august 17, 2010 pacific northwest national lab p.o. box

August 17, 2010 Michael Andersons Pacific Northwest National Lab P.O. Box 999, MSIN K5-26 Richland, WA 99352 EWI Project No. 51108GTH, “Support for Research on Welding Residual Stress Validation” Dear Michael: Enclosed is EWI’s final report for the welding residual stress validation mockups. In addition to this report, a portable hard drive with all pictures, data reports, and videos documented throughout the project has been provided to Paul Scott at Battelle in Columbus, OH. Please feel free to contact me at 614-688-5183 if you have any questions or comments regarding this project. Sincerely,

Steve Levesque Program Manager Arc Welding Enclosure

Support for Research on Welding Residual Stress Validation EWI Project No. 51108GTH August 17, 2010 Submitted to: Pacific Northwest National Lab Richland, WA

Progress Report

Project No. 51108GTH

on

Support for Research on Welding Residual Stress Validation

to

Pacific Northwest National Lab Richland, WA

August 17, 2010

Steve Levesque EWI

1250 Arthur E. Adams Drive Columbus, OH 43221

i

Contents

Page

Abbreviated Terms....................................................................................................................... iv

1.0 Introduction ............................................................................................................................ 1

2.0 Approach................................................................................................................................ 2 2.1 Material Property Plate Specimen .................................................................................. 2 2.2 IWRS Mock-Up............................................................................................................... 3

2.2.1 Stiffening Weldment .................................................................................................. 3 2.2.2 Nozzle Buttering ........................................................................................................ 4 2.2.3 Safe End Weld .......................................................................................................... 8 2.2.4 Back Weld ............................................................................................................... 15 2.2.5 Safe End to Stainless Pipe Weld............................................................................. 18

2.3 WOM Mock-Up ............................................................................................................. 23 2.3.1 Stiffening Weldment ................................................................................................ 23 2.3.2 Nozzle Buttering ...................................................................................................... 24 2.3.3 Safe End Weld ........................................................................................................ 32 2.3.4 Back Weld ............................................................................................................... 35

Appendix A: International Weld Residual Stress Mock-Up Appendix B: Weld Overlay Residual Stress Mock-Up Appendix C: Stiffening Weld Welding Procedures Appendix D: Nozzle Buttering Welding Procedure Appendix E: Butter Weld Penetrant Inspection Report Appendix F: Safe End and Back Weld Welding Procedure Appendix G: Safe End to Stainless Steel Pipe Tie In Weld Procedure Appendix H: Safe End Inco 182 SMAW Groove Weld Procedure

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Tables

Table 1. Typical Welding Parameters for the Material Property Plate..................................... 3 Table 2. IWRS Safe End Welding Parameters per Pass ...................................................... 11 Table 3. Joint Depth and Distortion Measurements for the IWRS Safe End Weld................ 13 Table 4. Typical Welding Parameters for the IWRS Safe End Back Weld............................ 15 Table 5. Distortion Measurements for the IWRS Safe End Back Weld................................. 17 Table 6. Welding Parameters for the IWRS Safe End to Stainless Steel Pipe Weld ............ 19 Table 7. Joint Depths and Distortion Measurements for IWRS Safe End to Stainless ......... 22 Table 8. Welding Parameters for WOM Butter Welds........................................................... 27 Table 9. Welding Parameters for Safe End Welds using Inco 182 ....................................... 33 Table 10. Distortion Measurements for the WOM Safe End Weld .......................................... 34 Table 11. Distortion Measurements for the WOM Safe End Back Weld ................................. 37 Table 12. Measurements for WOM Safe End to Stainless Steel Pipe Weld ........................... 42

Figures

Figure 1. Materials Properties Plate Joint Dimensions............................................................. 2 Figure 2. Welding of the IWRS Mock Up Internal Groove Stiffening Weld............................... 4 Figure 3. Set-Up for IWRS Mock Up Buttering Welds .............................................................. 5 Figure 4. Completed IWRS Mock Up Buttering Weld............................................................... 5 Figure 5. Bead Map of the IWRS Mock Up Buttering Weld...................................................... 6 Figure 6. Location of the Thermocouples on the Inside Diameter Surface of the .................... 7 Figure 7. Temperature Profile of Weld Pass 1 of the IWRS Butter Layer ................................ 8 Figure 8. Set-Up for the IWRS Safe End Weld with the Fixed GTAW Torch............................ 9 Figure 9. Bead Map for the IWRS Safe End Weld ................................................................. 10 Figure 10. Temperature Profile of Weld Pass 25 of the IWRS Safe End Weld .................... 12 Figure 11. Laser Profilometry Scan on the IWRS Safe End Weld........................................ 14 Figure 12. Laser Profilometry Measurements for the IWRS Safe End Weld ........................ 14 Figure 13. IWRS Safe End Back Weld Bead Pass Map....................................................... 15 Figure 14. Temperature Profile of Weld Pass 1 of the IWRS Safe End Back Weld ............. 16 Figure 15. Laser Profilometry Measurements for the IWRS Safe End Back Weld ............... 18 Figure 16. Photo Showing Thermocouple Locations on the OD of the IWRS Safe End ...... 19 Figure 17. Temperature Profile of Pass 3 of in the IWRS Safe End to Stainless Steel ........ 20 Figure 18. Photo Showing GTAW Root Pass on IWRS Safe End to Stainless Steel ........... 20 Figure 19. Photo Showing Typical SMAW Pass on IWRS Safe End to Stainless Steel....... 21 Figure 20. Photo Showing Completed IWRS Safe End to Stainless Steel Piping Weld....... 21 Figure 21. Bead Map for the IWRS Safe End to Stainless Piping Weld ............................... 22 Figure 22. Welding of the Stiffener Plate on the WOM......................................................... 24 Figure 23. Set-Up for Nozzle Buttering Welds on WOM....................................................... 25 Figure 24. Photo Showing Porosity Indications in WOM Butter Weld .................................. 26 Figure 25. Photo of Rejected Area on WOM Buttering after Grinding .................................. 26 Figure 26. Photo Showing Completed Butter Weld on the WOM Nozzle ............................. 27 Figure 27. Photo Showing ID Grinding and Groove on the WOM Buttering......................... 28 Figure 28. Photo of Dye Penetrant Test on the WOM Buttering........................................... 29 Figure 29. Photo of the ID Welding Torch on the WOM Buttering........................................ 29 Figure 30. Completed WOM ID Butter Weld......................................................................... 30 Figure 31. Thermocouple Locations on the OD of WOM Safe End Weld............................. 31 Figure 32. Thermocouple Locations on the ID of the WOM Safe End for Weld Buttering.... 31

iii

Figure 33. Location of Thermocouples relative to Mockup Lettering Grid ............................ 32 Figure 34. Bead Locations for OD Safe End Welds ............................................................. 33 Figure 35. Laser Scan Data from WOM Safe End Weld ...................................................... 35 Figure 36. Weld Bead Map of the WOM Safe End Back Weld............................................. 36 Figure 37. Temperature Profile of the WOM Safe End Back Weld....................................... 37 Figure 38. Laser scan of WOM Safe End Back Weld........................................................... 38 Figure 39. Location of Thermocouples on the WOM Safe End to Stainless Pipe Weld ....... 39 Figure 40. Typical Temperature Profile for the WOM Safe End to Stainless Pipe Weld ...... 40 Figure 41. Photograph of the GTAW Root Pass of the WOM Safe End to Stainless ........... 40 Figure 42. Photograph of a Typical SMAW Weld on the WOM Safe End to Stainless......... 41 Figure 43. Photograph of the Completed WOM Safe End to Stainless Pipe Weld............... 41 Figure 44. Weld Pass Map for WOM Safe End to Stainless Pipe Weld ............................... 42

iv

Abbreviated Terms

A ampere

Ar argon

cfh cubic feet per hour

GMAW gas metal arc welding

GTAW gas tungsten arc welding

He helium

ID inside diameter

ipm inch per minute

IWRS International Weld Residual Stress

NRC U.S. Nuclear Regulatory Commission

OD outside diameter

PNNL Pacific Northwest National Laboratory

PT penetrant tested

PWHT post-weld heat treatment

RES Office of Nuclear Regulatory Research

RT radiographic testing

s second

SMAW shielded metal arc welding

V voltage

WFS

WOM

wire feed speed

weld overlay mock up

WRS weld residual stress

1

1.0 Introduction The Pacific Northwest National Laboratory (PNNL) supports the Office of Nuclear Regulatory Research (RES) which is part of the U.S. Nuclear Regulatory Commission (NRC). One aspect of the NRC is to evaluate service degradation at commercial nuclear power plants including technologies applied by the industry for detecting this degradation. One of the primary obstacles in predicting service degradation is determining residual stress conditions existing in as-built components. Several computer models are being developed to determine residual stress as a function of materials and welding parameters, but the validity of these models must be factored into regulatory analyses to ensure continued safe operation. The NRC has engaged PNNL to provide technical assistance for these safety analyses. Specifically, a project entitled Residual Stress Analysis and Validation (JCN-N6547). The overall objective of the project was to provide validation assessments of the weld residual stress (WRS) models through nondestructive and destructive laboratory measurements of welded structures simulating actual plant component configurations. The project mainly consisted of fabricating three weldments which would be used to provide validation data for the WRS models. The intent of the first weldment (Material Properties Plate) was to provide mechanical property data that could be used in the (WRS) models. The intent of the second and third weldments was to provide actual residual stress data that could used as a baseline to compare to the (WRS) model results. These two mock-ups are both nozzle assemblies using either the gas tungsten arc welding (GTAW) or shielded metal arc welding (SMAW) process. Throughout this report, the GTAW weldment is refered to as the International Weld Residual Stress (IWRS) mock up and the SMAW weldment is referred to as the Weld Overlay Mock up (WOM). The objective of this report was to provide welding-related data for the Materials Properties Plate and the IWRS and WOM mockups. The assembly details and mockup drawings for the IWRS mock-up are provided in Appendix A. The assembly details and mockup drawings for the WOM are provided in Appendix B. The drawings numbers used during the mockup assembly are called out in the body of this report in the appropriate section.

