinspection effort in order to
determine the validity of the initial records. The initial records show
that the 10 welds with 6 returns in one connection were inspected and
accepted on Decenber 11, 1976. The reir.spectior identifiec' one undersized
weld, other undersized and overlength returns, and three overlength
returns. The initial records for thc other three connections show that
eight welds with four returns per connection were inspected and accepted
on Septerber 8, 1979. The reinspection of these welds and returns '

identified two returns which were overlength and undersized and two
returns which were overlength per connection.
The failure to execute the required welding inspection program is a
\
violation of Criterion X of Appendix B to 10 CFR Part 50. (482/8422-01) '

4. Observation of Electrical Separation (Class IE Cables)

The NRC inspectors observed the completed electrical cable work for
confomance to the separation criteria specified ir. the FSAR, IEEE
standards and site procedures. The specific areas inspected were the
physical separation between redundant safety groups and between safety and
non-safety groups. The plant areas inspected were the following:
 - . - _ _ ____

28 of 33

Applicable drawings were reviewed for similarities in beam numbers, floor

layout and beams at similar locations in an attempt to further identify
possible sources of confusion. As a result of the investigations conducted
only two (2) cases were identified where inspection documentation existed for
_w elds not 2nstal w -
-

The first case is the installation of beam No. 524E2 and its connection
to an embed in the Auxiliary Building. All available information indicates
that DIC Ouality Inspector V made a human error when documenting the
g/ inspection of this Leam connection. A review of the drawings shows that the
beam configuration and floor layout in the area (elevator shaft and equipment
hatch) directly beneath the beam connection in question are very similar. In
addition, the beam below beam 524B2. connects at the same building coordi-
nates.

It is possible that Inspector V could have been one elevation beneath

where he should have been when inspecting the connection. Out of the
multiple welds inspected by Inspector V this problem occurred _oniv once. If
actions which would result in other conclusions had occurred, it would be .

reasonable to assume that they would have occurred repeatedly. Inspector V's
signature appears on over eight hundred (800) MSSVR's. Each MSSVR could
document multiple weld inspections, therefore, Inspector V very likely
inspected over one thousand (1,000) structural steel welds, with the result
that this type of problem occurred once. A telephone conversation between
Inspector V and DIC management personnel concerning this incident revealed no
information that Inspector V could offer, since he could not recall the
specific connection from the more than eight hundred (800) he inspected. The
root cause conclusion in this case is human error.
The second case is the installation of beam No. 95ES to an embed in the
Control Building. All available information suggests' that DIC Quality
Inspector X made a human error when documentinE the inspection of this beam
.:sr connection. ~ The MSSVR documenting this connection shows Inspector X's
2 confusion in that he entered the joint number incorrectly when filling out
this portion of the MSSWR, then lined through, initialed and dated his error,
and entered what he thought was a correct entry. Drawing K6711-XI-I-E13
details this connection, but is unclear in that it does not designate the
connection number for the beam clip to embed weld, and only lists the beam
seat number (91M1).
Further research revealed that Inspector X completed one hundred
eighty-three (183) MSSVR's during his tenure on site, but only six (6) of
these MSSVR's were related to structural steel weld inspections. This is
indicative that Inspector X was possibly confused by the details on the -

erection drawing. It is probable that inspector X attempted to document the

welds attaching the beam clips to beam 95B5, since no retrievable MSSVR is on
file for these welds. These circumstances are documented on nonconformance
report ISN 20798CV for disposition and resolution. The root cause conclusion
.
in this case is human error. . .

Finding #5 of CAR-19 stated, " Objective evidence that the mechanical and
structural inspection / documentation problems identified in KG&E QA Surveil-
lance Report S-372 were rectified has not been provided."
 _ ~. -- - - - _ -- ,

'
'. -

O O 22 .f >>

The missing welds identified for installations involving other

miscellaneous materials and welds missing are of a smaller quantity.
Thorough investigation revealed the root cause of these missing welds to be
due to a lack of formal follow-up and inadequate statuses of completed work
and the subsequent completion of unfinished work. The missing welds on the
Incore tubing supports revealed that all investigatory information supports
the hypothesis that these missing welds were not installed due to oversite.
The four lateral support brackets, two at each of the vertical angle supports
(Incore tubing supports) located 32' 2 3/4" north of the Reactor Center
-

Line and 4' 10" east and west (one each direction) of Reactor Center Line on
Drawing GOS2919 were added by revision to drawing GOS2924 after the supports
had been presumed completed.

Nonconformance report ISN 21273CW documents missing welds on channel

clips to be- attachments. The channels that American Bridge Drawing
#C121-10675 shcos welded to a beam web along A2 at Elevation 2042' are bolted
instead. The channel clips are bolted to the web using the same bolts as
removable beams on the opposite side of the web. Research found that the
installation of the channel and removable beam was late in the construction ,

sequence of this area, also. Since the channel clips and removable beam clips
are bolted through a beam web with the same bolts, the channel clip
attachment welds were probably assumed to be unnecessary by the construction
personnel responsible for installation.

If the removable beams had been disconnected for the purpose of

construction, it would have become necessary to weld the channel clips to the
beam web at that time. The beams and channel in question were installed late ;
in the construction sequence of the area, removal of the beams never became
mandatory, the welds were not a recognized priority and were never installed
as required. The root ta_use of these missing welds is due to DIC error in r

assuming the bolted connections were acceptable rather than the reauired !
y.g.lds In the ciscellaneous group, investigations revealed that welds or
material found missing were those welds or materials that would not impede
construction progress related to that connection.

Finding' #4 o CAR-19 stated, "One (1) weld was documented as having been
[ inspected wh in reality the weld was not mac e _. Wef. NCR ISN 20495CW)."~
~

Corrective Action 4a)

" Investigate 'the concern to determine the root cause of the error.
Immediately notify KG6E Quality Assurance if any other problems of this
nature are identified. Document the investigative actions. The notification
of KG&E QA shall not preclude the issuance of an NCR."
The results of the CAR-19 inspection effort were tracked and each case
where a missing weld or missing material was identified was researched
thoroughly by DIC Engineering to determine whether documentation existed
pertinent to the installation of the missing weld / material. Miscellaneous
Structural Steel Weld Records (MSSWR's) were reviewed to determine if a trend
or pattern existed. Nonconformance reports identifying missing welds were
compared to MSSWR's to determine if there were repetitive occurrences.
.

,_,m_ , _ ... - - - - -
 ,

KANSAS GAS AND ELECTRIC CO.MPAhT

FINAL REPORT

CORRECTIVE ACTION REQUEST NO. 19

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FINAL REPORT
KG&E CORRECTIVE ACTION REQLT.ST NO. 19

TABLE OF CONTENTS ,

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I. Executive Summary

II. Introduction ;
i
III. Objective

IV. Discussion of Findings and Corrective Actions

|
V. Conclusions ,

*
I
e

VI. Appendix
A. KG&E Corrective Action Request No. 19
|
B. KG&E Management Plan 1

C. Procedure Change Notice No. 14 to QCP-VII-200 |

D. Bechtel Analysis of Structurally Significant Joints / Welds
E. Reports on Inspection of Welds through Paint
1. Letter BLKES-1348, C. M. Herbst to G. L. Touts, 11/05/84
2. Letter KNPLKWC-84-065, J. A. Bailey to G. L. Touts, 11/13/84
F. Leh'igh University Report - Structural Steel Welds at Wolf Creek
Generating Station
'
G. White Paper on Weld Evaluations by Reedy, Herbert, Gibbons &
Associates, Inc. of August 11, 1983.
H. DIC Program Assessment !

I. Referenced documentation and filed location (separated by Correc- f

ti Action).
s
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y

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1 of 33

I . CAR-19 EXECUTIVE SUT!ARY

Because of deficiencies (i.e., undersize, undercut,...) previously found

in fillet welds on ASME and Special Scope hangers, D1C performed a randoc_
reinspection of structural steel fillet welds in February, 1983__in all "Q"
designated buildings in the Powerblock. This reinspection indicated that an
unacceptable percentage of structural steel fillet welds were deficient in
the Auxiliary. Control and Fuel Buildings. A Corrective Action Report (CAR
1-V-0029) was initiated by DIC to implement reinspection, and nonconformance
reports were generated to document and disposition deficiencies noted.
Subsequent to the issuance of CAR 1-V-0029 it was determined, during the
course of document reviews in the Building turnover process, that Miscel-
laneous Structural Steel Weld Records (MSSWR's) could not be located as
procedurally required for all structural steel welds in "Q" designated
buildings. These missing MSSWR's resulted in DIC issuance of CAR 1-C-0031.
The concerns addressed in CAR's 1-V-0029 and 1-C-0031 as well as other
items listed in the " Introduction" section of this report caused KGLE
Construction Quality Control to initiate a limited inspection verification
program. Through this inspection program additional concerns were raised as
a result of the inspection verification results. These reruits identified
instances of missing welds which had no inspection records, two missing velds
which had inspection records, hnd welds with inspection records that did not
completely comply with project inspection and documentation criteria. The
results of the verifications combined with the missing weld inspection
records identified the need for a formalized action plan to fully investigate
the concerns and formulate corrective action as necessary. To accomplish
this KG&E QA initiated Corrective Action Request 19, describing the concerns
and recommending corrective action on October 17, 1984. Based on the correc-
tive actions recommended by CAR-19 and additional actions deemed warranted in
support of the investigations, a Management Plan was developed to designate
the nature and extent of the investigations.

The Management Plan covered three basic categories of investigation and

evaluation. One category was a process of reinspection to identify and
evaluate actual hardware conditions in me field. a second category addres-
sed the programmatic aspects of Structural Steel erection through evaluation
of both construction and quality program procedures. A third category
addressed related considerations such as other AWS DI.1 applications, evalua-
tion of missing welds identified during the reinspections, evaluation of
acceptable inspection records completed for welds found to be missing, and
review and evaluation of surveillances, audits, and reports pertinent to AWS
welding. Although not initially in the scope of KG&E CAR-19, non-welding
related quality programs were reviewed for comparable programmatic deficien-
cies. In accomplishing this KG&E and DIC conducted an extensive program
assessment of the Piping, Hanger, Mechanical, Electrical and Civil disci-
plines to ascertain the adequacy of the construction and quality programs
instituted. This program assessment was conducted by KG&E and DIC Hanagement
representatives, and concluded that a satisfactory level of confidence exists
to assure compliance of these to 10CFR50, the FSAR, ANSI N45.2, and design
and procedural requirements.
-
The intent of the program evaluation was to evaluate the various
, construction and quality programs / procedures to determine their compliance to
the AWS D1.1 Welding Code and FSAR commitments. This evaluation included

_ _ _ _ - _ _ _ _ _ _ _ _ _ _ - _ - - _ _ - _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ - - _ _ _ _ - _ _ _ _ _ _ - _ _ _ - - _ _ __ . _ - _ _ _ _ _ _ _ _ _ _ - - _ _ _ _ _ - - - _ _ _ - - .
 2 of 33

relevant aspects of the various related programs from the initiation of

purchase orders for procurement of structural steel and welding materials, to
final installation and qualitv acceptance. The procedures for receiving,
storage and handling of materials were evaluated, as well as compliance of
procedures for training and certification of inspectors to ANSI N45.2.6 and
welder qualification to AWF requirements. The procedure reviews included a
thorough evaluation from cheir origination through subsequent revisions,
including an analysis te assure current conformance to design document
requirements. No findings were noted that were determined to be contributing
factors to inadequacies in AWS D1.1 applications, although some procedural
inadequacies were discovered and reconciled.

All other safety-related programs utilizing AWS welding were analyzed to

ensure that the root cause identified as the reason for previous acceptance
of deficient structural steel welds was not inherent, or impactive, to these
programs as well. The method of documenting weld inspections, control of
this documentation, and cecountability to assure all required documentation
was retrievable was resecrched for AWS D1.1 welding applications in raceway
supports, electrical equipment, mechanical equipment, fire dampers, safety-
1
related HVAC ductwork and supports, miscellaneous steel and e= bed f abrica-
'
tion, and pipe whip rertraints for assurance that problems similar to those
encountered in structural steel did not exist. Previously compiled infor-
mation including Constru: tion Self Assessment Reports, KG&E QA Reports and
Surveillances, DIC QA Re; orts, DIC Project Monitoring Program Audits, and DIC
Corrective Action Reporus were reviewea to determine if the results of
previous investigations indicated other potential problem areas relevant to
AWS D1.1 welding. No fundings were noted that could be considered to be
contributing factors to inadequacies in AWS D1.1 programmatic applications.
An analysis of hardware installations for other prc, ject applications of AWS
D1.1 welding identified one other area to be investigated for AWS welding
problems. This is in the area of electrical equipment installations where
the method of permanent insta11ction is by welding the equipment mounting
frame to foundation embeds. DIC is addressing this potential problem on
Corrective Action Report No. 1-EW-0046.
Reinspection of field welds was conducted utilizing AWS Certified
Welding Inspectors who were also certified to the DIC Quality Program
requirements of ANSI N45.2.6. Inspections were performed in strict
compliance to the Inspection Verification Plan which established inspection
criteria and documentation requirements, and was incorporated into an
existing DIC Quality Procedure, QCP-VII-200, and approved by DIC, Bechtel,
and KG&E.

DIC and Bechtel research substantiated that all welders and welding
procedures applicable to AWS D1.1-1975 welding of structural steel
installations were qualified in accordance with AWS requirements. Research
by DIC and Bechtel resulted in assurance that the programs and procedures for
the purchase and control of weld filler materials used in AWS DI.1 applica-
tions were in compliance with AWS requirements, and were properly implemented
on site.

The retrievability and control of Miscellaneous Structural Steel Weld

Records was thoroughly researched, and a determination made that inadequate
* implementation of DIC Construction procedures was the primary contributing
' factor relative to retrievability and accountability problems in this area.

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3 of 33

An evaluation of the DIC Quality inspection training program demon-

strated that this program and related procedures were in compliance to ANSI
N45.2.6. Further investigation concluded that Quality inspection training
was appropriate and adequate during the structural steel installation time
frame.

An evaluation of DIC Quality inspection procedures and criteria

applicable to the original structural steel installation / inspection period
revealed several procedural inadequacies. A thorough analysis of the
omission of each inspection criterion of AWS D1.1 structural steel applica-
tions was accomplished, with the conclusion that no adverse impact had
resulted from these procedural inadequacies relative to AWS D1.1 welding
inspection.

Inspection criteria to be used in the structural steel reinspection

activities was procedurally defined and training of all personnel completed
prior to reinspection initiation. Sufficient technical justification was
established by Bechtel to validate inspection of welds through a predeter-
mined maximum thickness of paint. An analysis of reinspection results
determined the root cause of the previous acceptance of deficient structural
welds to be due to DIC inspection implementation differences relative to
inspection vs. reinspection techniques, and inadequate implementation of
applicable DIC procedures during original inspection efforts. These inspec-
tion implementation differences are discussed elsewhere in this report,
referencing the Reedy, Herbert, Gibbons documentary included in the Appendix,
section VI.G.
Two joints (each missing one weld) of the two thousand six hundred
sixty-nine (2,669) reinspected (representing more than 11,000 welds) had
documentation reflecting the installation of these welds when in reality they
were not installe_.
d

Research revealed no evidence to indicate that either was a case of

deliberate falsification. Additional investigations did indicate that human
error was the cause of incorrectly documenting these nonexistent installa-
tions. *

Reinspection found that approximately two (2) percent of the inspected

welds were not installed as required by design documents. These errors were
primarily due to craft / engineering confusion relative to installation drawing
details and requirements. Failure to install these welds and materials,
although in some cases determined to be significant in impact to stress
allowable calculations, would not have resulted in material or structural
failure if left uncorrected.

The total number of joints subjected to the reinspection program was two
thousand six hundred sixty-nine (2,669). These joints were selected oy
Bechtel as structurally significant (See Appendix IV. D) with the
distribution being: 693 in the Auxiliary Building, 1300 in the Resu.or
Building, 265 in the Control Building, 98 in the Diesel Generator Building,
36 in . the ESWS Pumphouse, and 277 in the Fuel Building. The reinspection
documented an as found condition regardless of the weld acceptability. All
\ results were forwarded to Bechtel in the form of inspection data sheets for
evaluation. This evaluation was based upon Bechtel's review of reinspection
data accumulated and nonconformance reports (NCR's) generated. The evalua-
tion for structural adequacy was made based upon this cumulative data that

_ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ . _ _ _ _ _ _
 . - - _ . . . _ .

; 4 of 33
,

I '

reflected the as-built condition of the structurally significant joints prior

5 to any rework or repairs. No deficiencies were identified, which if left
i uncorrected, would have adversely affected the safe operation of the plant. ;
'
The results of this evaluation provides assurance that Safety Related AWS
D1.1 structural steel welding complies with all Quality criteria as specified
in the related design documents, and is within the tolerances of acceptable
deviation as determined by the Architect / Engineer.
Joints that In the as-built condition were determined to exceed the
design allowable stresses were all reworked. In addition joints in which the
design allowable stresses were not exceeded in the as-built condition but
; were missing welds &ere also reworked.
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 -

5 of 33

II. INTRODUCTION TO CAR-19

.

