ALLIANT ENERGY.

IES Utilities Inc.

Duane Arnold Energy Center 3277 DAEC Road Palo, IA52324-9785

November 11, 1999 NG-99-1613 Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Attn: Document Control Desk Mail Station 0-P 1-17 Washington, DC 20555-0001 Subject: Duane Arnold Energy Center Docket No: 50-33 1 Op. License No: DPR-49 Authorization for Use of Code Cases for Nozzle-to-Safe End Repairs A- 100, A-286

Office: 319.851.7611
Fax: 319.851.7986 www.alliant-energy.com

File:

During the current refueling outage (RFO) 16 at the Duane Arnold Energy Center (DAEC), weld inspections are being performed in accordance with commitments to Generic Letter (GL) 88-01 and NUREG-0313, Rev. 2. The original scope of examinations included three recirculation riser and one core spray nozzle-to-safe end welds. These inspections identified indications in the nozzle-to-safe-end weld on one of the recirculation risers (weld RRB F002). Due to the identification of the indications in RRB-F002, the inspection scope has been expanded to include all eight F002 recirculation riser nozzle-to-safe end welds, as well as the other similarly-designed core spray nozzle-to-safe end weld. The inspections performed on the RRD-F002 and RRF-F002 nozzle-to-safe-end welds also identified indications. Currently, the remaining inspections are expected to be completed on November 13, 1999. A conference call was held between the Staff and IES Utilities Inc. personnel on November 9, 1999 to discuss the disposition of the indications that had been identified. During that conference call, IES Utilities Inc. proposed to repair these indications with asymmetrical weld overlays over the inconel safe end. That proposed design did not involve welding on the nozzle material itself. As the Staff pointed out during that call, buttering on the nozzle may contain IGSCC-sensitive inconel 182, and that it may be advisable to overlay this material as a precautionary measure. IES is designing an overlay which will extend over both the nozzle and safe end, completely covering the existing butter material. The proposed designs utilize ASME Code Cases N-504-1 and N-606, as interpreted for use with inconel overlays on nozzle-to-safe end welds.

November 11, 1999 NG-99-1613 Page 2 Code Case N-504-1 has been approved by the NRC and is included in the latest revision (revision 12) of Regulatory Guide (RG) 1.147. This code case allows the use of weld overlays to disposition defects in austenitic stainless steel piping. The interpretation of ASME Code Case N-504 for welding P-43 materials (inconel) rather than P-8 material (stainless steel) was approved by the NRC on April 29, 1999 for a weld overlay repair on a feedwater nozzle-to-safe end weld at the Perry Nuclear Power Plant. Code Case N-606 has not yet been approved by the NRC for generic use in RG. 1.147. Code Case N-606 contains provisions to allow the use of the gas tungsten arc welding (GTAW) temper bead technique without preheat or postweld heat treatment. While the stated applicability of the code case is BWR control rod drive (CRD) housing or stub tube repair/replacement activities, the principles apply equally well to the repair activity IES proposes for the nozzle-to-safe end welds. 1OCFR50.55a(a)(3)(i) states that proposed alternatives may be used when authorized by the Director of the Office of Nuclear Reactor Regulation provided that the proposed alternatives provide an acceptable level of quality and safety. IES Utilities hereby requests NRC authorization to use Code Cases N-504-1 and N-606, with the exceptions and clarifications noted in the attachment, to perform repair activities on nozzle-to-safe end welds. Authorization is requested prior to November 19, 1999 to support startup from the refueling outage. Sincerely,

Kenneth E. Peveler Manager, Regulatory Performance Attachment cc: C. Rushworth E. Protsch (w/o) D. Wilson (w/o) B. Mozafari (NRC-NRR) J. Dyer (Region III) NRC Resident Office Docu

Attachment to NG-99-1613 Page 1 of 8

BACKGROUND The eight recirculation inlet nozzle safe ends were replaced in 1978 with redesigned safe ends and thermal sleeve adapters. The safe ends are fabricated from SB- 166 (Alloy 600) material, also known as Inconel-600. The nozzle material is SA-508, Class 2 (P3 material, Group 3). The nozzle side of the weld was buttered with Alloy 182 material. During refueling outage (RFO) 16 for the Duane Arnold Energy Center (DAEC), inspections of welds susceptible to intergranular stress corrosion cracking (IGSCC) identified flaw indications on three recirculation riser nozzle to safe end welds. The indications were identified while performing ultrasonic (UT) examinations using GE's SMART 2000 automated UT system with TOMOVIEW analysis software. Two indications were identified in weld RRB-F002. An indication was also identified in weld RRD-F002. The table below provides the details of both the indications in RRB-F002 and RRD-F002. Weld ID RRB-F002 Flaw #1 Flaw #2 RRD-F002 Flaw #1 Thickness (t) 1.0" Length (1) Depth (a) Y a/l a/t Code Allowable 11.9% 11.4% 11.3%