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2.0 Approach Three mock-ups were fabricated under this program:

1. Material properties plate 2. IWRS mock-up 3. WOM.

These mock-ups were welded in accordance to drawings and procedures provided by Battelle personnel in Columbus, Ohio. 2.1 Material Property Plate Specimen The Material Property Plate weldment was fabricated out of two 1.75-in. (44.5-mm)-thick Inconel 690 plates. Each plate was machined with a J-prep and when butted up resulting in a final U-prep joint geometry. The dimensions of the welding joint are provided in Figure 1. The final dimensions of the completed weld plate were 11- × 40-in. (279- × 1016-mm).

Figure 1. Materials Properties Plate Joint Dimensions The Material Property Plate was welded using the GTAW process using 0.045-in. (1.1-mm) diameter Inconel 82 filler metal. The welding arc was shielded using a 75% argon/25% helium shielding gas at 45 cfh. The range of welding parameters is provided in Table 1. The welding

3

current and wire feed speed (WFS) was changed to increase the deposition rate of the welding process. A total of 96 passes were deposited to fill the U-groove. Upon completion the plate was shipped to EMC2 for machining and mechanical testing. Table 1. Typical Welding Parameters for the Material Property Plate

Current 220-285 A Voltage 10-7-11.2 V WFS 85-100 ipm Travel Speed 6 ipm

2.2 IWRS Mock-Up The IWRS mock-up consisted of several different welds which included a stiffening weldment, a nozzle butter, a safe end weld, a back weld and a safe end to stainless pipe weld. . Each weld is discussed in detail below. Upon completion of the back weld the nozzle was shipped out for residual stress measurements. Once the residual stress measurements were taken, the assembly was returned and the safe end to stainless pipe weld was fabricated prior to the final residual stress measurements. 2.2.1 Stiffening Weldment The intent of the stiffening welds was to simulate actual welding conditions by restraining the nozzle during the nozzle buttering, safe end weld, and back weld. The stiffening weldment consisted of an external fillet weld and an internal groove weld. The external fillet weld was deposited between the A36 steel flange and the SA105 carbon steel nozzle. The internal groove weld was slightly different do to the presence of an internal stainless steel liner on the carbon steel nozzle. This required three different welding procedures. The welding procedures that were used were a combination of pre-qualified welding procedures from AWS D1.1(1). The welding procedures that were used are provided in Appendix C. The welds were deposited using the gas metal arc welding (GMAW) process using spray transfer. The fillet stiffening weld was deposited manually with the flange/nozzle assembly in a fixed position. The internal groove weld was deposited by setting the torch in a fixed position and rotating the flange/nozzle assembly in the 1G welding position underneath the welding arc, using a positioner (Figure 2). The flange/nozzle assembly was preheated to 225°F (107°C) prior to welding with the temperature being maintained until the completion of the weld.

1 Structural Welding Code – Steel, AWS D1.1/D1.1M:2008, American Welding Society, Miami, FL, 2008.

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Figure 2. Welding of the IWRS Mock Up Internal Groove Stiffening Weld

with a Fixed Torch and Rotating Positioner 2.2.2 Nozzle Buttering The nozzle butter was deposited on the end of the nozzle opposite the flange. The butter was deposited using the GTAW with 0.045-in. (1.1-mm)-diameter Inconel 82 welding wire. The welding torch was set in a fixed position and the flange/nozzle assembly was rotated underneath the welding arc using a positioner (Figure 3). The positioner was tilted so the resulting weld would be deposited in the flat position. The welding procedure that was used to deposit the butter layers was previously developed and is provided in Appendix D(2). The first layer of the butter was preheated to 225°F (107°C), the second and third layers of the butter were preheated to 200°F (93°C). The remaining layers were deposited with no required minimum preheat. A total of 15 layers were deposited in 137 passes. The completed nozzle butter weld exceeded the final dimension requirements outlined in Battelle Drawing CG482478-204. Figure 4 shows a photograph of the completed buttering weld. Figure 5 shows the bead map for the buttering weld.

2 Levesque, S., “Cylindrical Weld Specimens for Residual Stress Validation,” Edison Welding Institute, Columbus, OH, Dominion Engineering, Inc, Reston, VA, EWI Project No. 51625CSP, March 2009.

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Figure 3. Set-Up for IWRS Mock Up Buttering Welds

Figure 4. Completed IWRS Mock Up Buttering Weld

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Figure 5. Bead Map of the IWRS Mock Up Buttering Weld

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Temperature profiles were recorded during welding by attaching thermocouples to the inside diameter (ID) and outside diameter (OD) of the nozzle. There were three thermocouples located on both the ID and OD surface for a total of six thermocouples (Figure 6). The thermocouples were located 0.25-in. (6.4-mm) from the edge of the machined bevel with 0.25-in. (6.4-mm) spacing between the thermocouples. The thermocouple locations are as follows:

• TC 1 – Located on the ID 0.25-in. (6.4-mm) from the nozzle edge • TC 2 – Located on the ID 0.25-in. (6.4-mm) from TC1 • TC 3 – Located on the ID 0.25-in. (6.4-mm) from TC2 • TC 4 – Located on the OD 0.25-in. (6.4-mm) from the nozzle edge • TC 5 – Located on the OD 0.25-in. (6.4-mm) from TC4 • TC 6 – Located on the OD 0.25-in. (6.4-mm) from TC5.

Figure 6. Location of the Thermocouples on the Inside Diameter Surface of the

IWRS Nozzle

A typical temperature profile is shown in Figure 7. All the temperature data is not included in this report but will be submitted to PNNL as a separate excel file entitled “IWRS Mock-Up – Nozzle Buttering TC Data.” The recording of the temperature data was stopped after butter pass 63 because the welding did not significant increase in temperature at the thermocouple locations.

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Thermocouple Data for Butter Pass 1

0

100

200

300

400

500

600

700

0 100 200 300 400 500 600

Time, sec

Tem

pera

ture

, deg

F TC1TC2TC3TC4TC5TC6

Figure 7. Temperature Profile of Weld Pass 1 of the IWRS Butter Layer The nozzle butter weld was videotaped for record and digital copies videos will be submitted to PNNL upon completion of this program. The nozzle butter weld was penetrant tested (PT) and radiographed (RT) for quality. The penetrant inspection showed only a couple light indications that did not require repair. The penetrant inspection report is provided in Appendix E. The radiographic inspection showed some signs of scattered, small-diameter porosity that was considered acceptable. The nozzle butter weld digital radiographs are not included in this report but will be submitted to PNNL as a separate file upon completion of this program. Upon completion of the weld and radiographic inspection, the assembly was post-weld heat treated (PWHT) to a temperature between 1100-1200°F (593-649°C) for 3 hours and allowed to air cool. The PWHT was to stress relieve the stiffening weldment as well as the nozzle butter weld prior to the machining operation and subsequent welding. 2.2.3 Safe End Weld The safe end weld joint was a partial penetration joint V-preparation described in Battelle Drawing CG482478-206. The measured joint depth was 1.56-in. (39.6-mm) prior to welding. The safe end weld was deposited using a combination of constant current and pulsed current GTAW with 0.045-in. (1.1-mm)-diameter Inconel 82 welding wire. The shielding gas that was used was a 75% Ar/25% He mixture. The welding torch was set in a fixed position with the safe end weld joint being rotated underneath the welding arc using a positioner (Figure 8). There

9

was a total of 40 passes needed to complete the safe end weld. The bead locations are provided in Figure 9.

Figure 8. Set-Up for the IWRS Safe End Weld with the Fixed GTAW Torch and Rotating Positioner

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Figure 9. Bead Map for the IWRS Safe End Weld The welding procedure that was used to deposit the safe end weld was previously developed and is provided in Appendix F. The welding parameters used to deposit each safe end weld pass are listed in Table 2. The passes in Table 2 which report both peak and background current were deposited using pulsed GTAW with a 0.10-s pulse frequency (0.10-s of peak current and 0.10-s of background current). All other passes were deposited using the constant current value listed. The travel speed values listed in Table 2 are the measured linear travel speeds. The variation in the linear travel speed was due to the change in the circumference as the weld was being deposited. As the weld progressed, the through thickness location of the weld changed which increased the linear length per rotation requiring the rotational setting of the positioner to be changed.