A series of activities as identified below pertaining to weld inspection

at Wolf Creek ultimately led to the issuance of KG&E CAR-19 addressing AWS
D1.1 Structural Steel welding concerns.
In September, 1980, DIC initiated Corrective Action Report 1-M-0007 due
to improper inspection technique application, which required 100*, reinspec-
tion of all socket welds on small bore piping installed prior to June, 1980.
Subsequent to this reinspection effort, DIC generated Corrective Action
Report 1-W-0019 on August 17, 1982, due to a significant quantity of fillet
weld discrepancies being identified, which required 100". reinspection of all
fillet welds on ASME and Special Scope piping hangers made prior to April1,
1981. DIC performed a random reinspection of structural steel fillet welds
in February, 1983, in all "Q" designated buildings in the Powerblock to ,

determine whether structural steel welds may have been deficient as a result {
of the same root cause relative to CAR 1-W-0019. It was determined from '
these reinspection results. that an unacceptable percentage of structural
steel welds were deficient in the Auxiliary, Control, and Tuel Buildings.
Thus CAR 1-W-0029 was initiated by DIC to implement reinspections, and
nonconformance reports were generated to document and disposition the
deficiencies noted.
i

As a result of documentation review prior to building turnovers DIC

initiated CAR 1-C-0031 in August, 1983, to document that Miscellaneous
Structural Steel Weld Records (HSSWR) could not be located as required by
procedures for all structural steel welds in "Q" designated buildings. .

Nonconformance Reports were generated to document missing MSSWR's in each of (

these buildings. -

KG&E and DIC site canagement held meetings in May, 1984, to further I
;
discuss retrievability of MSSWR's and the problems that had been identified
to date. Concerns were expressed through KG&E Quality First to KG&E
Construction Management regarding the acceptability of "Use-As-Is"
dispositions given to NCR's written as part of CAR 1-C-0031's corrective
action in July, 1984, and KG&E Management requested DIC to generate a
revision to CAR 1-C-C031 in letter KWCLC 84-814 of July 30, 1984, in response
to some concerns noted. Revision 6 to CAR 1-C-0031 was generated by DIC in
response to KG&E's concerns.

KG&E Quality Assurance performed a detailed review of DIC CAR 1-W-0029

and 1-C-0031 in August, 1984, identifying numerous concerns to KG&E Construc-
tion. In response KG&E Construction began a documentation reconciliation
task on August 13, 1984, to determine which safety-related structural steel :
welds did not have supportive MSSWR's.
On August 17, 1984, KG&E Construction Quality Control initiated an -

Inspection Verification Plan to provide an accurate assessment of the {

"as-built" conditions of safety-related structural steel s*1ds without
MSSWR's. DIC and KG&E Management discussed revision of this inspection *

program on August 30, 1984.

KG&E, DIC and Bechtel made a joint presentation to an NRC Task Force on
'
b September 10, 1984, which identified the belief at that time that the problem
was one of document retrieval, and not a hardware problem. The NRC Task

i
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 6 of 33

Force discussed the problems with KG&E again on September 13, 1984, during -

which KG&E Management agreed to perform a sample hardware inspection of six

(6) randomly selected structurally significant joints in the Reactor, Tuel,
Control, Auxiliary, Essential Service Water, and Diesel Generator Buildings.
This inspection resulted in the discovery of missing welds and missing
structural members, which were reported to the NRC by KG&E under
10CFR50.55(e) on September 18, 1984. Subsequent meetings were held with NRC
Representatives on . September 25, 1984, and September 28, 1984, to status
inspection efforts and provide information updates. An AWS Welding meeting
was held with the NRC on October 19, 1984, on site relative to structural
steel welding, with a follow-up meeting on October 22, 1984, in which KG&E
Management discussed AWS structural steel welding concerns with the NRC.

On October 17, 1984, KG&E Quality Assurance issued CAR-19 to KG&E

Construction to obtain corrective actions associated with AWS D1.1 structural
steel welding. The findings addressed in CAR-19 included missing MSSWR's for
safety-related structural steel welds; deficiencies being identified in
previously accepted structural steel welds, missing structural welds or
missing structural material; and documentation that a weld was inspected and
accepted, but no weld was installed. ,

KG&E and DIC Management representatives subsequently developed a logic

chart to organize resolutions relative to CAR-19's concerns, a Management
Plan to implement corrective actions, and published a CAR-19 Corrective
Action Schedule to provide a means for tracking corrective action progress.
In addition, KG&E Management contracted Lehigh University to review the
problems associated with the structural welds in the structures at Wolf Creek
Generating Station. The results of their review is included in Appendix VI.T
of this report.

.
 . - . - ._ - . . - __ -

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'

7 of 33
,

III. CAR-19 OBJECTIVES

To document a consolidated project plan for the 2dentificatio , evalua-

tien and resolution of problems associsted with Safety-Related AWS DI.1
Welding. '
:

To provide assurance, based on objective evidence, that AWS D1.1 Welding

of Safety-Related Structural Steel complies with all Quality Criteria as t

specified in the related design documents and is within the tolerances

'of acceptable deviations as determined by the Architect / Engineer.
To provide assurance that the documentation which supports the inspec-
tion of safety related structural steel welds is:

- Available - Complete - Reflects appropriate information - Traceable to

the item or activity

To evaluat e supportirig elements of the DIC Quality Assurance Program to

, ensure that those elements were adequately and effectively implemented
;
to demonstrate that the DIC welding of Safety Related Structural Steel,
HVAC Supports, Electrical Supports, Pipe Whip Restraints and any other
i AWS D1.1 safety related welding activities were in compliance with the
, FSAR (i.e. AWS DI.1 -
1975) and the Design and Construction QA Program
; Manual, Section.17.1.B.
'

To evaluate DIC Construction / Quality programs in areas other th.1 AWS

.
D1.1 welding to determine the potential of programmatic deficiencies.
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 8 of 33

IV. CAR-19, DISCUSSION OF TINDINGS AND CORRECTIVE ACTIONS

The KG&E Management Plan for the resolution of CAR-19 was developed by
DIC and KG&E Management personnel to document a consolidated project plan for
the identification, evaluation and resolution of problems associated with
safety-related AWS DI.1 welding. The intent of this plan is to verify that
both the hardware and programmatic aspects of all safety-related activities
utilizing AWS DI.1 welding are in compliance with the TSAR and the Design and
Construction Progran Manual.
The logic chart for the resolution of CAR-19 was developed to illustrate
the approach to be used in providing the verifications needed for implementa-
4
tion of satisfactcry corrective action. The Corrective Actions as described
in the KG&E Management Plan are identified in the flow of activities as
designated on the logic chart. The logic chart is included as an attachment
to this report in the Appendix, section VI.B.

Five (5) findings were included in CAR-19. The detailed activities and
investigative actions required to implement each Corrective Action are
delineated in the KG&! Management Plan. The process of corrective action for
each finding generated by CAR-19 entails multiple activities. Each finding
and it's respective corrective actions are discussed in detail in the
following. Supportive and/or investigatory documentation for each finding as
discussed in this section is delineated in the Appendix, sectior. VI.1.
Finding #1 of KG&E CAR-19 stated, "The results of tne Document Reconcil-
i'ation Task Force indicated that 1509 of 6816 MSSWR's for Safety Related
Structural Steel Welds are missing".
Six (6) corrective actions were prescribed as appropriate for the
resolution of this finding and related concerns. These corrective actions
were focused toward programmatic evaluations, procedural criteria evalua-
tions, and a reinspection program utilizing certified inspectors. Following
is each of the six (6) corrective actions for Finding #1 with an analysis of
the investigative actions taken and a summarization of each corrective
action's results in accordance with the KG&E Management Plan's directions.
Corrective Action la)
" Based on DIC program requirements assure that all of the welders and
.
welding procedures were qualified to AWS DI.1."
This activity was subdivided into three elements of research. These
elements included development of an AWS D1.1-75 Attribute Checklist analyzing
individual attributes relative to the welding process. The checklist lists
all AWS requirements and compares those requirements with DIC Construction
Welding Procedura requirements, in each case citing explicitly how the
corresponding D1C procedure addresses separate AWS criteria. This checklist
is conclusive data that provides evidence of all AWS D1.1-75 criteria being
adequately addressed by DIC Construction Welding Procedure, CWP-506, " Welding
of Carbon Steel". An attachment to this checklist documents the procedure
e review cycle for CVP-506, showing that each revision from 09/14/78 through
(- the current revision dated 05/21/81 was consistently reviewed and approved by
the individuals designated that responsibility. ,

_
 i

9 of 33

A second element of this activity was the statistical saepling of AWS ,

Welder qualifications in accordance with MIL-STD-105D. The total quantity of ,

retrievable Miscellaneous Structural Steel Weld Records (MSSWR) applicable to

AWS welding was initially identified to define the total population to be
used in selecting a sample size. A " Single Sampling Plan for Normal Inspec-
tion" was utilized, randomly selecting MSSWR's for review of welders' quali- ,
'
fications. This sample included a variety of welders, a variety of AWS
welding procedures, a representative sample of welders during the 1976-1984
time frame, and sampling from welders working in all Powerblock buildings.
Identification of welders was taken from the MSSWR's and welder qualification I
records (W-105). These were then reviewed to assure that each welder was !
'
qualified to the weld procedure entered on the MSSWR at the time of weld
installation.
'
A sample size of two hundred (200) was selected as being most represen-
tative, given thee previous considerations. Based upon Table II-A of
MIL-STD-105D, DIC desired a ninety-six percent (96i.) Acceptable Quality Level
(AQL). This AQL accepts fourteen (14) rejectable units from a sample of two
hundred (200), and rejects the entire population when the fifteenth (15)
rejection of the sample is observed.

Research performed by DIC Welding Engineering revealed thirteen (13) I

incorrect entries on MSSWR's, with only four (4) of these considered "rejec-
table" due to the nature of the discrepancies. All thirteen discrepancies
were due to incorrect entries being made on the MSSWR, with nine (9) of the
thirteen having the weld technique entered as N-1-1-A-6 rather than
N-1-1-A-6A. These two weld techniques were evaluated by DIC Welding Engi- .

neering by comparison of attributes and essential variables, and it was

determined that no adverse impact existed. The four (4) entries considered
rejectable were due to welders incorrectly entering a welding procedure
number for which they were not qualified on an MSSWR.
A Nonconformance Report, ISN 20984CW, was generated to document all
thirteen (13) discrepancies noted, and was recommended for a "Use-As-Is"
disposition by DIC Welding Engineering. This Nonconformance Report has been j
reviewed and disposition concurrence received from Bechtel, closing the NCR. '

The third element of this activity was a review by Bechtel of DIC Welder !
Qualification Procedure and the DIC Welding Procedure Specifications to i
assure compliance to AWS D1.1-75. -

Eechtel reviewed .DIC Construction Velding Procedure, CWP-502,

" Qualification of Welders", all revisions up to and including Revision 19. ;
This review indicated full compliance with the AWS D1.1-75 for revisions 1 ;
through 18. However, Revision 19 does not strictly comply with AWS D1.1-75 $

in the following areas. i

i
1. CWP-502 Rev. 19, Paragraph 3.2 -allows the DIC Project Welding [
Engineer to specify joint details not listed in Appendix II. ;

i
2. Joint designs for figures 5.2, 5.3 and 5.4 of Appendix II do not !

comply with AWS DI.1 joint designs for welder performance

qualifications.
~

3. CVP-502 Rev. 19 does not specify the test positions for AWS D1.1
welder performance qualifications.

i
 10 cf 33

4. CVP-502 Rev. 19 does not specify the radiographic or mechanical

testing requirements for AWS D1.1 welder performance qualifica-
tions.

Nonconformance Report ISN21472MW has been generated to document these

deviations and is awaiting disposition.

Bechtel randomly selected Welding Procedure Specifications (WPS) from

MSSWR's applicable to structural welds in the 1978-1984 time frame. The
review of the WPS' indicated full compliance with AWS D1.1-75 with one
exception, undercut criteria, which was allowed by the Wolf Creek Final
Safety Analysis Report, Revision 0, October, 1979. Three of the WPS'
permitted undercut to be acceptable provided the depth did not exceed 1/32
inch, which is a relaxation of AWS D1.1-1975 undercut criteria.

The exception to the AWS D1.1-75 undercut criteria exists in Revision 0 |

of the Wolf Creek Final Safety Analysis Report, Section 3.8.3.6.3.3, dated
October, 1979, and was also added by a revision to Bechtel Civil Specifica-
tion C-122 and C-132, the design specifications applicable to the structural
steel connections in the CAR-19 reinspection program. Based upon these facts
the Bechtel Material and Quality Services Department (M&QS) determined that
the WPS' used during erection / installation of structural steel members did
comply with AWS DI .1-75. Paragraph 1.1.2 of AWS D1.1 defines the " Engineer"
as the duly designated authority who acts for and in behalf of the Owner, and
the exception to AWS undercut criteria was documented in the FSAR to comply
with this paragraph. ,

It is Bechtel M&QS' conclusion that the review of the DIC WPS' and i
supportive documentation demonstrates that the welding procedures used by DIC
during structural steel installation did comply with the AWS D1.1-1975
Structural Welding Code Edicion when used concurrently with supportive design i
documents and the revisions to the FSAR.
In conclusion, the three elements of analysis included in the research
|
performed on Activity la offer assurance that all DIC welding procedures were
qualified in accordance with AWS DI.1-75 requirements.
Corrective Action Ib) ,

" Review the DIC Program for the purchase and control of filler material
to ensure that only acceptable ~ filler material was used in safety related ,

welds. Assure that both safety related and non-safety related filler
materials were properly controlled to preclude improper applications."
This activity was divided into two elements of research, those being; '
the DIC review of procedures for the purchase and control of filler and base i
materials, and Bechtel's review for the purchase and control of filler
materials.

DIC Civil Engineering performed an in-depth review of the D1C Program

for purchase of structural and miscellaneous steel and found the DIC Program
'
to be in accordance with the requirements of Bechtel Specifications
10466-C-121 (Purchase of Structural Steel), and 10466-C-131 (Purchase of 1

Miscellaneous Steel). These specifications and their respective DIC

u
 11 of 33

procedures were found to adequately address applicable requirements for

assuring corre.t material specification, grade, marking, traceability and
other Quality Assurance requirements. In addition these specifications and
procedures provide for buyer verification of any or all of the established
specification requirements.

The DIC procedures applicable to procurement activities are as follows:

AP-VII-01 Development and Approval of Bidders List

AP-VII-02 Requisitioning of Daniel Procured Materials, Equipment
and Service
|
|

AP-VII-03 Bid Requests

AP-VII-04 Receiving and Processing Bid Proposals
AP-VII-05 Issuing Purchase Orders and Change Orders )
!

During a self-initiated KG&E review of safety-related procurement )

records in January, 1984, several cases were identified in which DIC purchase
orders did not comply with all A/E specification requirements. As a result
of these findings, DIC initiated a Corrective Action Report (CAR) 1-G-0036,
to perform a complete review of all purchase orders to verify compliance to
specification requirements.This investigation encompassed the review of
five hundred thirty-six (536) safety-related purchase orders to assure
hardware and documentation to be in compliance with specifications. Any
discrepancies identified during this review were documented on Nonconformance
Reports for resolution by DIC, KG&E and the A/E. Those nonconformances
identified relative to structural steel were determined to be all documenta-
tion related with no hardware impact. All corrective actions were completed,
all Nonconformance Reports resolved and closed, and Corrective Action Report
I-G-0036 was closed on 05/24/84.
DIC Civil Engineering accomplished a detailed study of the control and
issuance of base materials applicable to structural steel installations.
This review was based upon a thorough analysis of material control require-
ments for this application in the following DIC procedures:
AP-VIII-02 Material and Equipment Receiving
AP-VIII-03 Identification, Marking and Inspection
AP-VIII-04 Receiving Discrepancies
AP-VIII-05 Material Storage and Control

AP-VIII-07 Material Issue

QCP-IV-111 Erection of Structural Steel and Pipe Whip

Restraints

WP-IV-111 Structural ~ Steel and Pipe Whip Restraint Erection

|
- - . ,
 32 of 33

This revie.e investigated such areas as the use of Structural Steel

Fabrication Requests, requisitioning and issuance of the material to craft
for erection, maintenance of traceability through heat number transfer for
material that is divided, and documentation of this heat number on permanent
plant records. DIC Civil Engineering's research concluded that acceptable
control and utilization of base materials is maintained through DIC programs
and procedures.
Bechtel's Materials and Quality Services Group furnished information
based on their research to ensure that the DIC Procurement program had in
fact resulted in the proper filler material being purchased and subsequently
utilized in structural steel installation activities. This review was
documented in attachments to a letter from B. W. Bain of Bechtel Materials
and Quality Services to Gary Stanley on 10/16/84 This analysis entailed the
following activities: (1) A review of purchase orders / certified material
test reports for conformance to AWS DI.1 requirements to verify that all heat
numbers for welding filler material are acceptable for structural steel
installations, (2) A comparison of all E7018 weld rod heat numbers issued to
the DIC Rod Roo= during the time frame of structural steel installation /
erection to verify that correct filler material was used, (3) A review of the
DIC weld filler material issuance control procedure / program to ascertain that
( welders were only issued filler material for the welding procedures to which
they were qualified, and applicable to the work being performed.
The results of these investigations were positive, with no discrepancies
being found. This effort further substantiates that correct weld filler
material was utilized in structural steel erection.
DIC Welding Engineering reviewed the procedural details relative to issue of
weld filler materials, identifying the control of filler materials explicitly
for field issue as well as test shop issue. This review indicates that
control is adequate, with supportive documentation, thereby assuring proper
filler' material issue. DIC Welding Engineering also noted that Quality
Inspection performed, as required by DIC Construction Procedure QCP-VII-200,
Inspection of Welding Process, random surveillances of welding process
attributes. Among the attributes covered by this surveillance are that
filler material control is implemented according to applicable welding
procedures, and that the welder is currently qualified to the weld technique
to be employed.