1.0"
1.0"

1.9" 2.2" 3.7"

.65" .44" .67"

0 0 0

.34 .20 .18

65% 44% 67%

In addition, an indication has been identified in weld RRF-F002. Analysis of the flaw thickness, length and depth are not yet complete. An investigation into the cause of the indications is being tracked by the DAEC corrective action program. EXAMINATION AND REPAIR PLAN Weld overlay repairs are proposed. The flaws in the welds will not be removed and weld overlays, using UNS N06052 Alloy 52 wire (Code Case 2142), will be deposited. The overlay will extend around the full circumference of the nozzle to safe end weld for the required design length. The repair activities will be performed by qualified personnel from Welding Services Incorporated (WSI) and shall be in accordance with WSI's Nuclear Repair (NR) Certificate of Authorization. The repair will be performed in accordance with ECP 1627 and a repair package as defined by WSI's Nuclear Repair Manual. The repair package will incorporate appropriate sign-off steps that specify each operation by sequence. An NR- I data report will be completed by WSI documenting these repairs. The ASME Section XI, NIS 2 form will be generated by DAEC for incorporation into the Summary Report.

Attachment to NG-99-1613 Page 2 of 8 The weld overlays will be completed with water on the inside surface of the nozzle. The weld overlays will be applied using IGSCC resistant UNS N06052 Alloy 52 wire (ASME Code Case 2142). The overlays will extend from the safe end material, over the defect and onto the P3 nozzle material. Code Cases N-504-1 and N-606, as interpreted for use with inconel overlays of nozzle-to-safe end welds, will be utilized. The welders and welding procedures shall be qualified in accordance with ASME Section IX. The welding consumables shall be in accordance with ASME Code Case 2142. The repair will be applied by welding the IGSCC-resistant Alloy 52 filler material using machine Gas Tungsten Arc Welding (GTAW) technology and applying the weld around the entire circumference of the safe-end and girth weld for the required design length, thereby providing a replacement pressure boundary for the original joint. Prior to initiation of the overlay, the design length will be marked using low stress dies. A second set of marks will be applied approximately 1/2 to 1 inch outside either end of the design overlay length. Punch marks shall be placed at 4 azimuthal locations. The axial distance between each set of marks will be measured and recorded. Following weld overlay application these measurements will be repeated and dimensions recorded to determine the axial shrinkage which occurred during the overlay operation. Following surface machining, the final weld overlay thickness will be determined using UT techniques. For reference, the applicable weld procedure is attached. Prior to the final weld overlay examination, the final weld overlay surface will be machined to an approximate finish of 250 RMS (no waviness). Subsequent to machining, the final weld overlay will be examined using liquid penetrant (PT) and UT methods in accordance with ASME Code Case N-504-1 and NUREG -0313, modified as necessary for examination of inconel overlays. The examination requirements for the weld overlay repairs are summarized in the table on the following page.

Attachment to NG-99-1613 Page 3 of 8

Acceptance Criteria N/A

Examination Description Thickness Measurements

Method UT

Technique 0' Long.

450 Ref. Long. 600 Ref. Long.

Notes N/A

As-Found Exam

Auto UT

60' Ref. Long.

600 Ref. Long. 700 Ref. Long.

IWB-3514

N/A

As-Found Sizing Weld and Safe-End Overlay Surface Preparation Exam First Weld Overlay Thickness Checks

Auto UT PT UT Visible Dye 00 Long, or

Hand Meas.

IWB-3514 N-504-1
N/A

Note 1 Note 1
N/A

First Weld Overlay Layer Surface Exam Exam of Completed Overlay for Lack-ofBond and Thickness Surface Exam of Completed Overlay Volumetric Exam of Completed Overlay Pre-Service Exam of Completed Overlay and the Upper 25% of the Flawed Weld and adjacent 1" TABLE NOTES: General Note:

PT Auto UT PT Auto UT

Visible Dye 00 Long. Visible Dye 600 Ref. Long. 600 Ref. Long. OD Creeping Wave

NB-5352 IWB-3514 NB-5352 IWB-3514

Note 2 Note 4 Note 1 Note 3 Note 4 Note 1

Auto UT

IWB-3514

Note I

The weld overlay examinations comply with the recommendations of NUREG-0313, Revision 2, and also with EPRI NP-4720-LD, "Examination of Weld-Overlayed Pipe Joints", as supplemented by EPRI TR- 101681, "Addendum to Examination of Weld-Overlayed Pipe Joints."