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Table 2. IWRS Safe End Welding Parameters per Pass

Current (A) Pass

Peak

Background

Voltage

(V)

Travel Speed (ipm)

WFS (ipm)

1 125 75 9.8 6 20 2 150 100 9.8 6 30 3 220 - 10.7 6 60 4 220 - 9.6 6 85 5 220 - 9.6 6 85 6 260 220 10.2 6 90 7 260 220 10.2 6 90 8 260 220 10.2 7 90 9 260 220 10.2 5.75 90

10 260 220 10.2 5.75 90 11 260 220 10.2 5.75 90 12 260 220 10.2 5.75 90 13 260 220 10.2 5.75 90 14 260 220 10.2 6 90 15 260 220 10.2 6 90 16 260 220 10.2 6 90 17 260 220 10.2 6 90 18 260 220 10.2 6 90 19 260 220 10.2 6 90 20 260 220 10.2 6 90 21 260 220 10.2 6 90 22 260 220 10.2 6 90 23 260 220 10.2 6 90 24 260 220 10.2 6 90 25 260 220 10.2 6 90 26 260 220 10.2 6.125 90 27 260 220 10.2 6.125 90 28 260 220 10.2 6.125 90 29 260 220 10.2 6.125 90 30 260 220 10.2 6.125 90 31 260 220 10.2 6.125 90 32 260 220 10.2 6.125 90 33 260 220 10.2 6.125 90 34 260 220 10.2 6.125 90 35 260 220 10.2 6.125 90 36 220 - 9.6 6.125 85 37 220 - 9.6 6.125 85 38 220 - 9.6 6.125 85 39 220 - 9.6 6.125 85 40 220 - 9.6 6.125 85

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Temperature profiles were recorded during welding by attaching thermocouples to the ID and OD of the safe end. The thermocouple numbering convention changed from the buttering numbering convention due to a faulty channel on the measurement equipment. There were three thermocouples on both the ID and OD surface of the safe end for a total of six thermocouples as noted in Battelle Drawing CG482478-214. The thermocouple location descriptions are as follows:

• TC 1 – Located on the ID of the safe end at 0.25-in. (6.4-mm) from the bevel edge • TC 3 – Located on the ID of the safe end at 0.25-in. (6.4-mm) from TC1 • TC 4 – Located on the ID of the safe end at 0.25-in. (6.4-mm) from TC3 • TC 5 – Located on the OD of the safe end at 0.25-in. (6.4-mm) from the bevel edge • TC 6 – Located on the OD of the safe end at 0.25-in. (6.4-mm) from TC5 • TC 2 – Located on the OD of the safe end at 0.25-in. (6.4-mm) from TC6.

The temperature profile of safe end weld pass 25 is shown in Figure 10. All the temperature data is not included in this report but will be submitted to PNNL as a separate excel files within a folder entitled “IWRS Mock-Up Safe End TC Data.” Random temperature spikes can be seen in a few of the data sets. These spikes should be disregarded due to the thermocouples losing contact, affected by GTAW high frequencies, or other communications errors in the hardware. No usable data was collected for passes 7 – 11, 27 – 29, and 33 – 36 due to data acquisition malfunction.

Thermcouple Data for Safe End Weld Pass 25

0

50

100

150

200

250

300

350

400

0 100 200 300 400 500 600 700 800

Time, sec

Tem

pera

ture

, deg

F ID - GrooveID - MidID - OutOD - GrooveOD - MidOD - Out

Figure 10. Temperature Profile of Weld Pass 25 of the IWRS Safe End Weld

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Measurements were taken during welding to record the associated welding distortion. There were eight pairs of punch marks located around the circumference spaced 45 degrees apart. Each pair of punch marks include one mark on the nozzle side of the joint and one punch mark on the safe end side of the joint. The punch marks were 1-in. (25.4-mm) from the beveled edge. Two distortion measurements were made. The first distortion measurement across the weld joint between each matching pair of punch marks. and the second distortion measurement was between the safe end punch mark and the end of the safe end opposite the weld joint. Distortion measurements were made after the safe end and nozzle were tacked together, after the root pass was deposited, after the hot pass was deposited, and after passes 3, 7, 14, 25, and 40. Passes 7, 14, 25, and 40 correspond with joint being filled 25, 50, 75, and 100%, respectively. The temperature of the assembly during the distortion measurements was kept below 150°F (66°C) to assure all the thermal shrinkage has occurred. The distortion measurements are shown in Table 3. Table 3. Joint Depth and Distortion Measurements for the IWRS Safe End Weld

Weld Pass Location 0 Root Hot Pass 3 7 14 25 40 1 1.5160 1.4085 1.3560 1.0930 0.7390 0.3430 -0.04303 1.4860 1.4275 1.3605 1.1080 0.7520 0.3520 -0.04105 1.4890 1.4155 1.3600 1.0990 0.7430 0.3410 -0.0530

Joint Depth

7 1.4890 1.4115 1.3500 1.0930 0.7230 0.3250 -0.06301 2.7080 2.6945 2.6795 2.6630 2.6130 2.5840 2.5765 2.5740 2 2.7185 2.7040 2.6895 2.6685 2.6230 2.5920 2.5875 2.5805 3 2.7635 2.7495 2.7340 2.7115 2.6640 2.6365 2.6290 2.6235 4 2.7355 2.7185 2.7045 2.6820 2.6340 2.5985 2.5950 2.5935 5 2.6935 2.6765 2.6620 2.6365 2.5920 2.5620 2.5520 2.5540 6 2.7255 2.7075 2.6920 2.6660 2.6230 2.5940 2.5850 2.5815 7 2.6490 2.6325 2.6180 2.5930 2.5475 2.5165 2.5115 2.5075

Point to

Point

8 2.7185 2.7015 2.6880 2.6650 2.6140 2.5905 2.5815 2.5800 1 4.3555 4.3515 4.3525 4.3570 4.3575 4.3575 4.3600 4.3605 2 4.3600 4.3575 4.3575 4.3620 4.3630 4.3650 4.3660 4.3655 3 4.3080 4.3070 4.3090 4.3090 4.3090 4.3095 4.3095 4.3050 4 4.2855 4.2830 4.2825 4.2835 4.2855 4.2835 4.2885 4.2890 5 4.2930 4.2945 4.2945 4.2995 4.2955 4.2990 4.3040 4.2990 6 4.3375 4.3345 4.3355 4.3375 4.3370 4.3415 4.3425 4.3430 7 4.3380 4.3395 4.3370 4.3315 4.3415 4.3450 4.3455 4.3420

Point to End

8 4.3425 4.3230 4.3255 4.3250 4.3265 4.3245 4.3310 4.3350 Laser profilometry was conducted on the safe end weld to map the bead location. A photograph of the laser scanning the safe end weld is shown in Figure 11. Laser scans for the machined joint, hot pass and passes 3, 7, 14, and 50 are combined and shown in Figure 12. All the laser

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profilometry data is included in this report; however, the data will be submitted to PNNL in a file entitled “IWRS Mock-Up Safe End Laser Scans.”

Figure 11. Laser Profilometry Scan on the IWRS Safe End Weld

Laser Profilometry of Safe End Weld

485

490

495

500

505

510

515

520

525

530

535

-60 -40 -20 0 20 40 60

Width of Joint, mm

Dep

th o

f Joi

nt, m

m JointPass 2Pass 3Pass 7Pass 14Pass 25Pass 40

Figure 12. Laser Profilometry Measurements for the IWRS Safe End Weld The safe end weld was videotaped for record and digital copies of the videos will be submitted to PNNL upon completion of this program in a file entitled “IWRS Mock-Up Safe End Videos”.

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2.2.4 Back Weld The back weld joint has a V-preparation which was machined into the previously deposited safe end weld and is described in Battelle Drawing CG482478-208. The back weld was deposited using GTAW with 0.045-in. (1.1-mm)-diameter Inconel 82 welding wire and with a 75% Ar/25% He shielding gas mixture . The welding torch was set in a fixed position with access to the ID surface was and weldment was rotated underneath the welding arc using a positioner. There was a total of 27 passes needed to complete the back weld. The bead locations are provided in Figure 13. The welding procedure that was used to deposit the safe end weld was also used to deposit the back weld (Appendix F). The welding parameters used to deposit each back weld pass are listed in Table 4.

Figure 13. IWRS Safe End Back Weld Bead Pass Map Table 4. Typical Welding Parameters for the IWRS Safe End Back Weld

Current 200 A Voltage 15.5 V WFS 20 ipm Travel Speed 6 ipm

Temperature profiles were recorded during the back weld by attaching thermocouples to the ID of the safe end. There were a total of five thermocouples used to monitor the temperature of the back weld. The thermocouple locations are as follows:

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• TC 1 – Located on the ID of the safe end at 0.25-in. (6.4-mm) from the groove edge • TC 2 – Located on the ID of the safe end at 0.25-in. (6.4-mm) from TC1 • TC 3 – Located on the ID of the safe end at 0.25-in. (6.4-mm) from TC2 • TC 4 – Located on the ID of the safe end at 0.25-in. (6.4-mm) from the groove edge and

rotated 45 degrees circumferentially from TC1 • TC 5 – Located on the ID of the safe end at 0.25-in. (6.4-mm) from the groove edge and

rotated 90 degrees circumferentially from TC1. The temperature profile of back weld pass 1 is shown in Figure 14. All the temperature data is not included in this report but will be submitted to PNNL as a separate excel file entitled “IWRS Mock-Up – Back Weld TC Data.”

Temperature Data for Back Weld Pass 1

0

50

100

150

200

250

300

350

400

450

0 100 200 300 400 500 600 700

Time, sec

Tem

pera

ture

, deg

F

TC1TC2TC3TC4TC5

Figure 14. Temperature Profile of Weld Pass 1 of the IWRS Safe End Back Weld Measurements were taken during welding to record the associated welding distortion. The punch marks that were used to measure distortion as a result of the safe end weld were also used to measure the distortion as a result of welding the back weld. Distortion measurements were made prior to welding and after the joint was 25, 50, 75, and 100% filled. The temperature of the assembly during the distortion measurements was kept below 150°F (66°C) to assure all the thermal shrinkage has occurred. The distortion measurements are shown in Table 5.