DIC Welding Engineering performed a review of the specification and

procedural requirements relative to the purchase, issue and control of filler
materials. It was determined that only E7018 electrodes have been used in
AWS D1.1 applications, as required by all site AWS D1.1 welding techniques.
All E7018 electrodes purchased by DIC are required to conform to AWS A5.1
(Specification for Mild Steel Covered Arc Welding Electrodes). To substan-
tiate this fact DIC Welding Engineering performed a review of all purchase
orders that involved E7018 electrodes. All these purchase orders were proven
to have adequate documentation to justify that the electrodes conform to AWS
specification AS.I.

Based upon procedural requirements, weld filler material issue controls,

1
'
and randoe Quality Inspection surveillances, assurance has been provided that
only acceptable filler me.erials have been utilized and that control has been
k as required for all AWS DI.1 applications.

- , . .
 __ - ._ . - . -. _ . - . _ - -,

13 of 33

Corrective Action Ic)

" Evaluate the adequacy of the DIC inspection criteria and procedures to
determine if these elements could have adversely impacted the inspection
results. Document and provide this evaluation to KG&E QA for review prior to
inspection implementation. Any changes in inspection criteria and procedures
shall be provided to KGLE QA for review prior to implementation."
This activity was divided into two elements. The first element was a
review of DIC weld inspection criteria contained in QCP-VII-200. The
inspection criteria was reviewed to determine compliance with AWS D1.1-75 and
: Bechtel Specifications 10466-C-132. Th. second element was to evaluate the
i
results and determine if these element > could have adversely impacted the
inspection results.

An AWS D1.1-75 and Bechtel Specification attribute checklist was

developed by DIC Quality Engineering. Inspection criteria defined in
QCP-VII-200, Appendix II was reviewed in accordance with the checklist. The
review indicated that currently QCP-VII-200, Revision 20, meets or exceeds
the inspection criteria as delineated in AWS DI.1-75 and the Bechtel
specifications. The review of the QCP-VII-200 procedural history revealed
d
most criteria was presented verbatim from AWS or the Bechtel specification.
! Other criteria, although not verbatim, was interpreted as being in compliance
with AWS and the Bechtel specification. The review did indicate four (4)
areas of inadequacy. The following is a list of these areas and the time i
frame affected:

1) Oversized Welds - 4/18/78 - 5/2/84 (Revisions 2 - 19)

Inspection criteria for oversized welds was not delineated in
QCP-VII-200 during this time frame.

2) Convexity - 3/30/77 - 1/18/83 (Revisions 0 - 15)

During the time frame 3/30/77 through 12/15/81, QCP-VII-200 ;

required the Quality Inspector to utilize the Weld Technique

Sheet for compliance. During the time frame 12/15/81 through
1/18/83, QCP-VII-200 required: " Fillet welds may be slightly
convex / concave." During the entire period, the following
4

criteria was not delineated in QCP-VII-200 or the Weld

Technique Sheets. "Except at outside corner joints, the
convexity shall not exceed the value of 0.1S plus (+) 0.03
inches where S is the actual size of the fillet weld in
inches."
3) Cracks - 12/15/81 - 5/26/82 (Revisions 9 - 11)
Inspection criteria for cracks was not delineated in
QCP-VII-200 duri n this time frame.
4) Lack of Fusion - 12/15/81 - 09/22/83 (Revisions 9-16)
!
.i Inspection criteria for lack of fusion was not delineated in !

k QCP-VII-200 during this time frame.

An evaluatior. was performed to determine if these procedural

inadequacies could have adversely impacted the inspection results. The
following-is the results of the evaluation: >

|
__ _ - _ _ .__ - ___
_
_ , , _ _ , _ _ _
 14 of 33

1) Oversized welds: Bechtel Specifications 10466-C-122 and

10466-C-132 were revised 4/18/78. This revision required
oversized welds not to exceed 100?, or 3/6" greater than
specified, whichever is less. During a civil retrofit review
of Bechtel specifications and DIC procedures, this procedural
inadequacy was identified. Nonconformance Report ISN 16988CW
documented this deficiency and resulted in a recommended
disposition of "Use-As-Is". Based on Bechtel's concurrence
with this disposition, the omission of this item is considered
to have no adverse impact to inspection results.
2) Convexity Bechtel specifications required welds to meet
-

convexity limits as delineated by AWS DI .1 until 12/08/82.

After this date, Bechtel specifications altered the convexity
requirement by stating that fillet welds need not satisfy
convexity limits of AWS D.1.1. DIC Procedures have delineated
criteria as " welds may be slightly concave / convex". Based on
procedural control and the relaxed specification criteria,
this item is considered to have no adverse impact to inspec-
tion results.

3 & 4) Cracks and Lack of Fusion - Inspection criteria for cracks and
lack of fusion were inadvertently omitted during general
revision from DIC inspection procedures on 12/15/81. The
criteria was reinstated in site procedures on 5/26/82 for
cracks and 9/22/83 for lack of fusion. The absence of this
criteria occurred afte.r the completion of main frame struc-
tural steel erection (5/81). However, to establish that there
was no impact in other AWS D1.1 applications due to the
omission of these items, twenty-six (26) DIC welding inspec-
tors were interviewed. These interviews were used to
determine the following:

1) Procedures used for training and inspection.

2) Inspection attributes addressed during training.
3) Inspectors' awareness that cracks / lack of fusion criteria
was omitted from procedures for a period of time.
4) Did inspectors inspect / reject welds for cracks and lack
of fusion?

The inspectors interviewed had inspected structural steel welds as well

as HVAC and electrical support welds during the time frame in which the
procedural deficiencies occurred. In all cases inspectors indicated that
they had inspected / rejected welds for cracks and lack of fusion. Inspectors
were aware of the procedural deficiencies, however, they continued to
inspect / reject for cracks and lack of fusion. This is further substantiated
based on re-inspection results conducted on structural steel. The rejection
rate for cracks and lack of fusion is minimal when compared to the total
number of welds inspected.
'
In conclusion, the review of weld inspection criteria utilized during
the history of this project did indicate areas of procedural deficiencies.
However, based.on the above information, it has been determined that these
inadequacies did not result in generic inadequacies in AWS D1.1 welding.

_ - -
- .
 85 of 33

Corrective Action Id)

"Obtain a documented evaluation to determine the validity of inspections
performed with the presence of paint on the weld."
This activity was divided into three elements: obtain information from
other utility /AE's that have developed a validation plan, with a subsequent
review by DIC Welding Engineering and Bechtel and the addition of site
specific requirements and justification, and Bechtel's submittal of a
' position letter' to KG&E for approval.
DIC Management obtained information from Carolina Power & Light Co., and
Ebasco Services Incorporated relative to the validity of inspections per-
formed with paint on the welds. This information was utilized by Bechtel in
conjunction with their additional research to establish an A/E's position to
KG&E. In summary, this position, more explicitly defined in letter BLKES-
1348 from C. M. Herbst to G. L. Fouts, is: "With the exception of a number
of attributes, fillet welds which have been coated with up to four (4) mils
of primer and in some cases, up to an additional ten (10) mils of topcoat can
be visually inspected to the AWS D1.1 acceptance criteria. Those attributes
which cannot be fully evaluated are of little or no concern on the structural
steel at WCGS."

This letter was submitted to KG&E, and subsequently KG&E discussed the
validity of inspections performed with paint on welds with NRC representa- ;
tives. KG&E Nuclear Plant Engineering reviewed letter BLKES-1348, concurring ,

with the position stated by Bechtel in their letter KNPLKWC 84-065 of l

November 13, 1984.

Corrective Action le)

" Utilize personnel certified to ANSI N45.2.6-1978 for the inspection of
safety related structural steel welds. Inspections shall be performed in
accordance with the DIC Quality Program and training shall be performed and
documented to assure that inspectors are cognizant of the DIC Quality program
,

requirements."
This activity was divided into three elements. The first element
required incorporation of the CAR-19 Inspection Verification Plan into DIC
Construction Procedure QCP-VII-200, " Inspection of Welding Process". The
second element required inspection personnel to be certified in accordance
with the DIC certification program and ANSI N45.2.6-1978. The third element
defined that the inspectors' site specific qualifications would be limited to
.the reinspection of structural steel welds in accordance with QCP-VII-200.
The Inspection Verification Plan was developed through the combined
efforts of - DIC, KG&E, and BPC personnel. Revision 0 was reviewed ' and
approved by KG&E Quality Assurance on 10/19/84. Although Revision 0 to the
Inspection Verification Plan in QCP-VII-200 was not issued until 10/19/84, .

some inspections were performed prior to this date by personnel qualified to

accomplish these inspections. The same inspection criteria was utilized in j
7
these efforts, and all personnel performing these inspection functions were ;

\ evaluated to ascertain their qualifications to be concurrent with the later '

certification requirements for KG&E CAR-19. Further discussion of these

personnel is included in this discussion of Corrective Action le) on the

'

!
 16 of 33

following pages. A meeting was held with the Quality Inspection personnel on
10/20/84 to discuss the impact of the Inspection Verification Plan on their
activities 4nd to ensure their understanding of the plan. As a result of
this meetirg, a new revision, Revision 1, was issued to incorporate inspector
feedback and KG&E Quality Assurance comments. Revision 1 of the Inspection
Verification Plan was then incorporated into DIC Quality Procedure
QCP-VII-200 with Procedure Change Notice 014. On 11/2/84 KGLE Quality
Assurance, DIC, and BPC personnel held a meeting to address KGLE Quality
Assurance concerns on gouges. Subsequently Revision 1 to PCN-014 was issued
to incorporate these concerns into the Inspection Verification Plan.

It was decided that all personnel performing inspection verifications

under the CAR-19 Inspection Verification Plan should not only be AWS
Certified Welding Inspectors, but also be site certified under ANSI
N45.2.6-1978.

ANSI N45.2.6-1978, Section 3.5.2 makes the following recommendations for

education and experience when certifying Level II personnel:
1. One year of satisfactory performance as a Level I in the
corresponding inspection, examination or test category or
class, or

2. High School graduation plus three years of related experience

in equivalent inspection, examination, or testing activities,
or
1
'

3. Completion of college level work leading to an Associate

Degree in a related discipline plus one year related
experience in equivalent inspection, examination, or testing
activities, or

4. Four year college graduation plus six months of related

experience in equivalent inspection, examination, or testing
activities.

When considering the certifiability of candidates, DIC management

ensured that all personnel met the recommendations of section 3.5.2, ANSI
N45.2.6-1978.

A training program for inspectors was established on 10/17/84. The

program consisted of self study material covering the following subjects:
1. Quality Orientation

2. DIC Administrative Procedure AP-VI-02, "Nonconformance Control

and Reporting"
3. The KG&E CAR-19 Inspection Verification Plan (PCN-014 to
QCP-VII-200)

Additionally, a meeting was held on 10/20/84 with the inspectors to

-
explain the contents of the Inspection Verification Plan, and to answer any
questions they might have about the program. In order to ensure the
capability of each candidate, a Field Practical Examination was also
administered.

._-
. |
 17 of 33

Certification files were compiled on each inspection candidate and are

available for review in DIC Quality Training. Each file contains a copy of
the inspectors resume', a signed copy of the Education / Experience evaluation
form, a copy of the inspector's eye examination, the document of certifica-
tion, the field practical examination, and the letter of recommendation.
Additionally there is a training summary documenting the completion of
required training and the training conducted on DIC Quality Procedure
QCP-VII-200, PCN-14, Revision 0 and Revision 1.

Each certification file was reviewed by the DIC Quality Training

Supervisor to ensure all candidates met the recommendations of ANSI
N45.2.6-1978. Each file was again reviewed by the DIC Project Quality
Manager (DIC's Certifying Authority) prior to the signing of the Document of
Certification. The completed certification files were audited by KG6E
Quality Assurance with no findings.

Eleven (11) personnel (Inspectors A through K) were involved in

Structural Steel Inspection Verification prior to the issuance of KG&E
CAR-19. These personnel were attached to DIC Engineering and were qualified,
but not certified prior to the issuance of KG&E CAR-19.

In addition to the eleven (11) personnel above, an additional eleven

(11) personnel (Inspectors L through V) were involved in Structural Steel
Inspection Verification after the issuance of KGSE CAR-19. The certification
status is given below:

.
 18 of 33

INSPECTOR STATUS ,

( 1) A Certified
( 2) B Certified
( 3) C Certified
( 4) D Certified
( 5) E Certified
( 6) F Qualified *
( 7) G Qualified *
( 8) H Certified
-

( 9) I Certified
(10) J Certified ,

(11) K Certified
(12) L Certified
(13) M Certified
(14) N Certified
(15) O Certified
(16) P '
Certified
(17) Q Certified
(18) R . ' Certified

(19) S Certified
(20) T Not Qualified **
(21) U Certified
(22) V Certified

NOTES:

* Personnel who were involved in Structural Steel Inspection

Verification prior to the issuance of KG&E CAR-19, but were not
involved in Inspection Verifications af ter the issuance of KG&E
CAR-19 were investigated and qualified, but were not certified as
they had already left the site or were assigned to other
non-inspection related activities.

** Several attempts were made to verify Inspector T's experience after

he left site. DIC Quality Training was unable to. verify enough
experience to qualify Inspector T's to ANSI N45.2.6-1978. All of-
' Inspector T's work was reinspected by certified personnel. .

Corrective Action If)

i
" Perform a 100*. reinspection of all structurally significant safety
related structural steel welds. The identification of " structurally .

significant" welds shall be made by the Architect - Engineer."

-
 19 of 33

" Structurally significant" joints were defined by Bechtel as all field

welded joints which support or potentially support safety related equipment
and building components for the purpose of this Corrective Action activity.
This basically included all field welds on structural and miscellaneous steel
with the exception of handrail, toeplates, grating, checkered plate, stairs,
ladders and monorail supports. These are non-Q items which typically see
significant service loads during the construction process. Some are
designated as II/I, however, II/I seismic loads are considered to be less
severe than service loads. Monorails have been load tested as part of
startup procedures, and were therefore not included in the scope of structur-
ally significant items requiring reinspection. The joints were selected by
Bechtel based on a review of erection drawings prepared by the structural and
miscellaneous steel fabricators and a review of Field Change Request (FCR's),
Nonconformance Reports (NCR's), Construction Variance Requests (CVR's) and
Structural Steel Fabrication Requests determined applicable.
The DIC Nonconformance program, as defined in DIC Construction Procedure
AP-VI-02, "Nonconformance Control and Reporting", was utilized to obtain and
document a suitability for service evaluation of welds that were inaccessible
due to physical location or embedment in concrete. All deficiencies identi-
fled during reinspection activities performed in accordance with Procedure
Change Notice - 014 to DIC Construction Procedure QCP-VII-200 were identified
on nonconformance reports for further dispositioning and resolution.
Bechtel performed a case by case evaluation of each structurally
significant joint inspected according to the data furnished on Inspection
Data Sheets and nonconformance reports. Their evaluation provided a
determination of whether each structurally significant joint's as-built
condition met design allowables, whether the as-built condition was a
significant deficiency in accordance with 10 CFR - 50.55(e), and whether any
rework or repair to each joint was required,
The following is a statistical summary of the evaluation completed by
Bechtel on all structurally significant joints:

._. _
.. _ _ , . - . . , , _ _ _ _,-_ _ .. _ _ _ . . . _
 20 of 33

TOTAL AWS VELDING

INSPECTIONS AND ENGINEERING EVALUATIONS

JOIhTS ADDITIONAL SIGNIFICANTLY

TOTAL JOIhTS JOINTS REQUIRING JOINTS TO BE DEFICIENT JOINTS
BUILDING JOINTS INSPECTED EVALUATED REWORK (1) REWORKED (2) (10CFR50.55(e) )
AUXILIARY 693 693 693 7 42 0
REACTOR 1300 1300 1300 69 15 0
CONTROL 265 265 265 3 18 0

DIESEL
GENERATOR 98 98 98 2 2 0
FUEL 277 277 277 0 6 0
ESWS
PUMPHOUSE 36 36 36 0 0 0
TOTAL 2669 2669 2669 81 83 0

(1) DESIGN ALLOWABLE STRESSES ARE EXCEEDED IN THE AS-BUILT CONTITION

(2) DESIGN ALLOWALLE STRESSES ARE NOT EXCEEDED IN THE AS-BUILT CONDI-
TION. THESE JOIhTS ARE BEING REWORKED PER KG&E MANAGEMENT DIRECTION
TO INSTALL MISSING AhT UNDERLENGTH WELDS.