1. The Edition and Addenda for the ASME Section XI acceptance criteria is the 1989 Edition with no Addenda. 2. A PT exam will be performed on the first layer of the overlay to ensure there is no cracking. 3. The lamination acceptance criteria of ASME Table IWB-3514-3 will be applied. 4. The Edition and Addenda for the ASME Section III acceptance criteria is the 1992 Edition with no Addenda. This is the Edition and Addenda of Section III that is specified by Code Case N-416-1.

Attachment to NG-99-1613 Page 4 of 8

NDE-R015, Revision 1 (approved by NRC by letter dated October 19, 1999) allows use of the 1992 Edition with the 1992 Addenda to governRepair Procedures and Replacement for Class 1, 2, 3 and MC pressure retaining components and their supports. Following the repair, a system leakage test shall be performed in accordance with ASME Section XI, 1989 Edition. There is no ASME Section III Subsection that directly applies to weld overlays. For the surface examination, the PT examination acceptance standards of ASME Section III, 1992 Edition, NB-5352 (applicable to most Class I welds) will be used. However, ASME Section III volumetric examination methods (i.e., typically radiography) are not practical for examination of the weld overlay repair. Also, NUREG-0313 specifies that Ultrasonic examination, using methods and personnel qualified through the EPRI NDE Center, be used. Furthermore, NUREG-0313 states that the Ultrasonic examinations should be performed in general in accordance with the requirements of the applicable edition of the ASME Code. The Code of record for the current 10-year inservice inspection interval is the 1989 edition of ASME Section XI with no Addenda. Therefore, the acceptance criteria that will be used for the volumetric examinations will be those of IWB-3514, "Standards for Examination Category B-F, Pressure Retaining Dissimilar Metal Welds, and Examination Category B-J, Pressure Retaining Welds in Piping." REPAIR JUSTIFICATION Weld overlays involve the application of weld metal circumferentially around the pipe in the vicinity of the flawed weld to restore ASME Section XI margins as required by ASME Code Case N-504-1. Weld overlays have been used in the nuclear industry to repair flawed welds since 1982. The application of weld overlay repairs has been shown to produce favorable compressive residual stresses on the inner portion of the pipe wall, which helps to minimize further crack growth and is welded using filler material with excellent resistance to IGSCC. The design of the overlays for the nozzle safe ends is using the standard methods for size determination. This approach has been used before for the design and application of weld overlays. There are no new or different approaches used in the overlay design, which are considered first of a kind or inconsistent with previous approaches. The overlay is designed as a full structural overlay in accordance with the recommendation of NUREG-0313, Revision 2, which was forwarded by Generic Letter 88-01 and by Code Case N-504-1 and ASME Section XI Paragraph IWB-3640. The overlay design will assume the underlying weld to be completely cracked through the original pipe wall and the first layer of overlay. In effect, credit is not taken for the first overlay layer, conservatively assuming that this layer remains susceptible to IGSCC due to possible dilution of the Alloy 52 weld overlay material from the underlying weld and base material. Thus, the first overlay layer is considered part of the original wall.