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Table 5. Distortion Measurements for the IWRS Safe End Back Weld

Percentage Filled of Joint Location 0 25 50 75 100 1 2.5740 2.5715 2.5920 2.5570 2.5785 2 2.5805 2.5805 2.6025 2.6000 2.5785 3 2.6235 2.6230 2.5440 2.6300 2.6280 4 2.5935 2.5940 2.6140 2.5960 2.5925 5 2.5540 2.5580 2.5640 2.5540 2.5465 6 2.5815 2.5820 2.6015 2.5835 2.5810 7 2.5075 2.5055 2.5255 2.5075 2.5000

Point to Point

8 2.5800 2.5785 2.5980 2.5805 2.5780 1 4.3605 4.3600 4.3570 4.3070 4.3555 2 4.3655 4.3625 4.3630 4.2870 4.3665 3 4.3050 4.3130 4.3035 4.3115 4.3035 4 4.2890 4.2855 4.2860 4.2900 4.2845 5 4.2990 4.3020 4.2965 4.3010 4.2975 6 4.3430 4.3400 4.3400 4.3450 4.3545 7 4.3420 4.3420 4.3445 4.3425 4.3420

Point to End

8 4.3350 4.3285 4.3245 4.3375 4.3280 Laser profilometry was conducted on the back weld to map the bead location using the same equipment that was used to measure the safe end weld. Laser scans for the machined joint and passes 2, 10, 20, and 27 are combined and shown in Figure 15. It is important to note that when scanning the joint the laser could not intersect the surface perpendicularly due to space constraints. For this reason Figure 15 appears skewed. All the laser profilometry data is not part of this report but will be submitted to PNNL as a separate file entitled “IWRS Mock-Up Safe End Back Weld Laser Scans.” The back weld was videotaped for record and the digital copies of the videos will be submitted to PNNL upon completion of this program. Both the safe end weld and the back weld were radiographically inspected for quality. The radiographic inspection showed some signs of scattered, small diameter porosity which were not considered rejectable indications. The digital radiographs are not included in this report but will be submitted to PNNL as a separate file upon completion of this program.

18

Laser Profilometry of Back Weld

400

425

450

475

500

525

550

-60 -40 -20 0 20 40 60 80

Width of Joint, mm

Dep

th o

f Joi

nt, m

m

JointPass 2Pass 10Pass 20Pass 27

Figure 15. Laser Profilometry Measurements for the IWRS Safe End Back Weld 2.2.5 Safe End to Stainless Pipe Weld After all the stress analysis testing was completed, the IWRS mock-up was returned to EWI for completion of the final weld. This weld was the stainless steel safe end to stainless steel pipe weld. The weld was performed per Battelle Drawing CG482478-213. For first two passes of the safe end to the stainless steel pipe weld were deposited manually using the GTAW process with E308L filler metal in the 2G (Horizontal) position. The balance of the welding was done using the SMAW in the 1G (Flat) rotated position. The procedure is located in Appendix G. As with the earlier safe end weld, temperature profiles, distortion measurements and laser scans were take before and during the welding of the safe end to stainless steel pipe weld. The parameters for welding the safe end to stainless steel weld are listed in Table 6. Figure 16 shows locations of some of the thermocouples. Figure 17 shows a typical temperature profile from one of the welds. Figure 18 through Figure 20 shows the GTAW root pass, a typical SMAW pass and the completed tie in weld respectively. Figure 21 shows the weld pass map. The joint depth and distortion data are listed in Table 7.

19

Table 6. Welding Parameters for the IWRS Safe End to Stainless Steel Pipe Weld

Pass Process Current Voltage Travel Speed

1 GTAW 110 Amps 9.2 Volts ~2.5 ipm 2 GTAW 90 Amps 9.2 Volts ~2.5 ipm

3 - 9 SMAW 1/8” 115 Amps 26 Volts ~4 ipm 10 - 27 SMAW 5/32” 147 Amps 26 Volts ~4 ipm

28 SMAW 1/8” 115 Amps 26 Volts ~4 ipm

Figure 16. Photo Showing Thermocouple Locations on the OD of the IWRS Safe End to Stainless Steel Pipe Weld

20

Figure 17. Temperature Profile of Pass 3 of in the IWRS Safe End to Stainless Steel

Pipe Weld

Figure 18. Photo Showing GTAW Root Pass on IWRS Safe End to Stainless Steel

Pipe Weld

21

Figure 19. Photo Showing Typical SMAW Pass on IWRS Safe End to Stainless Steel PipeWeld

Figure 20. Photo Showing Completed IWRS Safe End to Stainless Steel Piping Weld

22

Figure 21. Bead Map for the IWRS Safe End to Stainless Piping Weld Table 7. Joint Depths and Distortion Measurements for IWRS Safe End to Stainless Steel Piping Weld

Distance from OD Pass

1.3125 0.9585 0.6045 0 Type Location

0 1 Root

2 HP

3 SMAW 25% 50% 75% 100%

Depth A 1.6595 1.6340 1.6335 1.5220 1.2675 0.9535 0.0553

Depth E 1.6560 1.6390 1.6315 1.5310 1.1940 0.9345 0.5280

Depth I 1.6805 1.6720 1.6540 1.5680 1.2785 0.9300 0.5480

Depth M 1.6715 1.6610 1.6590 1.5575 1.2500 0.8950 0.5965

Width A 3.4300 3.4160 3.3955 3.3770 3.2780 3.2325 3.1840 3.1675

C 3.4470 3.4305 3.4075 3.3880 3.2880 3.2465 3.1970 3.1790

E 3.4690 3.4565 3.4385 3.4150 3.0160 3.2740 3.2260 No data

G 3.4285 3.4160 3.3895 3.3765 3.2745 3.2270 3.1890 3.1685

I 3.4040 3.3985 3.3785 3.3575 3.2545 3.2130 3.1695 3.1450

K 3.4450 3.4325 3.4135 3.3945 3.2930 3.2940 3.1015 3.1845

M 3.4450 3.4355 3.4185 3.3965 3.2990 3.2525 3.2065 3.1910

O 3.3885 3.3775 3.3570 3.3455 3.2380 3.1900 3.1480 3.1235

Safe End & Nozzle (IN)

Stainless Piping (OUT)

23

The safe end to stainless steel pipe weld was radiographically inspected for quality. The radiographic inspection showed some signs of scattered, small diameter porosity which were not considered rejectable indications. The digital radiographs are not included in this report but will be submitted to PNNL as a separate file upon completion of this program. After completion of this weld the IWRS mock up was returned for additional stress analysis. 2.3 WOM Mock-Up The WOM mock-up also consisted of several welds. Each weld is discussed in detail below. During fabrication of the initial WOM mock-up, RT results indicated porosity in the weld greater than would be representative of an ASME Section III component, and it was decided that the safe end to nozzle weld including the nozzle buttering weld needed to be repeated. This report details the fabrication of the mockup per the revised drawings located in Appendix B. The mock-up was sectioned per drawing CG482478-400 by water jet cutting to remove both the buttering passes as well as the actual safe end weld. This mock-up was then re-machined per drawing CG482478-401. Fabrication of the mockup continued at the nozzle buttering stage. These welds will be discussed starting in Section 2.3.2 of this document. 2.3.1 Stiffening Weldment The stiffening weldment consisted of an external fillet weld and an internal groove weld. The external fillet weld was deposited between the A36 steel flange and the SA182 (chrome moly) forged nozzle. The internal groove weld required three different welding procedures due to the presence of an internal stainless steel liner on the carbon steel nozzle. The welding procedures were a combination of pre-qualified welding procedures from AWS D1.1(3) and are provided in Appendix C. The welds were deposited with the GMAW process using spray transfer. The fillet weld portion of the stiffening weldment was deposited manually with the flange/nozzle assembly in a fixed position. The internal groove welds was deposited by setting the torch in a fixed position and rotating the flange/nozzle assembly in the 1G welding position underneath the welding arc, using a positioner (Figure 22). The flange/nozzle assembly was preheated to 400°F (205°C) prior to welding with the temperature being maintained until the weld was completed.

3 Structural Welding Code – Steel, AWS D1.1/D1.1M:2008, American Welding Society, Miami, FL, 2008.

24

Figure 22. Welding of the Stiffener Plate on the WOM 2.3.2 Nozzle Buttering The nozzle butter was deposited on the end of the nozzle opposite the flange. The butter was deposited using the GTAW with 0.045-in. (1.2-mm)-diameter Inconel 82 welding wire. The welding torch was set in a fixed position and the flange/nozzle assembly was rotated underneath the welding arc using a positioner (Figure 23). The positioner was tilted so the weld would be deposited in the flat position. The welding procedure that was used to deposit the butter layers was previously developed and is provided in Appendix D. The circumference of the mock-up was divided into eight segments of 45 degrees each labeled A through G. This was done to document the start/stop areas as well as any defects or repairs which might be required. All starts (except one) were done at the 90 degree locations (A, C, E, and G).

25

Figure 23. Set-Up for Nozzle Buttering Welds on WOM The first layer of the butter was preheated to 400°F (205°C), the second layer of the butter was preheated to 200°F (93°C). The remaining layers were deposited with no required minimum preheat. The first welding pass was placed at the ID sleeve interface such that it would tie the stainless steel sleeve to the carbon steel nozzle. During the welding of this pass several indications of porosity/contamination were noticeable in the weld (Figure 24). It was noted that the most likely cause of the porosity/contamination was due to the years of corrosion and contamination build up at the interface between the stainless steel sleeve and the nozzle ID. There was a concern that the porosity from the first pass would permeate through subsequent butter layer passes if it was not repaired or eliminated. A plan was formulated to grind out the porosity/contaminates (Figure 25) such that no surface porosity was visually apparent and manually repair weld the area using GTAW. The repair was completed and the welding on the WOM mockup continued. Each weld layer was completed using a continuous step over index which would provide one complete layer with only one start and one stop. This weld (layer) would amount to between 3 and 5 complete revolutions of the part. Subsequent layers were started from the WOM mock-up’s OD and welded until the last rotation of the torch deposited a weld which overlapped the ID bead by no more than one-quarter of a bead width. This process continued until the minimum thickness of the butter layer had been reached (per drawing CG482478-402) and with minimum overlap of the ID bead.