Finding 42 of KG&E CAR-19 stated, "An Inspection Verification effort of

safety related structural steel welding, undertaken by AWS certified weld
inspectors identified several areas of deficiencies. These deficiencies are
categorized as: undersized welds, weld defects, incorrect configuration,
weld underrun, and weld undercut."
One (1) corrective action was determined to be appropriate for
resolution of this finding, although this primary corrective action was
subdivided into seven (7) research/ data accumulation activities.
Corrective Action 2a)
" Determine and document the " root cause" of the previous acceptance of
deficient structural welds. Analyze the HVAC Support, Electrical Support,
Pipe-Whip Restraint and any other rafety-related program utilizing AWS D1.1
Welding to ensure that the same " root causes" inherent in the structural
steel welding program were not generic to other programs."
This summary reviews activities 2a-1 through 2a-7 of CAR-19 to determine
the root cause of the previous acceptance of deficient structural welds 'and
analyzes those root causes to determine if they were inherent to other
\ safety-related programs utilizing AWS D1.1 welding.

e - % g- T
 21 of 33

<

A review of DIC Quality procedures was performed by Quality Engineering

to determine if any historical procedural inadequacies could have been a
contributor to " root cause". Although some historical deficiencies in
inspection criteria were found to have existed, research demonstrated that
some of the procedural inadequacies occurred after the vast majority of
structural steel erection activities had been completed. Interviews with a
sample of Quality Inspectors revealed that inspectors were cognizant of the
omission of two other criterion (lack of fusion and cracks) during an appli-
cable time frame, but inspected for these deficiencies in spite of their
omission. Based upon this cumulative research procedural weld inspection
inadequacies are not considered to be contributors to " root cause" of
previous acceptance of deficient structural welds.

DIC Inspection training and certification procedure AP-VI-01 was used to

train and certify Quality inspection personnel during the structural steel
erection time frame. This procedure was analyzed to verify co=pliance to {
ANSI N45.2.6-1978, and was found to be in accordance with ANSI requirements. *

An evaluation of ANSI N45.2.6 requirements r,evealed that DIC procedure

AP-VI-01 was in full compliance to ANSI requirements for the structural steel
erection time frame and through all subsequent revisions to date.

The " root cause" of the previous acceptance of deficient structural

welds has been determined to be due to inspection implementation and
inadequate implementation of related procedures. Each of these contributing
factors has several facets that are considered to be partial reasons for
" root Cause".

Differences in inspection techniques and consideration of inspection j

attributes for the original inspection time frame vs. the CAR-19 reinspection j
time frame are definite root cause contributors. The differences indicated
are common to the nuclear construction industry and have been recognized as ,

prevalent at many projects. A white paper documentary prepared by recognized *

nuclear construction consultants Reedy, Herbert, Gibbons and Associates, Inc.

dated August 11, 1983, clearly defines the subject differences during their
in-depth analysis of weld inspection on nuclear sites. (See Appendix IV.G)
The differences cited, inspection technique and inspection attributes,
are addressed in section I of this white paper, " Continuous Measurement of
Fillet Welds". The paper states that until about 1980 accepted inspection
practice did not entail 100% physical measurement of each inch of welding,
but rather depended upon individual inspector's evaluation of the weld's
acceptability. Around 1980 QA/QC Inspectors began using fillet weld gauges
to measure each inch of fillet weld to verify that the specified minimum weld ,

size was met for the continuous length of weld. This physical measurement I

gradually replaced the previous accepted practice of visual judgement. The !

paper concludes that there has been a progression of the practice of |
physically measuring each inch of weld to a serious extreme. j

The documentary cites that there is no requirement either in the ASME

Section III Code or AWS D1.1 Standard to continuously measure the full length '

of fillet welds. Both ASME and AWS permit deviations froo minimum size ;

fillets as documented in ASME NB/NC/ND - 4427 and paragraphs 8.15.1.7 and ~

, 9.25.1.7 of AWS D1.1. The paper further contends that inspections can and
'
should be made on a random basis to determine nominal sizes with no detriment
to safety. Additional sections of this documentary address " Undercut
Provisions of AWS DI.1" and " Encroachment on Minimum Thickness" with similar
conclusions.

- -_., - - , - , -
i
-- - ,
 -- -. . _ - . =. - -_ . _- - _ - - .- -

22 of 33

DIC research has shown that the inspection technique implemented during
erection / inspection of structural steel at Wolf Creek was in accordance with
common industry practice as stated in the previously referenced documentary.
Inspectors were of the understanding that visual judgement was acceptable
j !
as an inspection technique in checking for nominal weld size, and that visual
evaluation rather than 100% physical measurement of fillet welds was accep-
table for assuring that welds met visual inspection attributes.
Given these considerations, one should expect a reinspection program
using current applicable techniques to find deficiencies in welds previously
accepted. The reinspection technique is one of 100% physical measurement of
f
all attributes applicable rather than the visual judgement i itially etployed
as acceptable during the structural steel erection time frame.

With the previous considerations in mind, an examination of the weld

i
'
deficiencies identified during reinspection and their relative significance
to the overall integrity of the initial inspection effort is in order.

! The scope of the CAR-19 reinspection effort identified two thousand six
2
hundred sixty-nine (2,669) joints requiring reinspection. Of the two
)
3
thousand six hundred sixty-nine (2,669) total joints, two thousand eight
hundred seventy (2,870) welds exhibited discrepancies of the more than
j eleven thousand (11,000) welds reinspected according to procedure
: QCP-VII-200, Procedure Change Notice 14. Each weld reinspected could have ;

potentially contained five (5) categories of deficiencies according to the '

) method utilized for tracking during the CAR-19 program, those being:
'

undersize, defects (cracks, lack of fusion, incomplete penetration, overlap,

slag inclusions, porosity, craters), underrun, undercut and configuration.
Of the two thousand six hundred sixty-nine (2,669) structural joints in-
spected, the following quantities -of weld deficiencies were noted by cate-
gory: 1,061 undersize, 330 defects, 476 underrun, 107 undercut, and -1,562
configuration.

;
'
The quantities of deficiencies noted for the three. categories following
are minor based upon a percentage comparison to the total number of welds.
,
'
reinspected. The approximate percentages for each of these three categories
are, underrun 4%, undercut 1%, defects 3%. These percentages are within
expectations considering reinspection emphasis and the previously noted
,
differences in- inspection technique and accepted inspection practice.
Further statistical analysis revealed a majority (more than 60%) of the welds
rejected for undercut discrepancies to be in excess of the 1/32" allowable
*
undercut criterion by less than 1/16". A majority (approximately 60%) of the
welds found to be underrun were underrun by less than 1/2". An analysis of
the attributes contained within the ' defect' category revealed only small
quantities in each. Based on the above statistical analysis the discre- ,

pancies identified in the categories of underrun, undercut and defects are

not considered to be contributors to the root cause that previously accepted
welds were found deficient upon reinspection.
'

4
The quantity of welds rejected that did not meet the minimum leg size
as specified on the design document, or exceeded the code allowable 1/16
f . inch undersize for less than 10% of the length of the weld, represents a
i ( percentage of 9% deficiencies for the total . welds inspected. Discussions
with DIC inspection personnel and Quality Management aware of approved
inspection practices utilized during the structural steel erection time frame
; indicated that inspection methods were similar for this period to
1
i

,
, , , , , , - , . , , . - -. ,_ ,, - _ -,e ,n,o-- --n---,--,--.-.,, . ,,,, n -.-w - ,w n ., , , , . , , , . ,
 33 of 33

those described in the previously addressed documentary by Reedy, Herbert,

Gibbons and Associates, Inc. Of the welds identified as being undersize,
more than 90% were undersize by less than 1/8", further substantiating that
inspection methods were as previously described. Based on the above
evaluation, the quantity of deficient welds identified as being undersize is
considered an indicator that previously accepted inspection techniques was
the root cause of previously accepted welds being found deficient upon
reinspection.

The quantity of welds indentified during reinspection exhibiting

configuration deficiencies represented 13% of all deficiencies for the total
welds inspected. Of the total number of deficiencies, more than 80% were
revealed by research to be directly attributable to one design change
implemented in February, 1978. This Design Change Notice C0011, Rev. 7,
dated February 23, 1978, changed detail 10 on drawing C0011 to limit the
length of the return welds on beam clip angle to embed plate welds. The
significant number of discrepancies identified in this category indicates
that the design change was not given sufficient emphasis by DIC Engineering,
craft, and Quality Inspection to enable deviations from this requirement to
be adequately controlled. This category is the largest single contributor to
" root cause" of previously accepted deficient structural welds. Bechtel, as
the Architect Engineer, performed an evaluation of all welds reinspected to
determine which welds were acceptable from a technical viewpoint relative to
allowable stress calculations and which welds would require rework in order
to meet this criterion. From this evaluation 2589 joints were determined to
be technically acceptable whereas 81 required rework. These statistics,
revealing that 97% of the joints reinspected were technically acceptable, are
indicative that the relative degree of significance of the deficiencies
identified due to reinspection is minor.
Those areas utilizing AWS D1.1 welding other than structural steel were
identified as: Pipe whip restraints; miscellaneous steel and embedment
fabrications; fire dampers and safety-related ductwork and supports; elect-
rical raceway supports; electrical equipment installation; and stud welding.
Previously compiled information including Construction Self Assessment
Reports, KG&E QA Reports and Surveillances, DIC QA Reports, DIC Project
Monitoring Program audits, DIC Corrective Action Reports and correspondence
was reviewed to determine results of previous investigations of AWS D1.1
welding. No findings were noted during this review that could be considered
contributing factors to root cause. Electrical II/I support welds were
reinspected by Bechtel (ELKC: 009) through the " Sampling and Inspection
,
Program for Electrical Support Welds" (7/84). Three hundred nine (309) were
inspected and found acceptable. Electrical Quality Welding Inspectors <

performed inspections on Class IE support welds raceway (8/82). Pipe whip

restraint welds were 100% nondestructively tested. HVAC ductwork support
welds were 100% reinspected through implementation of DIC Corrective Action
Report CAR-1-M-0012 and a traveler system was initiated to maintain better
control and accountability (3/82-1/83).
Programmatic elements utilized in the inspection and documentation of
*
the various applications of AWS D1.1 welding differed depending upon the
Quality discipline responsible for inspection activities. The following
methods were utilized in the applications noted to provide inspection
'

documentation:
 24 of 33

a) Raceway Supports - Raceway Support Checklist

b) Electrical Equipment - Quality Equipment Mounting Checklist in

addition to MSSWR's

c) Fire dampers and safety-related ductwork and supports -

Mechanical Travelers

d) Miscellaneous steel and embed fabrication - MSSWR's

e) Stud welding to embeds - Surveillance Reports
f) Pipe Whip Restraints - MSSWR's in addition to Nondestructive
Examination Reports

All the methods utilized above were effective in providing inspection

assurance and documentation of the respective activities when properly
implemented. The travelers utilized as well as the other checklists noted
provided a closed loop system where individual accountability for a weld was
required, controlled, and documentation verified accurate and complete by
'
Quality personnel. Conversely Miscellaneous Structural Steel Weld Records
(MSSWR's) were used in an open-ended system for Main Frame Structural Steel
Installations where craft construction personnel were responsible for con-
trol, maintenance and processing of this record following its completion.
This system proved less than satisfactory in some applications, resulting in
document retrievability problems that have been addressed by DIC and KG&E
Corrective Action Reports.

In summary the programmatic elements as described in DIC procedures for

each application of AWS D1.1 welding are adequate when properly implemented
by the persons responsible for those activities. MSSWR's utilized in
documenting structural steel weld connections were the subject of inadequate
implementation of procedural requirements, resulting in the problems being
addressed in this report. The research accomplished in completion of this
activity revealed no inherent " root cause" generic to all programs utilizing
AWS D1.1 welding, but rather indicates that the root cause of the previous
acceptance of deficient structural welds was as delineated earlier in this
section.

Finding #3 to CAR-19 stated, "A small number of safety related

structural steel welds were not made or had missing material."
Corrective Action 3a)
" Forward the "as-built" information to the Architect / Engineer via an NCR
to obtain an engineering evaluation and disposition".
All missing welds or missing material detected in the reinspections
performed were documented on nonconformance reports reflecting the as-built _

condition found by inspectors. Of the two thousand six hundred sixty-nine

(2,669) joints reinspected (more than 11,000 welds) only two hundred
seventy-three (273) welds were identified as missing where the applicable
design drawing required their installation. Of the two hundred seventy-three
 .

25 of 33
i
!
i

welds not installed, one hundred twenty (120) were applicable to the polar
crane girder radial stops (44*.), ninety-seven (97) were due to beam seats not !

installed ( 3 6*. ) , eighteen (18) were due to missing welds on six (6)
pressurizer support welds (7.0*.), and the remainder (38) due to missing welds
on clip to beam or plate installations ( 13*.) .
s
'

Under the purview of KGLE Construction, a detailed investigation was

undertaken by DIC Engineering and Management personnel to determine the root ,

causes of missing welds and materials in each case. Significant points of

that investigation included: grouping of missing welds / materials into
categories to aid in research; compilation of f actual data and anriysis for
trends / patterns; a thorough review of all applicable design chanrj documents
that may have deleted some of the items in question; visual e.aminations of
the areas where installations should have been made; and 2nterviews with
craftsmen, craft supervision, DIC Engineering and Quelity personnel for
information that may have added to root causes.

Missing welds and materials were grouped into categories based on

similarities that could be determined to exist in function or construction
sequence. Five groups were defined, those being: beam seats and attachment
welds, pressurizer support welds, Polar Crane girder radial stop welds ,
miscellaneous materials and associated welds, and beam to channel clip welds
(for one application only). Each of these groups is discussed in detail in
the following paragraphs in presenting the respective data accumulated and
the conclusions drawn.
Beam seat installation welds accounted for ninety-seven (97) of the
missing welds identified. Upon investigation several reasons were found as
contributing factors to the root cause of failure to install beam seats as
required. All beam seat connections in question were relevant to installa-
tion detail 10 on drawing C0011, which gave no required weld size, but
referenced note 14. Note 14 stated, "When end reaction exceeds maximum weld
size capacity provide seat angle." Discussions with personnel available who
were involved with structural steel installations revealed that this note may
have been incorrectly interpreted as an ' option' for beam seat installation.
This resulted in a craf t opinion that the beam seat was intended as a con-
struction aid to be used only during the erection process and then removed.
This contention is supported by the fact that ninety-three percent (93%) of
the areas / records examined pertaining to beam seat installation revealed that
the beam seats were installed prior to the beam's installation. Seventy-two
percent (72%) of the embed plates investigated showed evidence of temporary
welds made to attach a beam seat as a construction aid during the erection
sequence, but the beam seats were not found installed upon field investiga-
tion. A majority of the beam seat associated welds missing were the beam
seat to beam welds, which further indicates the questionable beam seats were
tack-welded to the embed, used as a construction aid, then removed prior to
welding to the beam. These above factors substantiate that the root cause of
missing beam seat welds (i.e., beam seats not installed) was due to a mis-
understanding of the beam seats' intended application as a permanent instal- ,

lation. This root cause conclusion is supported by the data accumulated and
, discussed in the preceding paragraphs. All missing beam seats and their
respective required welds were installed as a part of KG&E and DIC Manage-
ment's direction.
s

.
 36 of 33

The missing pressurizer support welds totaled eighteen (18) welds on six
(6) supports. The six (6) supports with missing welds are all of the upper
supports for the pressurizer beam foundation, and all six (6) supports were
found to be welded identically to each other. One inspector performed all
final visual inspections of the pressurizer supports, indicating a
possibility of human error being a contributor to root cause. Investigation
results indicated a misinterpretation of erection details and requirements as |

the primary root cause of the eighteen (18) missing welds. Twenty-four (24) ;
welds not detailed as required installations were added but not required by j
design drawings. The conclusion reached for root cause of the missing welds |
on the pressurizer supports is that DIC construction craft and Quality ;
personnel misinterpreted the installation details and applied this misinter- r
pretation consistently in the construction and inspection of all cix
supports. Nonconformance report ISN 20509CW was generated to document these
circumstances and all missing welds were installed as a part of the
disposition. ;
i
!
The Polar Crane girder radial stops were the subject of one hundred
twenty (120) missing welds. These missing welds are documented on noncon-
formance reports ISN 2130BCW, ISN 21309CW, ISN 213100W and ISS 22311CW.
Facts gathered during the investigation of these missing welds indicate that
a series of drawing revisions and misinterpretation of erection installation
details resulted in DIC construction error in not making all required welds j
'

en sixty (60) radial stops. The appropriate facts are as follows:

American Bridge Drawing E117 (C-121-8360) was revised concerning

the radial stop connection. Two of the three revisions to section
A were attempts to clarify the desired weld configuration at the h
radial stops, t

Revision B to American Bridge drawing E117 was produced to clarify

where actual welds were expected. ;

Revision C of Drawing E117 in part added "one side or.ly" to the

inner "C" portion of the radial stop welds.