Attachment to NG-99-1613 Page 5 of 8 ASME CODE CASE N-504-1 The repair will utilize Code Case N-504-1, Alternative Rules for Repair of Class 1, 2, and 3 Austenitic Stainless Steel Piping, with the following exception: The safe end is inconel (nonferritic), rather than stainless steel. Therefore, the provisions in the code case specifically related to stainless steel will be modified to apply to an inconel alloy 600 safe-end and inconel alloy 52 overlay. Weld metal will be UNS N06052 (F43 per Code Case 2142), rather than low carbon austenitic stainless steel as described in Reply (b). Reply (e) regarding delta ferrite is not applicable. ASME CODE CASE N-606 The ASME Code would require preheat and postweld heat treatment for this repair due to welding on the nozzle material. This would require draining the reactor vessel, which would require a full-core offload of the fuel. With the vessel drained, the dose rates in the nozzle area would be extremely high, resulting in adverse dose expenditures. Code Case N-606 allows the use of GTAW without the use of preheat or postweld heat treatment on Class 1, BWR CRD housing or stub tube repairs. Temperbead welding methodology is not new. Numerous applications over the past decade have demonstrated the acceptability of temperbead technology in nuclear environments. Temperbead welding achieves heat affected zone (HAZ) tempering and grain refinement without subsequent postweld heat treatment (PWHT). Prior to N-606, temperbead requirements stipulated elevated temperature preheat and elevated temperature post-soak. Recent research has demonstrated that acceptable HAZ properties can be obtained without these elevated temperature requirements, enabling temperbead welding on water-filled piping systems. This research is the basis for N-606. The standard temperbead requirements for preheat and PWHTs have been specified primarily to preclude the presence of hydrogen in the final weld. Hydrogen, the source of delayed cracking in the base material HAZ is of primary concern when welding ferritic materials. Elevated preheat is intended to eliminate moisture and contaminants (hydrocarbons) that could be introduced into the molten metal during welding. The PWHT, initiated immediately after welding is completed, allows the hydrogen potentially trapped in the HAZ and weld metal an extended time period to diffuse out of the HAZ and weld metal. However these requirements were initially imposed for SMAW temperbead welding where coated electrodes susceptible to hydrogen pickup were used. Studies have shown that the effects of humidity, shielding gas dew point and modem solid wire weld filler materials are negligible sources of dissolvable hydrogen during GTAW welding. Therefore if the weld joint receives proper cleaning and drying, the primary sources of dissolvable hydrogen will not be present during GTAW welding. Temperbead techniques result in improvement of the impact toughness in the HAZ over the base material toughness

Attachment to NG-99-1613 Page 6 of 8 and tempering of the HAZ. The depth of the HAZ using the ambient temperature temperbead welding technique is generally less than that obtained in temperbead welds using elevated preheat and PWHTs. The degree of carbide precipitation and ferrite formation using the ambient temperature temperbead welding technique is generally less than that obtained in temperbead welds using elevated preheat and PWHTs. The intent of the existing ASME Code temperbead welding technique requirements is to preclude the formation of an untempered martensitic microstructure and the introduction of dissolvable hydrogen into ferritic material thereby eliminating the potential for delayed underbead cracking. Mechanical properties and microstructure of the low alloy steel base materials have not been degraded by using the "ambient temperature" temperbead technique. Evaluations by EPRI concluded that the GTAW process with solid filler metal is not a significant source of dissolvable hydrogen to the weld. It was concluded, by a comparison between mechanical test results and microstructural evaluations performed on P-No. 3, Group 3 materials using the proposed ambient temperature temperbead welding technique and several other temperbead weld qualifications using elevated preheat and PWHTs that both techniques pass all Code requirements and provide acceptable results. Exceptions and Clarifications The repairs will utilize Code Case N-606, with the following exceptions and clarifications: Code Case N-606 specifies that it is applicablefor Class 1, BWR CRD housing or stub tube repairs. IES Utilities Inc. proposes that the code case be used on weld overlay repairs of nozzle to safe end welds. N-606 is the only published ASME Nuclear Code Case addressing ambient temperature temperbead. N-606 applicability is restricted to Class 1 BWR CRD housings and stub tube repairs, however, Duane Arnold has proposed that the NRC permit use of N-606 provisions in an alternate application. The acceptability of using N-606 provisions in alternate applications is substantiated by ongoing ASME actions. Specifically, draft ASME Code Case N-612 is essentially identical to N-606, except that N-612 permits use of ambient temperature temperbead in applications such as the DAEC's nozzle-to-safe end welds. N-612 received two BPV Main Committee negative votes. The Case was subsequently numbered N-638, and it has been unanimously approved by the BPV Main Committee. This approval substantiates use of N-606 ambient temperature temperbead methodology in applications such as the DAEC's nozzle-to-safe end welds.