26

Figure 24. Photo Showing Porosity Indications in WOM Butter Weld

Figure 25. Photo of Rejected Area on WOM Buttering after Grinding

27

A total of 17 layers were deposited in 29 passes and shown in Figure 26. The welding parameters are listed in Table 8. The completed nozzle butter weld exceeded the final dimension requirements outlined in Battelle Drawing CG482478-204.

Figure 26. Photo Showing Completed Butter Weld on the WOM Nozzle Table 8. Welding Parameters for WOM Butter Welds Parameter Edge Beads Standard Beads ID Weld Beads ID Groove Welds Current 220 240 240 240 Voltage 11.5 11.5 11.5 11.5 Wire Feed Speed 60 80 80 80 Travel Speed 5.5 to 6.5 ipm 5.5 to 6.5 ipm 5.5 to 6.5 ipm 5.5 to 6.5 ipm After completion of the butter layer, the ID bead at the sleeve/nozzle interface and the ID surface of the butter layer were ground cleanError! Reference source not found.. A small groove was ground at the location of the sleeve/nozzle interface to help eliminate some of the previously deposited porosity. After the ID grinding had been completed, the surface was dye penetrant inspected to assure no defects remained on the ID surface. If indications were present then these areas were ground again and an additional dye penetrant was performed (Figure 28). After the surface was free from indications it was wiped clean with solvent and prepared for welding. An ID welder (Figure 29) deposited weld metal on the ID of the butter to allow for proper machining of the safe-end weld joint. Welds started to the inboard side and

28

stepped outward (towards open end of the nozzle) taking care not to weld at the sleeve/nozzle interface. A total of four full or partial layers were completed on the nozzle ID to assure adequate material was present for proper maching. Two short autogenous passes were done to repair two areas of over/under fill, which completed the nozzle buttering operation. Figure 30 shows the completed weld ID.

Figure 27. Photo Showing ID Grinding and Groove on the WOM Buttering

29

Figure 28. Photo of Dye Penetrant Test on the WOM Buttering

Figure 29. Photo of the ID Welding Torch on the WOM Buttering

30

Figure 30. Completed WOM ID Butter Weld An RT of the butter weld was performed. Some small diameter porosity indications were detected; however, the indications were not considered rejectable. The digital radiographs are not included in this report but will be submitted to PNNL as a separate file upon completion of this program. Temperature profiles were recorded during welding by attaching thermocouples to the ID and OD of the nozzle. There were three thermocouples at each location for a total of six thermocouples (Figure 31 and Figure 32). The thermocouples were located 0.25-in. (6.4-mm) from the edge of the machined bevel with 0.25-in. (6.4-mm) spacing between the thermocouples. The thermocouples were located at 2 inches past the “C” location mark (Figure 33). The thermocouple identification and locations are as follows:

• TC 1 – Located on the OD 0.25-in. (6.4-mm) from the nozzle edge • TC 2 – Located on the OD 0.25-in. (6.4-mm) from TC1 • TC 3 – Located on the OD 0.25-in. (6.4-mm) from TC2 • TC 4 – Located on the ID 0.25-in. (6.4-mm) from the nozzle edge • TC 5 – Located on the ID 0.25-in. (6.4-mm) from TC4 • TC 6 – Located on the ID 0.25-in. (6.4-mm) from TC5.

31

Figure 31. Thermocouple Locations on the OD of WOM Safe End Weld

Figure 32. Thermocouple Locations on the ID of the WOM Safe End for Weld Buttering

32

Figure 33. Location of Thermocouples relative to Mockup Lettering Grid The temperature data is not included in this report but will be submitted to PNNL as a separate file entitled “WOM Mock-Up Buttering TC Data.” The recording of the temperature data was stopped after butter pass 26 as a result of welding not significantly increasing the temperature at the thermocouple locations. However, temperature data was again collected for the ID weld passes needed to complete the buttering process since those welds did result in a significant increase in the material temperature. The nozzle butter weld was videotaped for record. Digital copies of all weld videos will be submitted to PNNL upon completion of this program. Upon completion of the weld and radiographic inspection, the assembly was delivered to Battelle for post-weld heat treatment. The PWHT was to stress relieve the stiffening weldment as well as the nozzle butter weld prior to the subsequent machining operation and safe end weld. 2.3.3 Safe End Weld The safe end weld joint was a full penetration V-groove described in Battelle Drawing CG482478-403. The final machined depth of the joint was 1.22-in. (31.2-mm). The safe end weld was deposited with the SMAW process using 1/8-in. and 5/32-in. diameter Inco 182 filler metal. These welds were welded at an approximate linear travel speed of 4 - 6 ipm. The safe end SMAW procedure is located in Appendix H. The safe end weld was made in the 1G

33

position. A total of 24 passes were required to fill the OD portion of the safe end weld. Typical welding parameters are shown in Table 9. The bead locations are provided in Figure 34. Table 9. Welding Parameters for Safe End Welds using Inco 182

Diameter Current Voltage 1/8” 105 Amps 25 Volts 5/32” 130 Amps 25 Volts

Figure 34. Bead Locations for OD Safe End Welds Temperature profiles were recorded during welding by attaching thermocouples to the ID and OD of the nozzle. The numbering system for the thermocouples was as follows:

• TC 1 – Located on OD, 0.25-in. (6.4-mm) from the nozzle edge • TC 2 – Located on OD, 0.25-in. (6.4-mm) from TC1 • TC 3 – Located on OD, 0.25-in. (6.4-mm) from TC2 • TC 4 – Located on OD, 0.25-in. (6.4-mm) from the nozzle edge and 45 deg. from TC1 • TC 5 – Located on OD, 0.25-in. (6.4-mm) from the nozzle edge and 45 deg. from TC4 • TC 6 – Located on ID, 0.25-in. (6.4-mm) from the nozzle edge • TC 7 – Located on ID, 0.25-in. (6.4-mm) from TC 6 • TC 8 – Located on ID, 0.25-in. (6.4-mm) from TC7 • TC 9 – Located on ID, 0.25-in. (6.4-mm) from the nozzle edge and 45 deg. from TC6 • TC 10 – Located on ID, 0.25-in. (6.4-mm) from the nozzle edge and 45 deg. from TC9

All the temperature data is not included in this report but will be submitted to PNNL as a separate excel file entitled “WOM-2 Mock-Up Safe End TC Data.”

34

Measurements were taken during welding to record the associated welding distortion, as described in the IWRS mock-up section, and are shown in Table 10. Distortion measurements were made after the safe end and nozzle were tacked together, after the root pass was deposited, after the hot pass was deposited, and after pass 3, (the first SMAW weld) and at 25, 50, 75, and 100% joint fill. The temperature of the assembly during the distortion measurements was kept below 150°F (66°C) to assure that most of the thermal shrinkage had occurred. Table 10. Distortion Measurements for the WOM Safe End Weld

Distance from Mockup OD Pass 0.9705 0.6455 0.3205 0.0000 Type Location

0 1

Root 2

HP 3

SMAW 25% 50% 75% 100% Depth A 1.2955 1.2920 1.2655 1.1985 0.9405 0.6195 0.2940 n/a Depth E +1" 1.3050 1.3010 1.2630 1.2390 0.9895 0.6615 0.3030 n/a Depth I 1.3090 1.2995 1.2585 1.1605 0.9295 0.6150 0.2245 n/a Depth M 1.3090 1.2890 1.2650 1.1805 0.9445 0.5640 0.2530 n/a Width A 2.9435 2.9230 2.9130 2.9350 2.8080 2.7665 2.7380 2.7370

C 2.9310 2.9020 2.8970 2.8885 2.8070 2.7720 2.7270 2.7290 E 2.9410 2.9150 2.9110 2.8880 2.8170 2.7510 2.7280 2.7240 G 2.9450 2.8845 2.8720 2.8870 2.8130 2.7560 2.7430 2.7350 I 2.9755 2.9440 2.9335 2.9255 2.8435 2.7830 2.7585 2.7555 K 2.9975 2.9705 2.9685 2.9485 2.8655 2.8110 2.7850 2.7835 M 2.9810 2.9610 2.9165 2.9320 2.8555 2.8035 2.7820 2.7755 O 2.9875 2.9710 2.9610 2.9440 2.8660 2.8095 2.7855 2.7760

Laser profilometry was conducted on the safe end weld to map the bead location. An illustration of the laser scanning data is shown in Figure 35. All the laser profilometry data is not included in this report but will be submitted to PNNL as a separate file entitled “WOM-2 Mock-Up Safe End Laser Scans.”

35

494

495

496

497

498

499

500

501

502

503

504

-60 -40 -20 0 20 40 60 Figure 35. Laser Scan Data from WOM Safe End Weld The safe end weld was videotaped for record. Digital copies of all weld videos will be submitted to PNNL upon completion of this program. 2.3.4 Back Weld The back weld joint has a V-preparation which was machined into the previously deposited safe end weld and is described in Battelle Drawing CG482478-406. The back weld was deposited with the SMAW process using 1/8-in. and 5/32-in. diameter Inco 182 filler metal. The back weld groove was rotated using a positioner such that it would be a 1G weld. There was a total of 15 passes needed to complete the back weld. The bead locations are provided in Figure 36. The welding procedure that was used to deposit the safe end weld was also used to deposit the back weld (Appendix H).