Bechtel Drawing C-052963 concerning the polar crane girder radial

stop welds was altered at Revision 6 to note on Section A that the i

weld on the inner "C" indention was to be made on one side only. -

The MSSWR's documenting the radial stop welds made indicate

erection during 2/80-3/80, before American Bridge drawing E117
clarified the installation detail on Revision E, dated 12/80. }

Upon reinspection NCR #1SN 21196CW was initiated describing the

deficiency in nonexistent radial stop welds. The NCR was voided in-process
by the CAR-19 Inspection Supervisor due to a misinterpretation of require-
ments according to details on the American Bridge drawing E117, that seemed
to indicate a weld installation detail requirement concurrent with the actual ,

welds found installed during reinspection. Based upon the preceding facts,
it is concluded that the root cause of missing Polar Crane girder radial stop
g welds is due to unclear weld detail installation requirements as projected on
the American Bridge drawing E-117, and subsequent incorrect interpretation of
(- weld installation requirements by DIC personnel.

)
 27 of 33

The missing welds identified for installations involving other

miscellaneous materials and welds missing are of a smaller quantity.
Thorough investigation revealed the root cause or these missing welds to be
due to a lack of formal follow-up and inadequate stetusas of completed work
and the subsequent completion of unfinished work. The missing welds on the
Incore tubing supports revealed that all investigatory information supports
the hypothesis that these missing welds were not installed due to oversite.
The four lateral support brackets, two at each of the vertical angle supports
(Incore tubing supports) located 32' 2 3/4" ncrth of the Reactor Center
-

Line and 4' 10" east and west (one each direction) of Reactor Center Line on
Drawing GOS2919 were added by revision to drawing GOS2924 after the supports
had been presumed completed.

Nonconformance report ISN 21273Ch' documents missing welds on channel

clips to beam attachments. The channels that American Bridge Drawing
#C121-10o75 shows welded to e beam web along A2 at Elevation 2042' are bolted
inst 2ad. The channel clips are bolted to the web using the same bolts as
removable beams on the opposite side of the web. Research found that the
installation of the chennel and removable beam was late in the construction
sequence of this arca, also. Since the channel clips and removable beam clips
are bolted thrcugh a beam web with the same bolts, the channel clip
attachment welds were probably essumed to be unnect.ssary by the construction
personnel responsible for installation.

If the removable beams nad been disconnected for the purpose of

construction, it would have become necessary to weld the channel clips to the
beam web at that time. The. beams and channel in question were installed late
in the construction sequence of the area, removal of the beams never became
mandatory, tne welds were not a recognized priority and were never installed
as required. The root cause of these missing welds is due to DIC error in
assuming the bolted connections were acceptable rather than the required
welds. In the miscellaneous group, investigations revealed that welds or
material found missing were those we3ds or materials that would not impede
construction progress related to that connection.

Finding #4 to CAR-19 stated, "One (1) weld was documented as having been
inspected when in reality the weld was not made. (Ref. NCR ISN 20495Ch') . "

Corrective Action 4a]

" Investigate the concern to determine the root cause of the error.
Immediately notify KG&E Quality Assurance if any other problems of this
nature are identified. Document the investigative actions. The notification
of KG&E QA shall not preclude the issuance of an NCR."
The results of the CAR-19 inspection effort were tracked and each case
where a missing weld or missing meterial was identified was researched
thoroughly by DIC ' Engineering to determine whether documentation existed
pertinent to the installation of the missing weld / material. Miscellaneous ,

Structural Steel Veld Records (MSSWR's) were reviewed to determine if a trend

or pattern existed. Nonconformance reports identifying missing welds were
compared to MSSWR's to determine if there were repetitive occurrences.

,
 28 of 33

Applicable drawings were reviewed for similarities in beam numbers, floor

layout and beams at similar locations in an attempt to further identify
possible sources of confusion. As a result of the investigations conducted
only two (2) cases were identified where inspection documentation existed for
welds not installed.

The first case is the installation of beam No. 524E2 and its connection
to an embed in the Auxiliary Building. All available information indicates
that DIC Quality Inspector W made a human error when documenting the
inspection of this beam connection. A review of the drawings shows that the
beam configuration and floor layout in the area (elevator shaft and equipment
hatch) directly beneath the beam connection in question are very similar. In
addition, the beam below beam 524B2 connects at the same building coordi-
nates.

It is possible that Inspector W could have been one elevation beneath

where he should have been when inspecting the connection. Out of the
multiple welds inspected by Inspector W this problem occurred only once. If
actions which would result in other conclusions had occurred, it would be
reasonable to assume that they would have occurred repeatedly. Inspector W's
signature appears on over eight hundred (800) MSSWR's. Each MSSWR could
document multiple weld inspections, therefore, Inspector W very likely
inspected over one thousand (1,000) structural steel welds, with the result
that this type of problem occurred once. A telephone conversation between
Inspector W and DIC management personnel concerning this incident revealed no
information that Inspector W could offer, since he could not recall the
specific connection from the more than eight hundred (800) he inspected. The
root cause conclusion in this case is human error.

The second case is the installation of beam No. 95B5 to an embed in the
Control Building. All available information suggests that DIC Quality
Inspector X made a human error when documenting the inspection of this beam
connection. The MSSWR documenting this connection shows Inspector X's
confusion in that he entered the joint number incorrectly when filling out
this portion of the MSSWR, then lined through, initialed and dated his error,
and entered what he thought was a correct entry. Drawing K6711-XI-I-E13
details this connection, but is unclear in that it does not designate the
connection number for the beam clip to embed weld, and only lists the beam
seat number (91M1).
~

Further research revea1ed that Inspector X completed one hundred

eighty-three (183) MSSWR's during his tenure on site, but only six (6) of
these MSSWR's were related to structural steel weld inspections. This is
indicative that Inspector X was possibly confused by the details on the
erection drawing. It is probable that Inspector X attempted to document the
welds attaching the beam clips to beam 95B5, since no retrievable MSSWR is on
file for these welds. These circumstances are documented on nonconformance
report ISN 20798CW for disposition and resolution. The root cause conclusion
in this case is human error.

Finding #5 of CAR-19 stated, " Objective evidence that the mechanical and
structural inspection / documentation problems identified in KG&E QA Surveil-
lance Report S-372 were rectified has not been provided."
_
 29 of 33

Corrective Action Sa)

" Provide objective evidence that the mechanical and structural support
welding inspection / documentation problems identified in Surveillance Report
S-372 have been corrected. If such evidence is not available, research the
extent of the problem and take the appropriate remedial actions." Activity Sa
was broken down into two categories. Sa-1 was to review and provide
objective evidence that Nechanical Deficiency Reports identified in S-372
have been correctly closed out. Sa-2 was to review and provide objective
evidence that Civil Deficiency Reports identif. d in S-372 have been
correctly closed out.

A total of forty-two deficiency reports were reviewed encompassing the

departments of Civil, Civil / Welding, Mechanical, and Mechanical /Velding which
are identified in S-372. Below is a brief description of the closure to each
Deficiency Report (DR). (Deficiency Reports underlined.)

1. 645) was upgraded to an NCR (INN 4969CV) because all welds

were encapsulated in concrete and deemed structurally
acceptable by the A/E.

2. 6536 and 6538 were "Close in Process" because the hangers were
" VOIDED"; hangers were removed mechanically, and Quality
inspected the area to insure soundness of the affected
structure.

3. 6559, 6557, 6560, 6568 pertained to electrical raceway

hangers. DIC Mechanical / Welding inspectors performed
inspections to ensure the soundness of the removal area af ter
cut down, according to DR disposition. The reinstallation of
these hangers was inspected by DIC Electrical Quality
Inspectors and documented on Electrical Quality Raceway
Support Checklists.

4. 6535, 6537, 6539, 6576, 6575, had dispositions calling for cut
down of hangers only, therefore only the verification for the
inspection of the soundness of the removal area was required.
5. 6585 disposition was "Close in Process" because no hanger
could be located in the area called for by the Deficiency
Report. The two closest hangers have the required documen-
tation and their respective documentation is attached to the
Deficiency Report.
6. 6249, 6250, and 6349 Imve MSSWR's to reflect proper closure,
but the hangers are now voided.Based on this research an
inspection of the applicable Building, Location, and Area
(BLA) for these hangers was. initiated and the hangers were
verified as cut down.

7. The remaining Deficiency Reports have MSSWR's attached to '

reflect the proper documentation for the safety-related |

attachment welds. This group of Deficiency Reports numbers 26 '

total. *

__ __ - _ - _ _ _ - _ _ _ - - - _ - _ _ _ _ _ _ - - - _ - _ _ _ ._- _ _ _ - _ -_ _- _ __ _ _ _ - - - _ _
r'
!
|
30 of 33
|

No violations of 10 CFR 50 Appendix B exist in Items 1 thru 5 as defined

in the criteria of KG&E Surveillance S-372. The violations listed in S-372
pertained to velding documentation on Structural Steel. The dispositions for
the deficiency reports in items 2 thru 4 require the removal of deficient
welds. In some cases MSSVR's were used to document the removal so these
MSSWR's show blanks (or as non-applicable) for W-100, weld technique, filler
material, etc. These should not be mistaken for inco=plete MSSWR's for
required welding, since MSSWR's are not required for this activity.
In summary, all deficiency reports in KG&E Surveillance S-372, have been
reviewed and proper closure verified. All the deficiency reports were closed
properly according to the results of our investigation.

DEFICIENCY REPORT ft

6248 6454 6557 6568

6249 6455 6558 6569
6250 6456 6559 6570
6280 6457 6560 6571
6349 6535 6561 6572
6449 6536 6562 6573
6450 6537 6564 6574
6451 6538 6565 6575
6452 6539 6566 6576
6453 6556 6567 6577
6585
6588

l
-
1

&
 31 of 33

V. Conclusions

The technical evaluation of WCGS structural steel significant joints,

which was performed by Bechtel based upon reinspection data accumulated,
established that safety related AWS DI.1 structural steel welding complies
with all Quality criteria as specified in the related design documents, and
is within the tolerances of acceptable deviation as determined by the
Architect / Engineer. This evaluation for structural integrity was based upon
this cumulative data that reflected the as-built condition of Bechtel
identified structurally significant joints prior to any rework or repairs.

Two thousand six hundred sixty-nine (2,669) structurally significant

joints were identified by Bechtel and were subsequently reinspected by DIC
Certified Quality Inspectors who were all also AWS certified Welding
Inspectors. Eighty one (81) of these significant joints required rework due
to design allowable stresses being exceeded in the as-built condition. None
of the structurally significant joints where discrepancies were identified
would have failed if left uncorrected.

Research accomplished by DIC and Bechtel personnel substantiated that

all DIC welders and welding procedures applicable to AWS DI.1-1975 welding of
structural steel installations were qualified in accordance with AWS
requirements. Additional research resulted in assurance that programs and
procedures applicable to the purchase and control of wcld filler materials
used in AWS D1.1 applications were in compliance to AWS requirements.
7 Investigations into site implementation of these requirements and procedures
! provided assurance that implementation had been effective and properly
controlled by DIC during project construction activities.

The retrievability and control of Miscellaneous Structural Steel Weld

Records (MSSWR's) was investigated, and a determination made that inadequate
implementation of DIC construction procedures was a contributing factor to
retrievability and accountability problems with MSSWR's relative to struc-
tural steel applications. Thorough analysis of each applicable program was
undertaken by DIC Quality Engineerning to determine if similar programmatic
or procedural requirements existed, and whether inadequate implementation had -

resulted in similar deficiencies. The results of these assessments deter-

mined that no programmatic problems existed in any other AWS DI.1 application
relative to inspection documentation required for weld inspections. Evalua-
tions of each application identified that more efficient documentation
methods were utilized, and in each case there was more effective control of
the required documentation through its initiation and processing cycles.
Review of Quality Assurance historical audits and surveillances and an
evaluation of procedural implementation adequacy further assured no problems
existed in any other AWS D1.1 application similar to the MSSWR retrievability
problem on structural steel welding.
Hardware applications of AWS D1.1-1975 requirements were also analyzed
to determine if the root causes applicable to the previous acceptan:e of
deficient structural steel welds were of potential impact in applic.ations
other than structural steel. Reinspection and Corrective Action reports
existed in every case to ensure the acceptability of installed hardware where
'
i
AWS D1.1 welding was utilized except in Electrical Equipment foundation
| k welds. DIC Management determined that a subsequent investigatory effort was ~

,
necessary to provide data to ascertain the possible existence of deficiencies
! in welding and shimming in these installations. DIC Corrective Action Report
| 1-EW-0046 was initiated to document and accomplish these activities.
t,

!
e

,, - . - . . - , - - -,. , ,. _.. _
 1

32 of 33

DIC Corrective Action Reports (CAR) 1-W-0029 and 1-C-0031 were evaluated
to determine why neither of these documents resulted in the appropriate
identification and effective resolution of structural steel welding and
documentation problems prior to KG&E Corrective Action Request 19. CAR
1-W-0029 was found to be effective for the scope of welds identified. A
conclusion was reached, however, that if a larger sample size had been
utilized for CAR 1-V-0029's scope of inspection activities, that corrective
action concurrent with that identified for KGSE CAR-19 may have been decided
appropriate as resolution for the identified problems.

With the generation of DIC CAR 1-C-0031 DIC Hanegement recognized that
documentation did not exist for all structural steel welds as procedurally
required, and nonconformance reports were generated to document these
inadequacies. 'Use-As-Is' dispositions were assigned to these nonconformance
reports based upon the existence of definad programs and procedures that
required 100% inspection and documentation of structural steel welding
activities. An assumption was made that although required documentation was
not 100% retrievable, the programs in place during structural steel installa-
tion / inspection activities did result in all installations being completed
and inspected.
Neither CAR 1-W-0029 nor CAR 1-C-0031 required matching of MSSWR's to
structural steel welds or welded connections. If this had been a required
corrective action for either CAR, the problems identified in portions of KG&E
CAR-19 would have been realized.
The findings addressed in CAR-19 in addition to missing MSSVR's included
deficiencies identified in previously accepted structural steel welds,
missing structural welds or missing structural material, and documentation
that a weld was inspected and accepted, but no weld was installed.
An eveluation of the DIC Quality inspection training program demon-
strated that this program and related procedures were in compliance to ANSI
N45.2.6. Further investigation concluded that Quality inspection tra:ning
was appropriate and adequate during the structural steel installation time
frame. An evaluation of DIC Quality inspection procedures and criteria
applicable to the - original structural steel installation / inspection period
revealed several procedural inadequacies. A thorough analysis of the
omission of each inspection criterion of AWS D1.1 structural steel
applications was accomplished, with the conclusion that no adverse impact had
resulted from these procedural ir' adequacies relative to AWS D1.1 welding
inspection.

Inspection criteria to be used in the structural steel reinspection

activities was procedurally defined and training of all personnel completed
prior to reinspection initiation. Sufficient technical justification was
established by Bechtel to validate inspection of welds through a predeter-
mined maximum thickness of paint. An analysis of reinspection results
determined the root cause of the previous acceptance of deficient structural- .

welds to be due to DIC inspection implementation differences relative to

inspection vs. reinspection techniques, and inadequate implementation of
applicable DIC procedures.
-
 -- - __
. . .

33 of 33

Two (2) of the welds on joints reinspected were initially thought to be

documented as being installed when in reality they were not installed.
Research revealed no evidence to indicate that either was a case of delibe-
rate falsification. Additional investigations resulted in a conclusion that
human error was the cause of incorrectly documenting these nonexistent
installations.

Reinspection found that some welds and materials were not installed as
required by design documents. These errors were primarily due to craft /
engineering errors relative to misunderstanding of installation drawing
details and requirements. Failure to install these welds and materials,
although in some cases determined to be significant in impact to design
stress allowable calculations, would not have resulted in material or struc-
tural failure if left uncorrected. All missing welds will be installed in
accordance with a KG&E Management directive. [

As a result of those concerns identified in KG&E CAR-19, DIC conducted

an assessment of the programmatic aspects of the Piping, Hanger, Mechanical,
Electrical and Civil disciplines to ascertain the adequacy of those programs
instituted in the construction of Wolf Creek Generating Station. Other than
the concern identified in DIC CAR 1-EW-0046 the program assessment has
established a high degree of confidence in the adequacy of the overall DIC
Construction program to assure compliance with 10CFR50, ANSI N45.2, FSAR,
design and procedural requirements. The cause of the adverse conditions
identified in KGSE CAR-19 and DIC CAR 1-EW-0046 is limited to these areas in
that all other areas of work which would have been rendered inadequate or
suspect due to the identified root cause have been adequately addressed
through subsequent means such as retrofit or reinspection programs.