Attachment to NG-99-1613 Page 7 of 8 Code Case N-606, Section 1.O(a) states that the maximum area of an individual weld based on the finished surface be 100 sq. in. The maximum area of the weld overlay will exceed 100 sq. in.; however, the portion of the weld area which is over the P-3 material will be less than 100 sq. in. Code Case N-606 Section 2. 1(a) states that the base materialsfor the weldingprocedure qualificationshall be of the same P-Number and Group Number, as the materialsto be welded. The materialsshall be postweld heat treatedto at least the time and temperature that was appliedto the materials being welded. Nozzle welding will be performed by WSI, using their WPS-03-43-T-801. This WPS was qualified in accordance with Draft ASME Code Case N-638, and therefore complies with N-606 requirements. This WPS is qualified for welding on the existing RPV Nozzle (P3 Group 3 SA508 Class 2 material), the existing buttering/groove weld (Inco 82 and/or Inco 182 filler metal) and on the existing Safe End (P43 SB 166 Alloy N06600 material). The WPS achieves this qualification using two PQRs as follows: WSI PQR-03-03-T-801 was qualified by welding a 1.25" groove in a 3.5" thick, P3 Group 3 plate. Welding and testing was performed in accordance with draft ASME Code Case N-612, using Inco 52 filler material. Ambient temperature temperbead methodology was employed. WSI PQR A43256-52 was qualified by GTAW deposition 1.0" of Inco 52 filler metal in a full-penetration groove on P43 base materials. Standard welding procedure qualification requirements were used, since P43 materials are exempt from both PWHT and impact test requirements. WPS-03-43-T-801 combines PQRs 03-03-T-801 and A43256-42 into a single WPS in accordance with ASME Section IX, paragraph QW-403.5. QW-403.5, which is a supplementary essential variable for the GTAW process (ref. QW-256) states:
"... If, however, the procedure specification for welding the

combination of base metals specifies the same essential variables, including electrode or filler metal, as both specifications for welding each base metal to itself, such that base metals is the only change, then the procedure specification for welding the combination of base metals is also qualified." (1998 Edition with 1999 Addenda) QW-403.5, therefore, permits a single WPS to incorporate two separate PQR's, when each of the PQR's was qualified by welding a specific material to itself. WPS-03-43 T-801 uses the same essential variables from each referenced PQR, thereby achieving compliance with ASME Section IX and N-606 requirements. Note that N-606, paragraph 2.1 (a) states: "The base materials for the welding procedure qualification shall be of the same P-Number and Group Number, as the materials to be welded. The materials shall be postweld heat treated to at least the time and temperature that was applied to the materials being welded."

Attachment to
NG-99-1613 Page 8 of 8 WSI WPS-03-43-T-801 permits welding of P3 materials to P43 materials. P43 materials are not subjected to PWI-HT or impact test requirements, and therefore are not assigned group numbers. While N-606 paragraph 2.1 (a) implies that impact test and PWHT requirements apply to all base materials within its scope, this is clearly not the case. The "Reply" section of N-606 clearly includes P43 materials, yet these materials are exempt from PWHT and impact requirements. It is reasonable to conclude, therefore, that N-606 does not intend to invoke PWHT and impact test requirements on the P43 base material used in welding procedure qualification. WSI WPS-03-43-T-801, therefore, satisfies N-606 paragraph 2.1 (a) requirements.

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/11/99 Time: 11:59:52 AM

Page 2 of 10

Page 1 of 9

WELDING PROCEDURE SPECIFICATION

_

WPS 03-43-T-801 Rev~ 0 QA: 11/1 t/992

_____

Company Name: Welding Services, Inc. By:. Welding Procedure Specification No. WPS 03-43-T-801 (Note 0)

Date:

Revision No. 0 Supporting PQR No(s) 03-03-T-801, A43256-52 Welding Process(es) GTAW

Date Type(s) Machine

11/11/99

(Automatic. Manual, Machine. or Sami.Auo)

BASE METALS (QW-403)

P-No.
OR Specification type and grade to Specification type and grade OR Chem Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop.

3 (Note z)

Group No.

to P-No.

43

Group No.

NA

Base Metal: Thickness Range: Groove 518" Min. through Unlimited Fillet Pipe Dia. Range: Groove All Fillet Other P3 Group 3 base material cumulative PWHT time at temperature shall be 5 48 hours. JOINTS (QW-402) Joint Design: See page 2. Backing (other than gas backing) required'? 0 Yes C] No Backing Material (Type) Base material serves as backing, Retainers [ Not Permitted [ Permitted Other: None POSITIONS (QW-405)

NA NA

PREHEAT (-F) (QW-406) Preheat Temp- Min. Interpass Temp. Max. Preheat Maintenance: Preheat Notes:

50OF 150F (Layers 1-3) and 350OF (Rem.) o4) No 0 Yes See page 2, note D

I Position(s) of Groove
Welding Progression: Position(s) of Fillet:

All S Up C3 Down 0D Orbital All

POSTWELD HEAT TREATMENT (QW-407) Temperature Range None Time Range NA PWHT Notes: PWHT shall not be performed. Post-soak shall not be performed GAS (QW-408) Gas(es) Argon None None Percent Composition Mixture NA NA NA Rate (CFH) 30-65 NA NA