36

Figure 36. Weld Bead Map of the WOM Safe End Back Weld Temperature profiles were recorded during the back weld by attaching thermocouples to the ID and OD of the safe end side of the mock up. There were a total of ten thermocouples used to monitor the temperature of the back weld. The thermocouple ID and locations are as follows:

• TC 1 – Located on OD, 0.25-in. (6.4-mm) from the nozzle edge • TC 2 – Located on OD, 0.25-in. (6.4-mm) from TC1 • TC 3 – Located on OD, 0.25-in. (6.4-mm) from TC2 • TC 4 – Located on OD, 0.25-in. (6.4-mm) from the nozzle edge and 45 deg. from TC1 • TC 5 – Located on OD, 0.25-in. (6.4-mm) from the nozzle edge and 45 deg. from TC4 • TC 6 – Located on ID, 0.25-in. (6.4-mm) from the nozzle edge • TC 7 – Located on ID, 0.25-in. (6.4-mm) from TC 6 • TC 8 – Located on ID, 0.25-in. (6.4-mm) from TC7 • TC 9 – Located on ID, 0.25-in. (6.4-mm) from the nozzle edge and 45 deg. from TC6 • TC 10 – Located on ID, 0.25-in. (6.4-mm) from the nozzle edge and 45 deg. from TC9

The temperature profile of back weld pass 1 is shown in Figure 37. All the temperature data is not included in this report but will be submitted to PNNL as a separate excel file entitled “WOM-2 Mock-Up Back Weld TC Data.”

37

Figure 37. Temperature Profile of the WOM Safe End Back Weld Measurements were taken before welding began and again after all welding was completed to record the associated welding distortion. The same punch marks that were used to measure distortion during the safe end weld were used to measure distortion caused by the back weld. Note that these measurements were taken on the OD of the mock up. These distortion measurements should be substantially less then on the OD weld in part due to the distance involved from the point of welding to the point of measurement. The temperature of the assembly during the distortion measurements was kept below 150°F (66°C) to assure most of the thermal shrinkage had occurred. The distortion measurements are shown in Table 11. Table 11. Distortion Measurements for the WOM Safe End Back Weld

Location Before Welding

After Welding

A 2.7320 2.7435 C 2.7250 2.7390 E 2.7180 2.7275 G 2.7350 2.7315 I 2.7585 2.7620 K 2.7930 2.7905 M 2.7745 2.7730 O 2.7750 2.7865

38

Laser profilometry was conducted on the back weld to map the bead location using the same equipment that was used during the measuring of the safe end weld. A typical laser scans for pass 2 is shown in Figure 38. It is important to note that when scanning the joint the laser could not intersect the surface perpendicularly due to the mock-up constraints. For this reason Figure 38 appears skewed. All the laser profilometry data is not included in this report but will be submitted to PNNL as a separate file entitled “WOM-2 Mock-Up Safe End Back Weld Laser Scans.”

Figure 38. Laser scan of WOM Safe End Back Weld The safe end back weld was videotaped for record. Digital copies of all weld videos will be submitted to PNNL upon completion of this program. Both the safe end weld and the back weld were radiographically inspected for quality. The radiographic inspection showed some signs of scattered, small diameter porosity which were not considered rejectable indications. The digital radiographs are not included in this report but will be submitted to PNNL as a separate file upon completion of this program. 2.3.5 Safe End to Stainless Pipe Weld After machining the safe end back weld the mock-up was returned to EWI for completion of the final weld. This weld was the safe end to stainless steel pipe weld. This weld was performed per Battelle Drawing CG482478-414 which is attached in Appendix B. For this weld the safe end was welded to the stainless steel pipe section by first doing a manual GTAW root weld followed by a manual GTAW hot pass weld. These two passes were done in the 2G position. The balance of the welding was done using the SMAW process in the 1G position. The safe

39

end to stainless steel pipe welding procedure is located in Appendix G. . The parameters for welding the IWRS mockup were repeated for the WOM and are listed in Table 6. Distortion measurements, laser scans and temperature data were taken before and during the welding of the safe end to stainless pipe weld Figure 39 shows locations of some of the thermocouples. Figure 40 shows a typical temperature profile from one of the welds. Figure 41 through Figure 43 shows the GTAW root pass, a typical SMAW pass and the completed weld respectively. Figure 44 shows the weld pass map. Measurements for distortion are shown in Table 12.

Figure 39. Location of Thermocouples on the WOM Safe End to Stainless Pipe Weld

40

Figure 40. Typical Temperature Profile for the WOM Safe End to Stainless Pipe Weld

Figure 41. Photograph of the GTAW Root Pass of the WOM Safe End to Stainless

Pipe Weld

41

Figure 42. Photograph of a Typical SMAW Weld on the WOM Safe End to Stainless Pipe Weld

Figure 43. Photograph of the Completed WOM Safe End to Stainless Pipe Weld

42

Figure 44. Weld Pass Map for WOM Safe End to Stainless Pipe Weld Table 12. Measurements for WOM Safe End to Stainless Steel Pipe Weld

Distance from Mock Up OD Pass

1.069 .713 .357 0 Type

Loc. 0 1

Root 2

HP 3

SMAW 25% 50% 75% 100%

Depth A 1.6125 1.5995 1.5730 1.4360 .9965 .6575 .384

Depth E 1.5775 1.5730 1.5480 1.4405 1.0265 .7055 .3935

Depth I 1.5790 1.5745 1.5540 1.4120 1.0225 .7205 .4430

Depth M 1.5880 1.5875 1.5785 1.4350 1.0465 .7120 .4135

Width A 3.3330 3.3230 3.3080 3.2730 3.1945 3.1595 3.1525 3.1505

C 3.3530 3.3380 3.3275 3.2770 3.2085 3.1815 3.1740 3.1525

E 3.3220 3.3075 3.2960 3.2615 3.1740 3.1460 3.1375 3.1325

G 3.4090 3.3960 3.3830 3.3470 3.2490 3.2220 3.2155 3.2200

I 3.3660 3.3595 3.3370 3.3055 3.2220 3.1930 3.1830 3.1755

K 3.3830 3.3680 3.3590 3.3215 3.2340 3.2050 3.1985 3.1890

M 3.3630 3.3500 3.3365 3.3020 3.2180 3.1815 3.1730 3.1720

O 3.3440 3.3310 3.3165 3.2805 3.1945 3.1715 3.1610 3.1530

Appendix A

International Weld Residual Stress Mock-Up

Battelle Drawings CG482478-199 thru CR482478-213

Appendix B

Weld Overlay Residual Stress Mock-Up

Battelle Drawings CG482478-400 thru CR482478-414

Appendix C

Stiffening Weldment Welding Procedures

C-1

QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code)

Company Name Edison Welding Institute By David Link

Welding Procedure Specification No.

51108-WPS1 Date

06/15/2009 Supporting PQR No.(s)

N/A

Rev. No. 0 Date 06/15/2009

Welding Process(es) Gas Metal Arc Welding (GMAW) Type(s) Semi-automatic (Automatic, Manual, Machine, or Semi-Auto)

Joints (QW-402) Details Joint Design Vee Groove, partial Penetration Backing

(Yes) (No) X

Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 1 Group No. to P-No. 3 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove .500” nominal Fillet Other *FILLER METALS (QW-404) Spec. No. (SFA) ER80S-D2 AWS No. (Class) A 5.28 F-No. 6 A-No. 11 Size of Filler Metals .045” Weld Metal Thickness Range: Groove .500” nominal Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.

This form (E00006) may be obtained from the Order Dept., ASME, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300

C-2

QW-482 (Back)

WPS No. 51108-WPS1 Rev. 0

POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove 1G Temperature Range N/A Welding

Progression: Up N/A Down N/A Time Range N/A

Position(s) of Fillet N/A GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. 400 F Gases (Mixture) Flow Rate

Interpass Temp. Max. 500 F Shielding Ar/Co2 90%/10% 30-40 CFH

Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be

recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity EP Amps (Range) 250-325 Volts (Range) 29-31 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be

listed in a tabular form similar to that shown below.)

Tungsten Electrode Size and Type N/A (Pure tungsten, 2% thoriated, etc.)

Mode of Metal Transfer for GMAW Spray (Spray arc, short circuiting arc, etc.)

Electrode Wire Feed Speed Range 400-450

TECHNIQUE (QW-410) Sting or Weave Bead Stringer Orifice or Gas Cup Size .750” Initial and Interpass Cleaning (brushing, grinding, etc.) SS wire brush and acetone Method of Back Gouging N/A Oscillation N/A Contact Tube to Work Distance .500” - .750” Multiple or Single Pass (per side) Multiple Multiple or Single Electrodes Single Travel Speed (range) 12 - 15 IPM Peening N/A Other Part Rotated under fixed torch

Filler Metal Current

Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range

Other (e.g., Remarks, Comments, Hot Wire Addition, Technique, Torch Angle, etc.)