After completion of the program assessment, which addresses all aspects

of the DIC Construction programs in total, and as they might have been
affected by the identified root cause of deficient structural steel welds, it
is the conclusion of this assessment that all significant problems have been
identified and are being adequately addressed and resolved through
appropriate corrective actions.

This program assessment is included in the Appendix, section VI.H of the

KG&E CAR-19 Final Report, and has concluded that a satisfactory leval of
confidence exists to assure compliance with 10CFR50, ANSI N45.2, the FSAR,
and Design and Procedural requirements.
The objective of KG&E CAR-19 was to establish by review of Construction
and Quality programs, as-built conditions, nonconformance identification and
correction and by design evaluation and/or rework, that all structural steel
erection commitments in the Wolf Creek Final Safety Analysis Report were
satisfied. 'Ihrough the cumulative efforts in the resolution of CAR-19
assurance was obtained that all significant Quality criteria as specified in
the related design documents were satisfied, within the tolerances of accep-
table deviations as determined by the Architect / Engineer.
|

|
|

i
 .

* .

.e.. .iw eev ...a

q

,
INTEROFFICE CORRESPONDENCE
:

To: G.L. Feuts *

F3.C M,'.'02
FEM: R.M. Grant
DNIT: Octcber 17, 1954

%N: Corrective Action Request (CAR) No. 19

Attached is Cerrective Action Request (CAR) 819 which is bei.c issued t.c
obtain corrective actions to prehlems associated with safety-ralated %.3
D1.1 structural steel welding.

olease res;cnd
the subject CAR.to this Corrective Action Request by cr.pleti .g Sec.icn 5 cf
Your schedule for i..pleentire corrective actic .s and an
explanation of any actic .s you have already taken should be sub.:.tted te e
by Octcber 24,19M.

Et3/dkb
cc: K.R. Bresn
G.L. Koester .

F.J. Du:idy
W.J. R.:delch II
.
C.E. hr:y
.

4
C.G. ra trick

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1. CCfCI ;CN CE.5;RI?!!;N:

See Attached.

2. FE.SP4' 5131.F. CPCAN!!ATICN:

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 .. -. - - - - - _ - . . __

Pago 1
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I.
ua;m. . CI C!EGIFIICI -

A. Cbiactives
e
To dec=er:t a c::nsolidated project plan for de identific.ati:n,
evaluaticn and resoluti=s of p=blets assoc:.ated
Related Kas D1.1 Welding. with Saferf-
e To provide assurance, based en objective e/iderce. Sat Ah3
Dl.1 Weldirs; cf Safety-Related Structural Steel e n lies with
all cuality Criteria as specificed in d.e related desien
dec=ents and is
as detemined bywithin the tolerances
the Architect of accectable dev:.atter.s
- Engineer.
e To preside assurance that the doe.nentatim '-ttich s:;5cr s the
inscection of safety related str,.:ctura.1 steel wlds is:
- Available
- Co alete
- Reflects apprepriate infernatien
- Traceaole to the item er ac-dvity
e To evaluate s sp::rti.xy elernents of the CIC Cualitf Assurr.ca
-

P- 9 ito ensure that these elements were adecus.alf arxd

effectively i. plemented to dercestrate that the C;C wldi g Of.
safety related st=ctural steel, .WAC S = p;r 3, E le c :.:a l
Su:;crts,
. Pipe bhip Restraints and ar f c.her Jh3 C1.1 saferf
' relatef weldir::r activities were in a.wliance vid the FSA;.
(i.e. JA3 D1.1 - '

Pro:ra :P.anual, Secti n1975) and the Ces:en anc Cmst=== n CA

17.1.B.
B. Oefiniti. .:s
:

Joint - A structural steel wided connecti n. A feint ray

censist of n.. 4=us welds. A feir :ay also be
; referred to as a connec* den.
Weld
- A centir. acus length of weld : aterial with enly e .e
start and one step.
MSS'aA
- Miscellaneous Structural Steel Weld Facerd: a fem used
ty DIC to doc.rnerrt installati:n arrd inscectitn data fer
wlds r ade to structural steel.
.4 3 C1.1 - Arerican Weldirs;: Society's Structural Weldire Code.
This code covers wlding recuirernents applicable to
welded st=ctures. It is to be used in cenjun = t:n
with any cer =lernentary code or specification for the
design arxi constru =ien of steel structures.
.

*discellaneous St=ctural Steel - See Attach:nent S f:r C= plete

Defini* h .

Stru: urally Significant Welds - See Attat nent B for C=plete

Definitien.
.

, _

,- .,
-

, , , , - - ,, - . , - - - - , ., . - - . , , - , - . . . , . . - , - - -
 Paga 2 i
.

C. Back=rct9.d Iri-:=aHm
.

.e
EE Steveillance
Quality Recort S-372 (Octcber, 1931) identified a
FI %. c_2 breakt:bwn due to the felles:rg deficiencies:
- Missing inspectica docu entaticn
- Ino:2 olete/1: procer resolutien of ifentified electrical,
rechanical and structural weld docenentatien deficiencies.
The
$9.
Surveillance Re;crt resulted in the issuance of CIC CAR
CAR 89 pertained exclusively to"the major firding of the
Surveillance i
Report, that being electrical sucocrt veld
inspection docenentation. An agree ent beween EE ard t!C i
i
cuality Management was reached that recuired IGE to issue a '

CAR if the DIC resolution was unsatisfactory to EE.

o
DIC CAR No.1-E-009 (October, 1981) was subsequently issued to
,

adfress the electrical support weld inspection doc. entatien {

concerns identified in the KGE Surveillance Report. The rect
causes of the problems identified in the EE St=veillance
Reper. were determined by DIC to ber
'Ihe
lack of notification by the res;cnsible craft to cuality
inspecters that welding activit/ was schsiuled to c::mence.
- Ir:reper processire and filing of weld records. ,

- The existance of a sincie part dec.rnent as cypesed to a,

triplicate type ferm to record ins:ecticcs.
'
<

The corrective reasures taken by DIC invcived de re.rinirs cf

ccnstructicn ergineering persennel and the placement cf
limitatiens en
dis;:esitions tothe authoricaticn
reficiency level recuired to :=1tiate the
Rescrts.
Sever-ber, 1992. The Ca sas clesed in
i

e DIC CAR 1-W-0029 (March, 1993) was initiated to address s:rne

weld insceetien incensistancies in the Auxiliary, Centrol ard
Fuel Buildi:ss. 'Ib irr/estigate the extent of the prcblem 241
welds were
inspecto., as irwed of which 147 were identified by the
deficient.
7b resolve the conditica identified
on the CAR, NCR 1ml0381PW we.sigenerated. The evaluation of
the !CR involved another inspecticn by *deldirs 1'.'gineering
which resulted in the determinatien that c .ly 22 welds
exhibited potentially significant conditiens ard sere subse-
q;ently evaluated by the Architect'- Engineer and disscsitiened
"use-as-is". Based en the,tCR ard its clcsure, ''IC clcsed
CAR 1-W-0029 in Octcber, 1933.
*
DIC CAR l-C-0031 (August, 1983) sta'tes in part:
,

"MSE'Rs used to doct::.ent safety related structural steel

selded connectiens thrcugh out "O" designated areas is
.inadeg.: ate. A sa ele survey made by (DIC) Q.E. has shown
16.4%in
welds ofthe
theFuel
recuired
Bldg.!ESWRs cannot be located for all "Q"
A- survey of 6 erectien/ design
drawirgs in the Reactor Bldg revealed 24% of the velds are
( missirs docenentaticn. In additicG M/W Cuality has
initiated a !CR (1SN11957Cf) to docenent 42 missing MSShAs
for welds in the ISE PC."!phouse."
h
.,

_
 - - - - -

.
,

*
.
Fage 3

...
Se CJ was disicsiti:ned to write an tCR f:r eac:n safety
related building to address the :.irsi::: .%T s. Al*50cch de
Ca rermins cpen, the pr pesed justifiesti:n f r cl := e is
based in part on de elesure of DIC Ca 1-W-G29.
! e Current Project Acti=ns
- Doc.:nent Feer.ciliatien Tasa Cn Aue.:st 13,19M, a d:ctner.:
;
reconciliation erfert was initiated at de direc.icn of
project ry.:w;ernant to deter.ine which safety related
struct=al steel welds identified on design drawires were
, lacking inspection doct..nentatien in the fc=n of PSEn'Rs.
- Inroecticn Verificatien Plan: Cn Aucust 17, 19M, an
inspectica verification etfort sas initiated at the directicn
of project ranageme.st to pre /ide an accurate asses. nent cf
the "as-hsilt" ccnditiens of safety related st=cutral steel
welded cc=ecticns with unretrievable MSSWR's. These
activities are being perfer:ned by a c:rbined team cf DIC ard
Architect - Engineer E3 Certified Weldirz; Inspectcrs u-der
direct supe: vision of ME C nst=cticn CC. S ese activities
are beirs; perfermed in accer.'.ance with written inst =:: ens
issued by KGE Censcacticn CC which reflect the criteria of
L3 Dl.1-1975 and the apelicable Arenitect - Ercineer desien
docu ents. he results of these verificatiens ard te review
cf Surteillance Recer 5-372 have caused the fi-dirns in
Sectica E cf this re;crt to be issued.
.
D. Rec.lirecssnts

ne welding cf safety related stract=al steel cc=ectiens at m

is ce/erned by weldirq cede L3 D1.1-1975. ~he W CS N.R i:.tkes
dis code for each safety related st= tre. In additien, SWFPS
project specificatien 19466 c-122 (0) Rev. O thr:och 14 entitled
" Technical Specificatien fer C:ntract fer Erection of St==u.al
Steel fer the (S:iUPPS) Pcuer Plant" and specificati:n
1046G-C-132(C), Pav. O thrcugh 8 titled " Technical Specification
for Erecting Miscellaneous Metal fer the Stardardized ibclear Unit
PcMer Plant System (SNUFPS)" recuires st== tral steel welds : be
perf =ned in accer *ance with e3 C1.1-1975, sith exceptions in te
cr:.teria for undere..t (para. 8.5.2) and seld cc:riexity (para.
B.5.3).
2. Findincs - T cacts - F m .m ded Cerrective A W .s
?.e five fi-dings listed belcw were identified durire ce Oc FC05
: a . age ent assess ents described in the 'Sackgrc=d Infer:.stien'
secti n of dis repc= ard a reiiew cf Su:reillance Recert S-372
by ME CA. Cellectively, these represent a breakd:sn cf d e
ccnst=ctcr's Cuality Assurance crogram. This ccnditi::n sus -

caused by an a: parent incensistent applicatica cf weld inspection

criteria, fail =e to i=pleenent procedral re=uircrents for d:e.:-
rnenti:q inscecticas, and failure to i.=lement effective cer ective
-
ac-icns fer identified deficiencies.

-. ,-rm,e -
, y -,e--.-~
 -

.
page 4 .

/
'
.Pi .8irn $1t,'I?m . remits of the hN bu M 6ti=n hk
.

iMi6 trat 1*.39 cf s16 Nss:1Rs fcr saicty related

structural steel welds are m4=iny. (See Attacrrnent 2)
Ir::act:
Without the doe._nentatien fer the st== ural selds, the
f=11cwing areas are iMetemirate:
- Walder identification aM qualificatien
- Filler inetal traceability
- Visual inspection results ;
.

- Cualified weld p:ccedures specificati:n used ,

Recerrended Cer ective Actic .s Actions la throu t, lh belcw will

adecuately address all of the conce=s identified in Firriig al ,

aM the " rect cause" concems associated with FiMing 42. -

!
i

la. Based cn DIC p:t: gram recuirements, assure that all of the I,
welders aM weldirn procedure specificatiens were qualified
to AWS Dl.1 - 1975.
lb. Review the DIC program fer the p.rchase arvi cont:01 cf filler
raterial to ensure that only acceptable filler raterial ses .
used in safety related structural steel welds.
}
Ic. Dialuate the adecuacy of the CIC ir.specticn criteria a:xi-
procedures to cetemine ~ if these elements cculd ' rave ,

j
adversely i. pacted either the results of the initial inspec-
tiens er the results of the verificatien clan. Docu::ent aM
preiide this evaluatien to KG&E CA fer review prier to any
additional irwien i: plementatien. Ar:y earx;es in
1.specticn criteria and precedures shall be previded to :C&I
CA fer review.
:
!
ld. Cbtain a doe.rnented evaluatien to determine the validity cf '

inspectiens perfc=ad with the presence of pairt en the veld.

le. Utilize persennel certified to ANSI N45.2.6 - 1978 fer the :
inspecticn of safety-related structural steel welds. '
Inspections shall be perfe: nod in acccrdance with the CIC
Cualitf P. v and training shall be perfc med and
doe.:nented to assure that inspecters are cogri nt of the CIC y

Cuality Inspectica program regairements.

.

lf. Perfer= a 100% rei .srectica of all structu ally signifier.: t

safety-related structural steel welds with missi:n ."SSWR's.

W.e identificatien cf " structurally significant" selds shall
te :ade by t'.e Architect -
Encineer (See Atta@ren 3).
Inspect the selds per rec = r erristiens 1c, Id, le,19, lh r.d
2a.
|
Ig. Use an :LR to c'etain arxd doc mnt a suitability fer servica |

evaluatien of iraccessable welds. !

( lh. Report all identified deficiea.cies en an :LR. |

\

...................................... 1
u
||
11

b
 __ -.

Page 5
.. , .
)
,

Fi~lir::: ^2: An i ,nset.ics verifica+4 ~s e.h of safety-relata:1

i

str.=:tural steel wid.irg, i6 by 12 cartifad

weld inscectcrs idarv 4 #M several areas of
GNH M =. > NM M M - have txen
C2t* W b el D W:
- Undersized welds
- Wald defects
- L- i. configuratico
- Wald ur u
- Weld undercut
L et: W.ese deficiencies cculd jWire de st=ctural
integrity of the cen:.ecti:n.
Fec=79eMed Cerree.ive Actiens: Acticns 2a th.Ough 2d belcw will
acecuacely acdress all or tr.e cencerns identified in Fi:dirg :2
a-d de irrestigative actiens regaired t/ Findire 35.
2a.
ete =ine aM doc nent the " rect cause" cf de previcus
acceptance of deficier.t st=c=.._1. elds.
Supocrt, Elec rical Str yert, Pipe-b~ nipAnalize the E.7-C
Festraint aM any
cther safety-related progra.a utilizira EG Dl.1 ieldi.; c,
-

ensure dat ce
steel -eldirg prsa. e " '.ere
gram rect causes" inherent
nct gener:0 in the str.:= ural
te cther r. 4.: .s .
Ib.
Ferfc= a 100% reinsree-den of all stru=urally sig.ificen.
safe /-related st=ctural steel -elds havirs P.5LTs. 2.e
identificatien cf "st=cturally significan_" ' elds shall be
ade tf the Architect - Engineer (See Attach.nent 3). ;.spect
te wlds per reccmerxiatiens Ic, Id, le,1g, lh, arri 2a.
7c.
Evaluate the results of the c= pleted Inspection Verificatien
.
Plan agair.st the accectance criteria used in Ac*.icn ic.
2d.
Any ider.tified deficiencies shall be dec:mented en an : 7CR.
....
**............+..................
Firriirx2 53: A snal.1 r:mber of safety-rnlated strmal steel
w_lds were not rnade or had missirg r:ntarial.
: cac : ?.e str.:etural integrity has possibly been jeccardized.
Fec=: e~3ed C - e_ive Ac-icn: ?.e fell: vira acticn and the
encir.eerirg c s;csitten will adecn:ately address Findirg 53. -

3a. F:: ard the "as-built"

infer: atien to the Arc.hitect -

. Encineer via an II~.R to cbtain an engineering evaluatien and

dispcsiti:n.
k
............
.........................
.

.
 __ . _ _ _ - . _ . _ _ . . - - . _ __ _ _ _
.

-
Page 6
.

"Pi iirr ner $4s' Cid (1) wmM was hed as having been insmect:ss
Wun in reality t h weld was not nede. (Raf. Ht2
1sI29495ct)
I=act: The in. w w Qio made the error cculd have i. preperly -
|
'
%=nted other welds. The structural integrity has
poesiMy been jeopardized. I

R - ...e-Jed Corrective Actient The folicwing acti:n will ade-

; quately address Fin:a.ng 94.
4a. Investigate the concern to deterr.u.no the root cause of the
error. Lm ediately notify M Quality Assurance if any
other problems of this nature are identified. Doctrnant the
investigative actions. The noe48!r2tien of M CA shall not
preclude the issuance of an !CR.

. . **..**.................***....* ....