ELECTRICAL CHARACTERISTICS (QW-409) Current 0 AC 0 DC Polarity 0 Straight C] Reverse Amps (Range) See pg. 2 Volts (Range) See pg. 2 Tungsten Type EWTh-2 Size 3/32", 1/8", or 5/32" GMAW Xfer Mode NA Maximum Heat Input See Note 0) FILLER METALS (QW-404) Spec. No (SFA) None Z AWS Class ERNiCrFe-7 Solid Bare Wire Z_ F-No. F-43 A-No. NA Filler Size 0.035" or 0.045" Weld Metal Max. Dcposit Thick, 2,50" Fillet Thk Range AllI_ Flux Class None Flux Trade Name NA Consum Insert 0 Permitted C3 Not Permitted 0 NA Insert Materials NA Filler Wire Feed N Cold Wire C] Hot Wire TECHNIQUE (QW-410) String or Weave Bead Orifice or Gas Cup Size Initial and Interpass Cleaning Method of Back Gouging Oscillation (Machine/Auto Only) Contact Tube to Work Distance Multiple or Single Pass (per side) Multiple or Single Electrodes Travel Speed (Range) Peening Welding without filer material Supplemental filler material Qualified for Impact Test Apps: Pass exceeding 1/2" permitted:
I

Shielding Trailing Backing

_1; _

1
_

Permitted C] Not Permitted

- NA

Permitted (] Not Permitted C] NA

C] String Q3 Weave S Both [3Other (explain): #4 through #13, 0 Mechanical L) Thermal [3 Chemical 0 Other (explain) C3 Mechanical ' Thermal 0 None Backgouging is not permitted. Permitted (0.5" Maximum) NA C] Single M Multiple 0 Single C] Multiple See attached Technique Data Sheets, [E Prohibited [] Permitted (explain) 0Z Prohibited [] Permitted (explain) S Prohibited [] Permitted (explain) S Yes C] No 0 Yes 0 No

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/11/99 Time: 11:59:52 AM

Page 3 of 10

Page 2 of 9

Joint Details (QW.402)

K~.marnd~r L~yr 3 Layer ZX 7 L.dyff I

WPS 03-43-T-801 Rev, 0 WPS 03-43-T-801 Rev 0

P3 0"10, 3 MA,,t

P4 Mat~iai

S~Temperbead

Overlay

Temperbead Groove

This WPS may be used for all temperbead groove and fillet weld configurations. This WPS may be used for temperbead installation of weld metal buildup on existing P3 Group 3, P43, and F43 (deposited weld) materials. Weld configurations shall comply with configuration requirements imposed by governing Code(s) and Specification(s). (See notes (1)and M). Use of this WPS is subject to the restrictions of Draft ASME Code Case N-638. The joint designs shown are typical. Engineering drawings or other work documents may be used to provide additional/different temperbead joint configurations/details, within the limits of good welding practices and governing restrictions (including ASME Section IX restrictions). In all applications, however, minimum bevel angle (per side) shall be no less than 37.5 degrees, and minimum root width shall be no less than 1/2". Filler Metal Weld Layer(s) Ail (D A]I M Process GTAW Mach. GTAW MachClass ERNiCrFe-7 G ERNiCrFe-7 M Diameter 0.035" 0.045" Type/ Polarity OCEP V DCEP e

Current Amperage Range a) 0)

Volt Range

Travel Speed Range 3 0)

Other NA NA

NOTES CD Step-by-step Instructions governing weld installation are documented on the attached pages. Compliance with these instructions Is mandatory. * This WPS may be used for temperbead welding of all P3 Group 3 base materials (excluding SA302 Grade B base materials) to all P43 base materials and to all deposited F43 filler materials. * Heat input control is mandatory. For all weld layers, primary current, background current, primary voltage, pulse width, and travel speed shall be controlled in accordance with the attached technique data sheets to assure that heat input rates do not exceed the minimum and maximum values specified. Q! Prior to welding, the temperature of the area to be welded shall be !500F. In addition the temperature of a band, around the weld area, that is a minimum of 1.5 times the component thickness or 5.0", whichever is least, shall be 2 50F. Interpass temperature for temperbead layers 1, 2, and 3 shall not exceed 150oF. Interpass temperature for all remaining weld passes shall not exceed 3501F. CD ERNiCrFe-7 solid bare wire (UNS N06052) is classified as F-43 in accordance with ASME Code Case 2142. * Pulsed current shall be used. SThis WPS is issued based on the requirements of Draft ASME Code Case N-638- Temperbead layers on P43 base material are optional. Z The outermost bead on the second weld layer shall be no closer than 1/8" and no further than 1/4" from the point where the first layer contacts the base material. The outermost bead on the third layer shall not extend past the point where the second layer contacts the first layer. Subsequent weld beads shall not extend past the outermost edge of layer 3. See attached instructions for additional information.