All GMAW ER80S-D2 .045” DCEP 250-325 29-31

12-15 IPM WFS 400-450

C-3

QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS)

(See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code) Company Name Edison Welding Institute By David Link


51108-WPS2 Date 06/15/2009 Supporting PQR No.(s)

N/A

Revision No. 0 Date 06/15/2009


Joints (QW-402) Details Joint Design Fillet, Partial Penetration Backing (Yes) (No) X Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 1 Group No. to P-No. 3 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove Fillet 1.000” Other *FILLER METALS (QW-404) Spec. No. (SFA) ER80S-D2 AWS No. (Class) A 5.28 F-No. 6 A-No. 11 Size of Filler Metals .045” Weld Metal Thickness Range: Groove N/A Fillet 1.000” Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


C-4

QW-482 (Back)

WPS No. 51108-WPS2 Rev. 0

POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove 2F Temperature Range N/A Welding


Position(s) of Fillet Horizontal GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. 400 F Gases (Mixture) Flow Rate Interpass Temp. Max. 500 F Shielding Ar/Co2 90%/10% 30-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or

DC DC Polarity EP

Amps (Range) 250-325 Volts (Range) 29-31 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be




Electrode Wire Feed Speed Range 400-450

TECHNIQUE (QW-410) Sting or Weave Bead Stringer Orifice or Gas Cup Size .750” Initial and Interpass Cleaning (brushing, grinding, etc.) SS wire brush and acetone Method of Back Gouging N/A Oscillation N/A Contact Tube to Work Distance .500” - .750” Multiple or Single Pass (per side) Multiple Multiple or Single Electrodes Single Travel Speed (range) 12 - 15 IPM Peening N/A Other Part Rotated under fixed torch


Weld Layer(s)

Process Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


All GMAW ER80S-D2 .045” DCEP 250-325 29-31

12-15 IPM WFS 400-450

C-5


(See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code) Company Name Edison Welding Institute By Steve Manring


51108-WPS-3 Date 6-15-2009 Supporting PQR No.(s)

N/A

Revision No. 0 Date 6-15-2009


Joints (QW-402) Details Joint Design Vee Groove Partial Penetration Backing

(Yes) (No) X

Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 1 Group No. to P-No. 1 Group No. OR Specification Type and Grade A-36 to Specification Type and Grade A105 OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove .500” nominal Fillet N/A Other *FILLER METALS (QW-404) Spec. No. (SFA) ER70S-6 AWS No. (Class) A 5.18 F-No. 6 A-No. 1 Size of Filler Metals 0.045” Weld Metal Thickness Range: Groove 0.500” nominal Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


C-6

QW-482 (Back)

WPS No. 51108-WPS-3 Rev. 0



Position(s) of Fillet N/A GAS (QW-408) PREHEAT (QW-406) Percent Composition

Preheat Temp. Min. 225 F for Pass 1, 200 F for Pass 2 & 3, RT remainder Gases (Mixture) Flow Rate

Interpass Temp. Max. 500F Shielding Ar/CO2 90/10 30-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity EP Amps (Range) 250 - 325 Volts (Range) 29 - 31 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be




Electrode Wire Feed Speed Range 400 – 500 ipm

TECHNIQUE (QW-410) Sting or Weave Bead Stringer Orifice or Gas Cup Size 0.750” Initial and Interpass Cleaning (brushing, grinding, etc.) SS wire Brush Method of Back Gouging N/A Oscillation N/A Contact Tube to Work Distance 0.500 – 0.750 inches Multiple or Single Pass (per side) Multiple Multiple or Single Electrodes Single Travel Speed (range) 12 – 15 ipm Peening N/A Other Part rotated under fixed torch


Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


All GMAW ER70S-6 0.045” DCEP 250 – 325 29 - 31

12 – 15 IPM WFS 400 - 450

C-7





N/A



Joints (QW-402) Details Joint Design Fillet Backing (Yes) (No) X Backing Material (Type) N/A (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 1 Group No. to P-No. 1 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove N/A Fillet 1.000” Other *FILLER METALS (QW-404) Spec. No. (SFA) ER70S-6 AWS No. (Class) A 5.18 F-No. 6 A-No. 1 Size of Filler Metals 0.045” Weld Metal Thickness Range: Groove N/A Fillet 1.000” Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


C-8

QW-482 (Back)


POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove 2F Temperature Range N/A Welding


Position(s) of Fillet Horizontal GAS (QW-408) PREHEAT (QW-406) Percent Composition

Preheat Temp. Min. 225 F for Pass 1, 200 F for Pass 2 & 3, RT remainder Gases (Mixture) Flow Rate

Interpass Temp Max. 500F Shielding Ar/CO2 90/10 30-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A






TECHNIQUE (QW-410) Sting or Weave Bead Stringer Orifice or Gas Cup Size 0.750” Initial and Interpass Cleaning (brushing, grinding, etc.) SS wire Brush Method of Back Gouging N/A Oscillation N/A Contact Tube to Work Distance 0.500 – 0.750 inch Multiple or Single Pass (per side) Multiple Multiple or Single Electrodes Single Travel Speed (range) 12 – 15 ipm Peening N/A Other Part Rotated under fixed torch


Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


All GMAW ER70S-6 0.045” DCEP 250 – 325 29 - 31

12 – 15 IPM WFS 400 - 450

C-9





N/A


Welding Process(es) Gas Metal Arc Welding (GMAW) Type(s) Semi-Automatic (Automatic, Manual, Machine, or Semi-Auto)

Joints (QW-402) Details Joint Design Vee Groove Backing (Yes) (No) X Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 1 Group No. to P-No. 8 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 0.250” Fillet N/A

Other Welded 1 entire layer in groove of 309L to completely cover the Carbon Steel base metals. Balance will use ER308L

*FILLER METALS (QW-404) Spec. No. (SFA) ER309L AWS No. (Class) A 5.9 F-No. 6 A-No. Size of Filler Metals 0.045” Weld Metal Thickness Range: Groove 0.250” Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


C-10

QW-482 (Back)




Position(s) of Fillet N/A GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. 225 F Gases (Mixture) Flow Rate Interpass Temp. Max. 500F Shielding Ar 100 30-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity EP Amps (Range) 250 - 325 Volts (Range) 29 - 31 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed

in a tabular form similar to that shown below.)






Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


All GMAW ER309L 0.045” DCEP 250 – 325 29 - 31

12 – 15 IPM WFS 400 - 450

C-11





N/A



Joints (QW-402) Details Joint Design Vee Groove Backing (Yes) (No) X Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal

Nonmetallic Other

*BASE METALS (QW-403) P-No. 3 Group No. to P-No. 8 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 0.250” Fillet N/A

Other Welded 1 entire layer in groove of 309L to completely cover the Carbon Steel base metals (WPS-5). Balance will use ER308L (WPS-6)

*FILLER METALS (QW-404) Spec. No. (SFA) ER309L AWS No. (Class) A 5.9 F-No. 6 A-No. Size of Filler Metals 0.045” Weld Metal Thickness Range: Groove 0.250” Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


C-12

QW-482 (Back)




Position(s) of Fillet N/A GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. 400 F Gases (Mixture) Flow Rate Interpass Temp. Max. 500F Shielding Ar 100 30-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity EP Amps (Range) 250 - 325 Volts (Range) 29 - 31 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed

in a tabular form similar to that shown below.)






Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


All GMAW ER309L 0.045” DCEP 250 – 325 29 – 31

12 – 15 IPM WFS 400 - 450

C-13


(See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code) Company Name

Edison Welding Institute By Steve Manring



N/A

Revision No.

0 Date 6-15-2009


Joints (QW-402) Details Joint Design Vee Groove, Partial Penetration Backing Yes) (No) No Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 8 Group No. to P-No. 8 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 0.250” Fillet N/A Other Welded balance with ER308L *FILLER METALS (QW-404) Spec. No. (SFA) ER308L AWS No. (Class) A 5.9 F-No. 6 A-No. Size of Filler Metals 0.045” Weld Metal Thickness Range: Groove 0.250” Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


C-14

QW-482 (Back)




Position(s) of Fillet N/A GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. RT Gases (Mixture) Flow Rate Interpass Temp. Max. 500F Shielding Ar 100 30-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A








Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


All GMAW ER308L 0.045” DCEP 250 – 325 29 - 31

12 – 15 IPM WFS 400 - 450

Appendix D

Nozzle Buttering Welding Procedure

D-1




51108-WPS-8 Date 6-15-2009 Supporting PQR No.(s) N/A


Welding Process(es) Gas Tungsten Arc Welding (GTAW) Type(s) Machine (Automatic, Manual, Machine, or Semi-Auto)

Joints (QW-402) Details Joint Design Bead on Pipe Backing (Yes) Yes (No) No Backing Material (Type) SA105 (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 1 Group No. to P-No. N/A Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base

Metal: Groove N/A Fillet N/A

Other Butter Thickness 1 ¼ “ minimum *FILLER METALS (QW-404) Spec. No. (SFA) ERNiCr-3 AWS No. (Class) A 5.9 F-No. 43 A-No. Size of Filler Metals 0.045” Weld Metal Thickness Range: 1 ¼” minimum Butter layer Groove N/A Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


D-2

QW-482 (Back)


POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove N/A, Flat Temperature Range N/A Welding Progression: Up N/A Down N/A Time Range N/A Position(s) of Fillet GAS (QW-408) PREHEAT (QW-406) Percent Composition

Preheat Temp. Min. 225 F for Pass 1, 200F for Pass 2 & 3, RT remainder Gases (Mixture) Flow Rate

Interpass Temp. Max. 500F Shielding Argon 100% 30-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity En Amps (Range) 175 - 225 Volts (Range) 9.2 – 11.2 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular form

similar to that shown below.)

Tungsten Electrode Size and Type 1/8” dia 2% Ce with a 22 deg included angle and a .02 - .03” flat (Pure tungsten, 2% thoriated, etc.)

Mode of Metal Transfer for GMAW N/A (Spray arc, short circuiting arc, etc.)

Electrode Wire Feed Speed Range 70 - 90 ipm

TECHNIQUE (QW-410) Sting or Weave Bead Stringer Orifice or Gas Cup Size #12 (0.750”) Initial and Interpass Cleaning (brushing, grinding, etc.) SS wire Brush Method of Back Gouging N/A Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple Multiple or Single Electrodes Single Travel Speed (range) 5.8 – 6.8 ipm Peening N/A Other Part Rotated under fixed torch


Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range

Other (e.g., Remarks, Comments, Hot Wire Addition, Technique, Torch

Angle, etc.)