Firriirrr $5: Cbjective evir*=nt-= t2at the anchanical and struct2xral

w=Mirry inspecticnfr rvswmeirm pedalens identafied a
.

in M CA Surv=$11anr m Rapart S-372 were recei 6 ari

*
has not been prev 2 dad.
; Ir=act: tere is a sessibility that the rechanical arxi
structural sup weldi::p inspecticn/ doc'rentaticn
pr bleres identified in the Surveillance Regert were not
corrected.
Reccrrerxiad Cerective Actien: ne foll:.wi:q acticn will ade-
cp.ately accress Finalng a:5.
;

Sa. Provide objective evidence that the mechanical and structural

support welding inspecti:n/decznentation problems identified
in Surveillance Report. 5-372 have been acrrected. If such
evidence is not available, research the extent of the prcblem
and take the appropriate remedial actiens.
i |
1
] |
i
|

| F. F ...-ed Cerrive Acticn Flc e Diacr=ts

See Attach.ent C.
|

'
l
i
I
I

I
I

\.

1 -

i
.
.r.,, -, - - - , - - , - - -,w---~-y,, y.- . , , -,_y ,,,~sr -va''r --'e'-- -e-+m'r --''-Ha------T---'e~---*------*-e' e--ww--*""r- "i-6r e*e'*-*-r*-"w -
 .

"aLNAGEMENT
.

* *
PLAN POR THE RESOLUTION OF CAR-19
T-
Overview

The objectives of this plan are as delineated in CAR-19. These

objectives will be met by providing objective evidence that each of

the corrective actions specified within CAR-19 are satisfactorily imple-

cented. The intent is to verify that both the hardware and programmatic
aspects of all safety related activities utili:ing AWS Dl.1 welding

are in compliance with the FSAR (i.e. AWS Dl.1 - 1975) and the Design

and Construction Program Manual (Section 17.lB).

The attached logic chart illustrates the approacn to be used in

providing the above mentioned verifications. The Corrective Actions

associated with each of the steps on the logic enart are identified

en the chart.

All Corrective Actions shall be implemented in strict accordance

with CAR-19 including review and approval cf specific items by KG&E

QA where requested. Flow diagrams ! attachments C-1 and C-2 of the
CAR) have been and will continue to be' considered in developing corree-
tive actions.

, Upon completion of each of the corrective actions necessary to

resolve CAR-19, reports will be prepared which su==arize action taken.

These summary reports will be used internally by DIC in the preparation

of evaluations which will be submitted to KG&E to be used in the prepara-
tion of a final report.
.

Findings and Corrective Actions

The following pages include the Findings and Corrective Actions

.

, as presented in the subject CAR. The detailed activities required

(,
to implement each Corrective Action are listed beneath the Corrective

y --, , . , -
v - - - , , , r , -- % - , - , y -
7
 .

Actions. The nu= baring, system for.. findings and corrective actions

used in CAR-19 correspond directly with those used herein. Responsible

key personnel are also provided.

I
w
 i

*
ATTACIDiENT (2}
7 . .

.c

KG&E MANAGEMENT PLAN

NOVEMBER 14, 1984 (Revision 1)

(,
m ,

|
- 1
. . - . -
 ,

.
.

K Cr & & CAR 17 ATTAcnu u c.2

p;oawENats cossecT.ivs . A:ftos .5:,0W s: AqxA/A
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516,41.5| CA 47 :

... -
 _ _ _ . . _ . . . .

l - - - - * -
AMCDENT B

1.
Definitlen of Min 11anaa= St_m- al st 1:
Miscellaneous
p:rpcses Str.:ctural
of this CAR. Steel is divided into t o (2) parts fer the
4

A.
i
Main Prums arid Asw4= tad :"_m.:
Main frame welds are
which suppert the main building flecrsthese welds en structural steel cenne
*
reefs. Ter efficiency, (c::ncrete er grating) ard
these
drawing" basis rather than connections are identified on a "per
individually. Therefore, categcriring each piece of steel
a
include certain "asacciated" connecticns, such as,it is inevitable th
welds other than
these which support main building ficers a.M roof, which are
, depicted
steel. en drawings prirarily shcv.ng rain tuilding f1cer and reef
l

1.
B. Miscella. w :
Miscellanecus welds
connect steel which does not
buildi.7 ficers er roofs rt rain' si.
(i.e.,
classified as rain fra.e
9 all structural steel'' welds rce
j er associated welds). ':his dces ret
,
include hard-rails, tee-plates, and si:.ilar iter.s.
2.
Definitic:n of Str.:ca.:rallv Sicnificant Melds:
':supycrt
hose welds
and which
protectare recuirad in the ccrelated buildi:n str.:cture to
*'
n elds for te perary supeerts, safety related soui; rent and buildi r.J c::r;cnents.

4
tee-plates, and similar ite.s ncc-safety related sucports, ha.M -rails,
significant by this definiticn. are not censidered to be str.:cturally

! /
:
(.
;

, . . _ _ _ _ . _ _ . _ _ _ , _ . - - - _ _ - - . _ , . , , _ _ , _ , _ , _ , _ _ . . . , _ _ _ . . . _ _ , _ _ _ _ - _ _ _ _ _ __ _ , _ _ _ . . - _ _ _ _ _ _ . _
 ,

e - -
.

.
A CA~- E .'~'A
DATE: C /l / 4
' E: v5LNGC
_

TIME: T OO ' * _

TE _an675-V150
TE: _!!564-150

TELEcuCNE ChtL MECCRD

TO: Lawrence Martin
FRCM _CMaynard. PAudoloh.
MLinesav. CParr i
CCMPANY: NAC Deoten IV
ADOREES: Arlincten. Texas
TELEPHCNE NO. _817/960 a100

SUBJECT: (use anx)

Pctential 10CFR50.55(e) Inspecticn of Welds.

We infermed Mr. Martin that during cur re-inspection of

which
we had nc inspection raccrcs, welds fer
we identified
and 4 lateral suoports4ferwelds
the en tpa
centainment
eccler
instrumentaticn platfrom
tubing that were inecre
not installed. We are
investigating to determine whether or not
the ccnciticn was
dccumentec and why they had not been installed.

'

O "w".. T,*
. :J" ,T

$5%Q
e
.. e
@ s~ .
..

ACTICN REQUIRED AND DATE:

Licensing coordinate 20-day rescrt -
due 10/18/84
DISTR 15UTICN:G Kcester
F Rhc=es F Dudcy H Pundy/B Partlett/W Gulcemend
M Will:ams R Pcque/F 2aval
G Fcuts C Parry /M Lindsay
R Hagan R Grant
M Jennsen W Rudolch J Bailey /D Prichard ,,
A Beat
G Rathbun R G1=ver S Seiken f, / ,,/ /
L Stevens G Baker gg/f|i '
,
O
F Field B M2yer f l'
,e t?^: M/,9 ~
(signature

4
 _Pindino 01:
_
.
"The.results of the. Docurent 'ecenc:liat en Task Force
.
-

indicated that 1509 of 6Eli "s S'.;P ' s fer sciety Related
.

Structural Steel uelds are missin=."

RESPONSIBILIT_Y

la) " Based on DIC program require..ents assure tnat

all of the welders and welding procedures ';ere .

qualified to AWS'D1.1."
K. Hollinesworth la-1 DIC develop AWS DI.1 attribute
B. Newton checklist
and review welding procedure and welder
qualification procedure against this check-
list; include documentation of procedure
review cycle.
K. Hollinesworth la-2 DIC perform statistical
B. Newton sampling plan in

accordance with MIL-STD-10f D to verify quali-

fications of welders appearing on randonly
selected MSSWR's.
G. Stanlev la-3
M. Pitre Bechtel review and comrent on DIC Welding
Procedure Specification and Welder Qualifica-

tion Procedure as to co.mpliance to At:5 D1.1.

D.
Mauldin_ la-4
Provide report su:T.arizing the results of
the above.
lb) " Review the DIC program for the purchase and control

.
of filler material to ensure that only acceptable
filler caterial was used in safety related welds.
Assure that both safety .

related and non-safety |

;

related filler materials were properly controlled i

(. to preclude inproper application."

 --

?. Mollineswerth lb-1
B. Newton DIC review procec.:re s ter :ne pur: nase and
- - - - * **
centrol
'o f filler and rase raterials and i

prepare descriptiensjust:.fi:ation.
G. Stanlev lb-2
Bechtel review procedures for the purchase
and control of filler : aterials and comment.
D. Mauldin Ib-3 Prepare summary repert.
Ic)
" Evaluate the adequacy of the DIC inspection criteria
and procedures to determine if these elements could
have adversely impacted the inspection
results.

Document and provide this evaluation to KG&E CA

for review prior to inspe= tion implementation.

Any changes in inspection criteria and procedures

shall be provided to KG&I CA for review - prior to
implementation.
D. Mauldin Ic-1
J. Ayres Develop AWS and site steelfication attribute
checklist related to inspecticn requirements.
Review DIC inspection criteria and procedures
in accordance with checklists.
J. Avres
le-2.0 Document this evaluation.
J. Avres le-2.1 Surr.arize results of le-2.0 and provide

results to XC&E CA.

J. Avres ic-2.2 Ccntinue further actions as 'a result of
Ic-2.0 evaluations.
J. Avres
le-3.0 Discuss evaluation uith KG&E QA.
D. Piedon
T. naleckit
Ic-3.1 KG&E QA provide input / comment on evaluation .

of le-3.0 to DIC.
J. Avres ic-4 Prepare changes / revisions' as necessary and

submit to EC&E QA for review.

.- - - _ _ _ - - _ - - - _ - _ _ - _ _ _ _ _ - - _ - _ _ _ _ _ _ _ _ _ - . - _ _ - _ _ _ _ _ - - - - _ _ _ _ _ _ _ - -- _ _-
 D. "suldin le-5 Prepare sunnary report items 1:-1
' ** '
throuen
J. Ayres 7 ,

ic-4.

L. Pardi Id) "Obtain a documented evaluation to determine the

validity of inspections performed wi n the presen:e
of paint on the weld."

K. Hollinesworth id-l Chtain information from other utility /AE's

B. !;ewton
that have developed a_validatien plan.
B. 1;ewton Id-2 DIC Welding Engineering and Bechtel Review;
G. Brown
add site specific requirements / justification

as necessary and develop site position letter.

C. Stanlev Id-3 Submit letter to KG&E for review and acproval.

D. Mauldin Id-4 Prepare summary report items Id-l througn

Id-3.

le) " Utilize personnel certified to A::SI :;4 : . 2. 6 -

1978 for the inspection of safety related strurtural

steel welds. Inspections- shall be perforced in

accordance with the DIC Quality Program and training

shall be performed and documented to assure that

inspectors . are cognizant of the DIC - Quality program

requirements."
'

D. "a ul t'i n le-1 Incorporate CAR-19 Inspection Verification

Plan into DIC| procedure CCP-VII-200, "Inspec-

tien of 1:elding Process."

W. C. Nesthofh' le-2 Inspection personnel ,to be certified to

J. Fletcher
Af3SI . I;45.2.6 -
'1978 in accordance with DIC -

certification program based on education

~

( and experience levels.

-
,

f
s
 ,

L. Easteruced
J. Fletcher
le-3 S::e spec fic cuah her ces .:: a l :. e hn ted
- . to the re-:nspe:::en cf structural :: eel
I

welds in accorcance .. : t .- tne rece re.ents )

!
I

C ., yF_u..s
s
,
-a .

D. Mauldin le-4 Prepare summary repcrt iters le-1 t .".r c u g n

le-3.

If)
" Perform a 1001 reinspect:en of all structurally
significant safety related strue ural steel welds.
The identification cf " structurally s gnifican:"

welds shall be made by the Architect - Eng:neer."

G. Brown
J. Fletcher
if-l Identification of " structurally significant"
welds by the Arch:tect - Eng:ncer.

" Structurally significant" ;cin:s are defined

as all field welded joints . mien sutter

or potentially support safety related equ:;-

rent and build:ng corpenents. This cas: call;.
includes all field eelds en structural and
miscellaneous steel with the exceptien cf
.

handrail, toeplates, grating, checkered

plate, stairs, ladders and renorail supports. .

These are non-Q itens enzen typically see

significant serv:ce leads during :ne censtruc-
tien process. rome are des gnated as II. I,
.
however, II/I seismic loads are .ons dered
to ;be less severe than service 1 cads. ::eno-
,

.
rails nave been lord tested as part of startup
.

g procedures.
' ,

. I

m_____._.______ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ . . . . _ _ _ _ _ _ _ _ . . _ _ _ . _ _ _ _ _ . . _ _ . _ _ _ _ _ _ _ _ _ . _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ . _ _ _ . _ _ _ _ _ _ _ . _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ . _ _ . _ _ __
F1

~he ;cints are se;e :c: Peentel based

.
en a rev:ew cf cre :::n irs:;ngs preparec
.
, .. .

! by the stru:tural in: ;scellaneous steel

fabricators.

L. Easterwood if-2 Perform re-inspee::ces in at:Ordance with

J. Fletcher
the CAR-19 Inspection Verificatzen Tlan.
*
Use the project nonconfernance program

to obtain and docunent a suitability

for service evaluation of inaccessible

welds.

*
Report all identified def;ciencies en

an NCR.

Bechtel will perform a case by case evaluation

of each joint inspected to determine if

*
as-built condition meets design allowables.
*
'if the as-built condition is a signi-

ficant deficiency in accordance with

10CTR50.55(el.
*
any rework is required.

D. Mauldin 'If-2.1 Summarize data frca if-1, if-2.

J. Fletcher

v. McBride if-3.0 Collect relative data from FCR's, CVR's,

D. Armstrong
NCR's for additional structural welds and

furnish to Beentel.

V. McBride' -1f-3.1 Collect information and furnish -to Bechtel

D. Armstrong
for evaluatien to determine if any additional

structurally significant welds were made.

Reinspect .any additional welds as directed

(
'

from Bechtel evaluation.

D. '4a uldin if-4 Prepare sunmary report on data from items
if-1, if-2, If-3.

_
 Finding 12: "An Inspect:en verificatren cffert cf safety-related

1
.

_.
structural
g
steel welding, undertasen zy A* S cert:fied
.- -
'

welding inspecters ident fied se cerci areas cf deficiencies.

These deficiencies have been categer::ed balcw "
-
Undersized welds
-
Weld defects
-
Incorrect configuration
-
Held underrun
-
Weld undercut

RESPONSIBILITY CORRECTIVE ACTIONS

D. Mauldin 2a)
J. Ayres
" Determine and document the "rco cause" of the
previous acceptance of deficient stractural welds.
Analyze the HVAC Support, Electrical Support, pipe-
Whip Festraint and any other safety-related program
{' .

utili:ing AWS Dl.1 Welding to ensure that the ssre

" root causes" inherent in the structural steel

welding program were not generic to other programs."

D. Meuldirt 2a-1
J. Ayres Review evaluations of DIC inspection program
as performed in Ic. Determine if procedures
could contribute to " root cause".
D.' "auldin 2a-2
D. Garrett
Review inspection training and certification
procedures to- verify ccrpliance to A::SI
M45.2.6 - 1978.
D. vauldin 2a-3
J. Ayres Analyze the deficiencies found in structurally
significant safety related structural steel
welds as documented in the CAR-19 Inspection
-Verification Plan utilizing the original
( .
*:S S WR ,
the Re-Inspection Data Sheets, and
the /.rchitect Engineer evaluation.

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

J. Avres Oa-4 Identif all safe:y relcted activities utill:-

,. * .- ing AWS Di .1 eld: .g.

J. Avres la-5 Review prevacusly cenpalec infermation rela-

tive to inspect:en anc acceptance cf HVAC
and Electrical Supports, and Pipe Knip Res-
traints and any other safety related program
utilizing AWS Dl .1 . Exanples of compiled

information include Construction Self Assess-

ment,. task force reports, QA audits and
surveillances.

D. Mauldin 2a-6
J. Ayres Sumnart:e results of any previous investiga-
tions/ reports related te welding / inspection
of above items.
D. Mauldin 2a-7 Analyze
J. Ayres
prograr.atic elements utilized in .

i
1

the erection /uelding of structural steel

and HVAC and Electrical Supports, Pipe Uhip

Restraints and other items. Develop list
,

of programmatic differences and determine

extent to which these differences would i
1

influence " root causes".

D. Mauldin 2a-8
Provide summary report items 2a-1 through
2a-7

Finding 13:
"A small nutter of safety related structural steel welds
were not r.ade or had missing material."
.

RESPONSIBILITY CORRECTIVE ACTIONS

3a)
" Forward the "as-built" inf',rmation to the Architect /
k
Engineer via an UCR to obtain an engineering evalua-
tion and disposition."
 L. Easteruced
'J. Pletcher
la-1 Missing velds er rater::1 detectec in the
inspections *
,.erferred :: 15 s n.= 11 ce de:u-
- -
9 -

mented on !;CR c 3 I snew ng tne "as-tuilt"

inforratien. Tnese !;;E i s )

shall be 9:ven
to the AE for evaluation a:. :sposition.
D. Bli:zard 3a-2 Verification of incorporatzen of design
F. Raycner
changes.
D. Armstrene Sa-3 Evaluate and deterntne probable cause cf

3a-l.