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/111/99 Time: 11:59:S2 AM

Page 4 of 10

Page 3 of 9

WPS 03-43-T-801 Rev. 0

Instructions for WPS-03-43-T-801

Temper Bead Welding of P-3 Group 3 Base Materials to P43 Base Materials

using ERNiCrFe-7 Solid Bare Wire

The following instructions shall be followed for all repairs performed in accordance with this WPS. These instructions are to be used in addition to those contained on pages I and 2 of this WPS. All welding shall comply with ASME Section XI and Draft ASME Code Case N-638. 1. Draft ASME Code Case N-638 imposes the following restrictions on the use of this WPS: A. For the portion of the weld that covers the P3 Group 3 material, the maximum area of an individual weld, based on the finished surface, shall be 100 square inches, and the depth of the weld shall be no greater than 1/2 the base metal thickness. B. Repair of dissimilar-metal welds is limited to repairs along the fusion line of the nonferritic weld to the ferritic base material, on which 1/8 inch or less of nonferritic weld deposit exists above the original fusion line. If a defect penetrates into the base material, this WPS may be used to perform the defect repair. provided the depth the repair extends into the base material does not exceed 3/8 inch. Use of this WPS to perform welding in a pressurized environment is permitted only when authorized, in writing, by the Customer. Other, specific restrictions may be warranted (including additional procedure and performance qualification requirements) prior to welding in pressurized environments. Particular care shall be given to ensure that the weld region is free of all potential sources of hydrogen.

C.

D. 2.

All welding filler materials shall be controlled in accordance with a program that assures they are identified as acceptable until consumed. Preparation for welding: A. When defect removal is required: 1. 2. B. The defect shall be reduced to an acceptable flaw by excavation using a mechanical or thermal process. Preheating to a temperature >50F is required prior to use of any thermal metal removal process. The excavation configuration, location, and dimensions shall be within the restrictions identified in paragraph 1 above.

3.

After defect removal and for applications where defect removal is not required: 1. Prepare the base metal surfaces for welding using mechanical processes. Back gouging is not permitted. 2. 3. Cavity configuration shall comply with the "Joint Details" restrictions shown on page 2 of this WPS. The prepared areas shall be examined using Magnetic Particle or Liquid Penetrant testing.

4.

The weld installation sequence shall be as follows: A. The base material shall be buttered with a single-layer GTAW deposit. Welding parameters for this layer are defined on the attached Technique Data Sheet for Layer 1. The final appearance of the first weld layer is shown in the following sketch.

Layer 1

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11111/99 Time: 11:59:S2 AM

Page S of 10

Page 4 of 9

WPS 03-43-T-801 Rev. 0

B.

A second weld layer shall be installed, completely covering the first weld layer. Welding parameters shall be controlled in accordance with the Technique Data Sheet for Layer 2. The outermost bead on this second layer shall be no closer than 1/8", and no further than 1/4" from the point where the edge of the first layer contacts the base material. The final appearance of the second weld layer is shown in the following sketch.

Layer 2 C. A third weld layer shall be installed, completely covering the second weld layer. Welding parameters shall be controlled in accordance with the Technique Data Sheet for Layer 3. The outermost bead on this layer shall not extend past the point where the edge of the second layer contacts the first weld layer near the face of the base material. Minimum, combined weld deposit thickness after completion of layer 3 (i.e., layer I thickness + layer 2 thickness + layer 3 thickness) shall be > 1/8". The final appearance of the third weld layer is shown in the following sketch.

minimum

Layer 3 D. The remainder of the weld shall be installed. Beads may be deposited in any sequence, e.g., completion of individual weld layers that span the entire weld groove is not required. Welding parameters shall be controlled in accordance with the Technique Data Sheet for 'Remaining Weld Passes'. No weld pass shall extend past the outermost edge of Layer 3. For groove welds, the completed weld shall have at least one full layer of reinforcement (weld crown) that extends above flush with adjacent base material (see sketch below). This reinforcement layer is not required when the repair consists of a structural weld overlay.

Remaining Layers

From: Bruce Newton 770 209 9664 To: Scott Presler

Date: 11/11/99 Time: 11:59:52 AM

Page 6 of 10

Page 5 of 9

WPS 03-43-T-801 Rev. 0

E.