All GTAW ERNiCr-3 0.045” DCEN 175 - 225 9.2 – 11.2

5.8 – 6.8 IPM WFS 70 – 90 ipm

D-3



Welding Procedure Specification No. 51108-WPS-9 Date 6-15-2009 Supporting PQR No.(s) N/A



Joints (QW-402) Details Joint Design Bead on Pipe Backing (Yes) (No) No Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 3 Group No. to P-No. N/A Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base

Metal: Groove N/A Fillet N/A

Other Butter Thickness 1 ¼ “ minimum *FILLER METALS (QW-404) Spec. No. (SFA) ERNiCr-3 AWS No. (Class) A 5.14 F-No. 43 A-No. Size of Filler Metals 0.045” Weld Metal Thickness Range: 1 ¼” minimum Butter layer Groove N/A Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


D-4

QW-482 (Back)


POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove N/A, Flat Temperature Range N/A Welding Progression: Up N/A Down N/A Time Range N/A Position(s) of Fillet GAS (QW-408) PREHEAT (QW-406) Percent Composition

Preheat Temp. Min. 400 F Pass 1, 400F Pass 2 & 3, RT Balance Gases (Mixture) Flow Rate

Interpass Temp. Max. 500F Shielding Argon 100% 3o-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity En Amps (Range) 175 - 225 Volts (Range) 9.2 – 11.2 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular form







Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


All GTAW ERNiCr-3 0.045” DCEN 175 - 225 9.2 – 11.2

5.8 – 6.8 IPM WFS 70 – 90 IPM

Appendix E

Butter Weld Penetrant Inspection Report

Appendix F

Safe End and Back Weld Welding Procedure

F-1






Joints (QW-402) Details Joint Design Double Sided Groove Weld Backing (Yes) x (No) Backing Material (Type) P8 and P43 (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 8 Group No. to P-No. 43 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1” Fillet N/A Other *FILLER METALS (QW-404) Spec. No. (SFA) ERNiCr-3 AWS No. (Class) A 5.14 F-No. 43 A-No. Size of Filler Metals 0.045” Weld Metal Thickness Range: Groove 1” Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


F-2

QW-482 (Back)


POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove 1G Temperature Range Welding Progression: Up N/A Down N/A Time Range Position(s) of Fillet N/A GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. RT Gases (Mixture) Flow Rate Interpass Temp. Max. 500F Shielding Ar/He 75/25 30-40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing Ar 100 10-30 CFH

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity En Amps (Range) 75 – 260 * Volts (Range) 9.5 – 10.3 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular form





TECHNIQUE (QW-410) Sting or Weave Bead Stringer Orifice or Gas Cup Size #12 (0.750”) Initial and Interpass Cleaning (brushing, grinding, etc.) SS wire Brush Method of Back Gouging Machined back side groove Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple Multiple or Single Electrodes Single Travel Speed (range) 5.8 – 6.8 ipm Peening N/A Other Part Rotated under fixed torch


Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range Travel Speed

Range


1 2

3-4 Balance

Cap

GTAW GTAW GTAW GTAW GTAW

ERNiCr-3 ERNiCr-3 ERNiCr-3 ERNiCr-3 ERNiCr-3

0.045” 0.045” 0.045” 0.045” 0.045”

DCEN DCEN DCEN DCEN DCEN

125 – 175 150 – 100 210 – 230 160 – 220 210 – 230

9.5 – 10 9.5 – 10 9.5 – 11

9.5 – 10.5 9.5 – 10

5 – 7 IPM 5 – 7 IPM 5 – 7 IPM

5.5 – 6.5 IPM 6 – 6.5 IPM

WFS 15 – 25 IPM WFS 25 – 35 IPM WFS 60 – 85 IPM WFS 85 – 95 IPM WFS 80 – 90 IPM

Appendix G

Safe End to Stainless Steel Pipe Weld Procedure

G-1





Welding Process(es) Shielded Metal Arc Welding (SMAW) Type(s) Manual (Automatic, Manual, Machine, or Semi-Auto)

Joints (QW-402) Details Joint Design Vee Groove, 15 degree extended land Backing (Yes) X (No) Backing Material (Type) 308L (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 8 Group No. to P-No. 8 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1” nonimal Fillet N/A Other *FILLER METALS (QW-404) Spec. No. (SFA) E308L AWS No. (Class) A 5.4 F-No. 6 A-No. Size of Filler Metals 1/8 – 5/32” Weld Metal Thickness Range: Groove 1” minimum Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


G-2

QW-482 (Back)


POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove 1G Temperature Range Welding Progression: Up N/A Down N/A Time Range Position(s) of Fillet GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. RT Gases (Mixture) Flow Rate Interpass Temp. Max. 500F Shielding Ar 100 30 – 40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity EP Amps (Range) 110-150 Volts (Range) 23-27 (Amps and volts range should be recorded for each electrode size,

position, and thickness, etc. This information may be listed in a tabular form similar to that shown below.)

Tungsten Electrode Size and Type (Pure tungsten, 2% thoriated, etc.)


Electrode Wire Feed Speed Range

TECHNIQUE (QW-410) Sting or Weave Bead Stringer Orifice or Gas Cup Size Initial and Interpass Cleaning (brushing, grinding, etc.) SS wire Brush Method of Back Gouging N/A Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple Multiple or Single Electrodes Single Travel Speed (range) 4-6 IPM Peening N/A Other Part Rotated


Weld Layer(s)

Process

Class

Diameter

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


Any Any

SMAW SMAW

E308L E308L

1/8” 5/32”

DCEP DCEP

110-120 140-150

23-27 23-27

4-6 IPM 4-6 IPM

G-3






Joints (QW-402) Details Joint Design Vee Groove, 15 degree extended land Backing (Yes) (No) X Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 8 Group No. to P-No. 8 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1” nonimal Fillet N/A Other *FILLER METALS (QW-404) Spec. No. (SFA) ER308L AWS No. (Class) A5.9 F-No. 6 A-No. Size of Filler Metals 0.045” Weld Metal Thickness Range: Groove ¼” Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


G-4

QW-482 (Back)


POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove 1G Temperature Range Welding Progression: Up N/A Down N/A Time Range Position(s) of Fillet GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. Gases (Mixture) Flow Rate Interpass Temp. Max. 500F Shielding Ar/He 75/25 30 – 40 CFH Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing Ar 100 10 – 20 CFH

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity EN Amps (Range) 75 – 260 * Volts (Range) 9.5 – 10.3 (Amps and volts range should be recorded for each electrode size,

position, and thickness, etc. This information may be listed in a tabular form similar to that shown below.) Pulsed and Non Pulsed Current, See information below.






Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range Travel Speed

Range


1 2

3-4 Balance

Cap

GTAW GTAW GTAW GTAW GTAW

ERNiCr-3 ERNiCr-3 ERNiCr-3 ERNiCr-3 ERNiCr-3

0.045” 0.045” 0.045” 0.045” 0.045”

DCEN DCEN DCEN DCEN DCEN

125 – 175 150 – 100 210 – 230 260 – 220 210 – 230

9.5 – 10 9.5 – 10 9.5 – 11

9.5 – 10.5 9.5 - 10

5 - 7 IPM 5 – 7 IPM 5 – 7 IPM

5.5 – 6.5 IPM 6 – 6.5 IPM

WFS 15 – 25 IPM WFS 25 – 35 IPM WFS 60 – 85 IPM WFS 85 – 95 IPM WFS 80 – 90 IPM

Appendix H

Safe End Inco 182 SMAW Groove Weld Procedure

H-1





Welding Process(es) Shielded Metal Arc Welding (SMAW) Type(s) Manual (Automatic, Manual, Machine, or Semi-Auto)

Joints (QW-402) Details Joint Design Double Sided Groove Weld Backing (Yes) Yes (No) Backing Material (Type) P-No and P-No 43 (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other *BASE METALS (QW-403) P-No. 8 Group No. to P-No. 43 Group No. OR Specification Type and Grade to Specification Type and Grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1” nonimal Fillet N/A Other *FILLER METALS (QW-404) Spec. No. (SFA) ENiCrFe-3 AWS No. (Class) A 5.11 F-No. 43 A-No. Size of Filler Metals 1/8 – 5/32” Weld Metal Thickness Range Groove 1” minimum Fillet N/A Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other N/A *Each base metal-filler metal combination should be recorded individually.


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QW-482 (Back)


POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove 1G Temperature Range Welding Progression: Up N/A Down N/A Time Range Position(s) of Fillet GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. Min. RT Gases (Mixture) Flow Rate Interpass Temp. Max. 500F Shielding N/A Preheat Maintenance N/A Trailing N/A (Continuous or special heating where applicable should be recorded) Backing N/A

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC DC Polarity EP Amps (Range) 100-140 Volts (Range) 23-27 (Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular form




Electrode Wire Feed Speed Range N/A

TECHNIQUE (QW-410) Sting or Weave Bead Stringer Orifice or Gas Cup Size N/A Initial and Interpass Cleaning (brushing, grinding, etc.) SS wire Brush Method of Back Gouging The back groove was machined Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple Multiple or Single Electrodes Single Travel Speed (range) 2 – 4 IPM Peening N/A Other Part Rotated


Weld Layer(s)

Process

Class

Dia.

Type Polar.

Amp

Range

Volt

Range

Travel Speed Range


Any Any

SMAW SMAW

ENiCrFe-3 ENiCrFe-3

1/8” 5/32”

DCEP DCEP

100-110 125-125

23-27 23-27

2 – 4 IPM 2 – 4 IPM

august 17, 2010 pacific northwest national lab p.o. box

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