D. i'a ul din 3a-4 Prepare summary report.

Finding 64
Cne (1) weld was documented as having been inspected
when :n reality tr e weld was not made. (Ref. :;CR IS::

10495Cla

RESPONSIBILITY CORRECTIVE ACTIONS

4a) " Investigate the- concern to determine the root

cause of the error. Ic=ediately notiff KG&E Quality
Assurance if any other problens of this nature
are identified. Document the investigative actions.
The notification of KC&E CA shall not . preclude
the issuance of an :iCR."
D. itauldin 4a-1 Evaluate the results of the CAR-19 Inspection
D. Armstreng
*lerification Plan ti.e., those in s p+.ct icn s

perferred in if) and determine whether a

pattern of deficiencies is found.

O. Arrstrone 4a-2
F. i<a yene r
Identify further actions required if a pattern
of deficiencies is found.
D. ?!auldin 4a-3 Prepare summary report.

_ - _ _ - - - - - _ _ _ _ _ - _ _ . - _ _ _ __- _ - _ _ - _ _ _ - _ _ _ _ _ _ - - - - _ _ _ __
 Pindine 85: "Ob3 ective evidence ina the 3: nan:r31 and 2:r::::r31
.
-. . eldtr.c. . inspect:en/d: n ents :rn re:;e s ;dentif:cd

in EG&E OA Sarveillance Fe;cr 3-2 2 eere rer ;fted

has not been prov ded."

RESPONSIBILITY CORRECTIVE ACTIONS

Sal " Provide c=]ective evidence that the reenanical

and structural support welding Inspect:en/documenta-

tion problems adentified in Surve:11ance Reper:
S-372 have been corree:ed. If such evidence is

not available, research the extent cf the proclen

and take the appropriate renedial actions."
3. Mauldin Sa-1 Review anc prevade os;ect:ve evidence that

Mechan: cal Def:::ency Reports identified

in 5-372 have ceen corree:12 closed cut.

O. "auldin Ea-2 ?eview and provije :::e:::ve e":dence :n::

Civil Oefic:ency Peports . dent fied in 5-2?:

have been : rrectly closed cut.
D. Mauldin Sa-3 Prepare sut.ary report.
.

RESPONSIBILITY _96 REPORT

D. Mauldin
A final comprehens:ve report inclue:n? all evaluations
performed and tne results Of scriv ::es conducted te
provide co;e::ive ev:ience to satisfy -he correct:ye

actions required :y CAP.-l? *a ll te f.repared and subnit:cd

to EG&E Ouait:7 This report vill also include an evalus-

tion of Ocnstructien/Ouslity progrsns in arcas other
inan A>;S 31.1 veldino to detern:ne the pctential of
deficiancias.
-
progrsmnat -
 -
.

ppftd ~ W
f) $Y ,..
--- .. . ... -. . . -

. .

'
.
. .
b .h .

MISC / STRUCTURAL STEEL WELD RECORD (SAFETY-RELATED) doO G

KG 7to o VSoz) A"X
',' '

DWG. C, /d l- 062 9-Q3 JOINT NO.# fg g AREA / LOCATION g I f.g

BASE M ATERIAL PIECE OR HEAT NO. *
_ . . .. --
52 4 !3't. TO
--
4 (D w e /d5 - --

M ATERIAL TYPE g . 3(, _ _ W-100. Ser. No,_ Si 2 cl 6

Ku d t-
, FILLER MATERIAL HEAT NO.lLOT NO. oy.p. A g3 f g WELD PROCEDURE/ A -/./-4 4
WELDER ID .D '2 / 7 QCP-Vil-200
CODE AWS D1.1-75
VISUAL INSPECTION)f M.W 4/,
,
DATE /2 // 4/7 g
, ,
JOINT PREP f//
TYPE NDE A/g FIT-UP g//
RESULTS /
A/ e
OC INSPECTOR /
Ag h pca,.. tid b..i..l TE REVIEWED BY ,)
M/~
'c .T U 'f
REMARKS & Rpnm p/;o d j A)lM Q) % ] U
, a,n,i-u. o A lo74
m.m.m...
.
---

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-- .. v w' . -,-,a s.
DOCUMENT St.cnua
InIHmIg[' 9Qf4f/FY
'

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p
*

/6.5
.,

MISC / STRUCTURAL STEEL WELD RECORD (SAFETY-RELATED)

'

D W G. p g,' 7 fg g [f fgg) hv E JOINT NO. p pgg AREA / LOCATION fgg

L /
BASE M ATERIAL PIECE OR HEAT NO. fy pdra TO _dde r/;or
-

I- i
M ATERIAL TYPE gy4 W-100 Ser. No. 6D pn
FILLER MATERIAL HEAT NO.lLOT NO. gy,p. gcP 3//R. WELD PROCEDURE A/-/-/-
t WELDER 10 .D /87 CODE AWS D1.1-75 OCP-Vil 200
' VISUAL INSPECTION 9hg/ t// DATE_ .3/g/7 f
'
JOINT PREP A/_f
.
/ '
TYPE NDE pg
''
FIT-UP g/// _
-

,
,'RESULTS 44 ,,
-

OC INSPECTOR f, DEM7g DATE 4'A oppem 9.g.|

, REMARKS _
j// //,(:,76 . /,.*, <
. ,,, DANIEL .11tu.. 1070 .!N.R
tus /'ds A|C- .I, ' ' !
.

_.
nt?L!V CONTRDL
\
.
..

_ N /_J Rinm%
% ReisNMfMNT SECTION
% w
 . .
.

,
.- -
.
_

_ _ _ _ . _ _

C cr5 / O,b |..

_.
_. -

. . _ _

.
C._ . . - - - .
- - .c

.
'
.
.
. . .
I 4.7 .

MISC / STRUCTURAL STEEL WELD RECORD (SAFETY RELATED)2 o 41 G

KG7to o A*'
DWG. c /gf._ o62 V502)
''
. 9-o3 JOINT NO.' pa g ARE A/LOCATlON g J /,3,. _

BASE M ATERIAL PIECE OR HEAT NO. *

_ . . .- -
52 M TO /] ( D w e /d5
M ATERIAL TYPE
/. 34 ,
_
_ W-100..Ser. No SI 2 9 6
Ku t
,

. FILLER MATERIAL HEAT NO.lLOT NO. oy.p_ A g3 /R WELD PROCEDURE A/././.4 4

!

- WELDER ID .D ti7 OCP-Vil-200

CODE AWS D1.1-75
VISUAL INSPECTION)f' MW 4/i -

,
DATE /2 // //7 g
, .
JOINT PREP f// j

TYPE NDE_ A// FIT-UP g//

RESULTS /
4/ f, f
OC INSPECTOR /
A/ h g g ,,g,[ t;..i..l TE MI~ REVIEWED BY.)
4 e urEj
REMARKS V- R pm p[.,o
y
g;$ggp .' .n,nuo
m....'.m... o A 1.Q74 -

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inikelo
.
[[h.Y.2y( . - - . . , ...
\ / DOMEM WN
y;
.[
.

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.

!
. - -
MISC / STRUCTURAL STEEL WELD RECORD (SAFETY-RELATED)
pose
'
DWG.y[-[f, o [f.fgz) 7(v 2. JOINT NO. pgr62 AREA / LOCATION
'
% ./
fgg
i BASE M ATERIAL PIECE OR HEAT NO. f y 1 6 2. r/>or
.

: TO .4<t?+
!- 'M ATERIAL TYPE
r
gp4 W.100 Ser. No. 63;1 pn
FILLER MATERIAL HEAT NO.lLOT NO. pp.p. gf3//R. WELD PROCEDURE g,/-/- -

WELDER ID .E> /8f

| CODE AWS D1.175 OCP-Vil 200
VISUAL INSPECTION 9hd (//
.
-

1
DATE .3//<//yf JOINT PREP X//
TYPE NDE pg / /

'
FIT-UP gN/
,
;RESULTS /// -
,,

OC INSPECTOR ,,,
4
NCf/A73
~,.a
k q
DATE /v4
onunm.; 7f
|o
REMARKS _
g// 7
,,//,i,p %.4 / r /* < g
DMIEL Jtyg > 1979
*
-

sus /dc N #iC- -1979 ,

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*= / _

nruno nn cc ;;;;3L
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.

. ._ - .. _ _ _ .
 ~

- - - . . .-. .. . . _~ . 2 -. . ~ . . . . . . .Z . . .

.
- {

*;C-AP-GC2.5
.

dev. E-16-i'
-

- - . - . * - -

PROCEOUPI CHA';GE NOTICE

PC N 0014IRI
NOTICE NCSIR
[
( PROCEDUFI NUMBER OC P-VII-200 PIVISION NDsER 20

JUSTIFICATION FOR CHANGE:

|
To include inspection criteria to be in compliance with Bechtel
,
,
Specification 10466-C-122.
A
)

REQUESTED CHA: IGE (S):

j *

%gST R U g+, c7j

Add Paraaraoh 3.2.5
~ * D A"'
Ca. .g C.,m ~ **
.~a a
, n . e.,
w- 5r.\ , .

--

_
,w _
'
. %

I O ~\
6-

,EROCILUPIS AFTECTED SY THIS CHA:;GE 240TICI:

I
, V1
! !
NONE
e

I
e

(Additional procedures to be listed on back, if necessary.) d

'

APPROVALS:

.-
.

[' ?ORIGI;AICR
||.c .an //- Q ~? 4 -

w~$ i,/,[ya
DATE
DROJECT :1ANAGER // .:AIE

? r'?f!*.v . wr . '.i .I h $
4
/)<M|tLt *
,,,b h ||
" [$
[ROJECT QUALITT : GR. y ~; ATE 0 KG&E. CO.';STAUC['"ICN .' DATE
GR.
V
NOTE:
'
Upon issusnee by Document Control, responsible holders of this
document are required to place this document iznediately follow- -

ing Page 1 of the sffected procedure (s), identifieo above.

.
 - - . . ..- . .

Appenrix Vill
PcgeI
1.0
SC OPE
/
~

g
- :- This instruction
s provices direction for the inspection and do
-Engineering
AWIDI.'l ' intructural steel welds icentified for
accorcance with KC& E C A R-19,
inspectio
cumentation of
2.0
RESPONSIBILITIES
f' 2.1
(' The KC&E Construction Quality Control l.ead Welding
y Conti
Engineering
instruction. shall be responsible for the implementati
2.2
7
i

,
Personnel
of Inspection. certified in accordance
Examination, with ANS
and Testing Personnel for
cati

Phase of Nuclear Power Plants" and

, shall be responsible for performing the inspections and
3.0
activities defined in this instruction.
GENERAL.

3.1
Inspections specified in this instruction shall be performed
utilizing f.'llet weld gauges, steel rulers or steel taceually
measur
-
cacable
gages will be of measurements
capable of measuring 1/32".within 1/16 inch increm
,

; 3.2
"- The welds shall be inspected in accorcance with the d :;
and paragraoh 8.15.1 of the AWS - Structural
(Se2 Page 3) with the following exceptions:
Welcing
.- Code
3.2.1
e

inspected. In these cases visual exa

Engineering evaluation of the inspection ..

performed knowing that paint coes exist on most welcr..

Foreign
cleaning. material (fireproofing, etc) may remain after
This condition is acceptable if the foreign
a determination of the weld status per t
criteria outlined in this appendix.
. .

!
f,
!:
if the foreign material precludes this determination
the weld shall be recleaned prior to inspection. ,

'
3.2.2
Convexity- Fillet welds need not satisfy the convex
;
'
limitations 10466-C-122
Specification of AWS DI.I. Section
and 3.6.1paragra
10466-C-132 Refe
...
3.2.3
Undercut - Undercut shall not exceed 1/32 inch
. Reference
Bechtel Specification
paragraph 6.5.2. 10466-C-122 and 10466-C-132
3.2.4
\
-
" Nail Holes"(Construction Aids) " Nail Hole
some instances will be located where a weld ise required
s in
The " nail holes" may remain open provided the weld o .

both sides of the " nail hole" is increased from

2 inches per side.sh.own on the drawing by 1/16 of an in

- -
. -
I

. Appenoix VI!!
Page 2

-
Reference Becht el crawing C-1003 .*.'iscellaneous St eel
Genera! Note !!.
-
-~ : '

3.2.5 Couges - Gouges in base materials shall not be longer than 3

inches nor deeper than 3/16 of an inen. Couges in weld
metal shall not reouce the section thickness of the weld below
specified size,
f
i' Gouges exceeding the above shall be noted on the Weld Data Sheet
(Exhibit A or B) including cetails such as depth, length, and location
on base or weld material.

Document discrepancies on a nonconformance report.

t
,'
3.3 When inspection reveals a rejectable weld or joint configuration (exclucing)
clip to embed top or bottom weld overrun), the entire joint is to be
"as-built" inspected and all weld sizes and lengths documented. The
"as-built" weld sizes should be accurate as possible ano should reflect
any significant oversized welds within the joint.
3.4 Any missing material identified as a result of insoection per the design
drawing shall be identified on an NC R.
3.5 Document any welder identification (D number) marked on the joint.
, 4.0 DOC UMENTATION

, 4.! The insnection results will be documented on an inspection recort similar

to Exhibit A or B and submitted to KCE,E Construction Quality Control
for final review for completeness ano accuraev. These reports must
be completed in a consistent manner and as a minimum shall contain
the following information.
1. Description and size of weld deficiency.
2. The cimension (distance) between beam and ernbed (to be
reported as " set-back cap").
3. Drawing and detail number.
4. D1ste of inspection.
5. Name and certification number of the AWS CWI who performed
the inspection.
6. Accept / reject.
. 4.2 When any condition is found that does not meet the acceptance criteria
outlined in paragraph 12 and 3.3 of this instruction, a nonconformance
report will be generated in acccrdance with the applicable project
procedi.:re and forwarded to Becntel for evaluation. In order to reduce
the amount of paperwork, it is acceptable to generate one
noncentormance report per building.
4.3 The documentation generated as a result of this inspection Verification
Plan snall become an attachment to C AR-19.
5.0 EXHIBITS
m
'

x 5.I Exhibit A - Weld Data Sheet -

5.2 Exhibit 9 - Weld Data Sheet
!

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GcEZ:X '.' : :
. : AGE 2
8.15 QUALITY OF WELDS
~

8.15.1 Visual Inspection. , All welds
s shall be visually inspected. A weld
shall be accepted by visual inspection
if it shows that:
, 8.15.1.1 The weld has no cracks.
/ 3.15.1.2 Thorough fusion exists
'.
' between weld metal and base metal.
8.15.I.3 All craters are filled to
the full cross section of the welds.
8.15.1.4 Weld profiles are in accor-
,,. dance with 3.6.
'
t
8.15.1.5 - The sum of diameters of
., piping porosity does not exceed 3/8 in.
(9.5 mm) in any linear inch of weld
and shall not exceed 3/4 in. (19.0 mm)
in any 12.in. (305 mm) length of weld,
8.15.l.6Fillet welds in any sinole
continuous weld shall be permitted
to underrun the nominal fillet size re-
quired by 1/16 in. (1.6 mm) ' without
correction provided that the undersize
weld does not exceed 10 percent of
the length of the weld. On web-to-flance
,- welds on girders, no underrun is permitted
'
.
3.6.3 Surfaces of butt ioints recuired
to be flusn shall be finisnec so as not
to recuce the thickness of the thinner
base metal or weld metal by more than
1/32 in. (0.8) or five percent of the
thickness, whicnever is smaller, or leave
reinforcement exceecs ||32
that in.
How e ver, all reinforcement must be
removed where the weld forms part
of a faving or contact surface. Any
reinfercement must blend smootnly into
the plate surfaces with transition areas
free from ecae weld uncercut. Chiocinc
may be used provided it is followe'd by
grinding. Where surface finishing is
required, its roughness valueII shall not
exceed 250 pin. (6.3).
Surface fin:shed
to values of over 125 uin. (3.2 um) throuch
250 uin. shall be finished parallel to
the direction of crimary stress. Surfaces
finisned to values of 125 pin. or less
may be finished in any direction.
3.6.6 Welcs shall be free from overlac.

at the enes for a length equal to twice

,
the width of the flange.
'
g
microir'enes (pin.).
3.6 WELD PROFILES
3.6.I The faces of fillet welds may
be sliqhtly convex, fla t, or sligntly
concave as shown on page 4, with none
of the unacceptable profiles also shown
on Page 4. Except at outsioe corner
joints, the convexity shall not exceed
the value of 0.!S plus 0.03 in. where
5 is the actual size of the fillet weld
/,
in inches. (See Page 4).
*
3.C.2 Croove welos shall preferab!v
'
be made with slicht or minimum rein-
forcement except ' as may be otherwise
provided. In the case of butt ano corner
joints, the reinforcement shall not exceed
1/8 in. (3!2 mm) in height and shall have
gradual transition to the plane of : the
base metal surface Isee Pace 41 Thev i

snall be free of the discontinuities shown

for cutt joints on Pape 4

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