For temperbead groove welds, weld reinforcement shall be mechanically removed, making the surface of the repair substantially flush with the base material surface. Use of thermal processes for reinforcement removal is prohibited. Reinforcement layer installation; removal is not required when the repair consists of a structural weld overlay.

Reinforcement Removed (Temperbead Groove Welds Only) F. Nondestructive examinations of the completed weld shall be performed in accordance with governing requirements.

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/11/99 Time: 11:59:52 AM

Page 7 of 10

Page 6 of 9

WPS 03-43-T-801 Rev. 0

Laver 1
Technique Data Sheet for First Temperbead Layer
(Applicable only to Layer 1)
BACKGROUND

UPSLOPE TIME

PRIMARY CURRENT

CURRENT

DOWNSLOPE TIME

0 3
0-30 SEC

2 410
0-300 AMPS 0-300 AMPS 0-30 SEC

TRAVEL START DELAY

TRAVEL SPEED

LOW PULSE FREQ

LOW PULSE WIDTH

SYNC PULSE

0
0-30 SEC

31.0

2.00
0-9.9 PPS 0-99%
D OFF

PA

0-20.0 IPM

WIRE SPEED PRIMARY

I BACKGROUND

SYSTEM MODE OPERATEV ST

START DELAY

014
0-30 SEC

40
0-99 1PM

30
0-99 1PM FWD OFF REV MAN, 1i

OSCILLATOR AMPLITUDE

OUT DWELL

EXCURSION TIME

IN DWELL
FIXTURE MODE

PREPURGE SAMPLED

0.99 INCHES

0.1-0.9 SEC

0.1-0.9 SEC

0.1-0.9 SEC

PRIMARY

BACKGROUND

9 .0
5.0-25.0 VOLTS

.NA
5.0-25.0 VOLTS

RESPONSE

NOTES: Average Amperage=(Primary Amps*Pulse Width) + Background Amps*(1-Pulse Width) = 220 Amps Background Volts*(l -Pulse Width) = 5.4 Volts Average Voltage=(Primary Volts*Pulse Width) -+Heat Input Rate (Joules per inch) = (Average Amperage*Average Voltage*60) + Travel Speed = 23,760 J/In. Layer 1 heat input rates must be within the range 21,384 Joules per inch minimum through 26,136 Joules per inch maximum. The "RESPONSE" dial shall remain set on "SANMPLED". Pulsed current shall be used. Values shown on this sheet other than Primary Amps, Background Amps, Primary Volts, Pulse Width, and "RESPONSE" dial settings are for information only, and these values may be changed as desired.

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/11,/99 Time: 11:59:52 AM

Page 8 of 10

Page 7 of 9

WPS 03-43-T-801 Rev. 0

Layer 2
Technique Data Sheet for Second Temperbead Layer
(Applicable only to Layer 2) BACKGROUND CURRENT

UPSLOPE TIME

PRIMARY CURRENT

DOWNSLOPE TIME

2 60
0

10
170 0-300 AMPS 0-30 SEC

_ SEC 0-30 S

0-300 AMPS

TRAVEL START DELAY

TRAVEL SPEED

LOW PULSE FREQ

LOW PULSE WIDTH

SYNC PULSE

0
0-30 SEC

.0

.0

60
0-99%

PA

0-20.0 IPM

0-9.9 PPS

OFF

SYSTEM MODE

17

WIRE SPEED

I BACKGROUND

OPERATEST

START DELAY

PRIMARY

0i4
0-30 SEC

60
0-99 1PM

609
0-99 1PM
FWD OFF REV 15

OSCILLATOR AMPLITUDE

OUT DWELL

EXCURSION TIME

IN DWELL
FIXTURE MODE PREPURGE SAM PLED CONT LOCKt

0.99 INCHES

0.1-0.9 SEC

0.1-0.9 SEC

0.1.-0.9 SEC

PRIMARY

BACKGROUND

1 0 .3
5.0-25.0 VOLTS

NA
5.0-25.0 VOLTS

RESPONSE

NOTES: Average Amperage=(Primary Amps*Pulse Width) + Background Amps*(1-Pulse Width) = 224 Amps Average Voltage-(Primary Volts*Pulse Width) + Background Volts*(1-Pulse Width) 6.18 Volts Heat Input Rate (Joules per inch) = (Average Amperage*Average Voltage*60) + Travel Speed = 27,686 J/In.
-

Layer 2 heat input rates must be within the range 24,918 Joules per inch minimum through 30,445 Joules per inch maximum. The "RESPONSE" dial shall remain set on "SAMPLED". Pulsed current shall be used. Values shown on this sheet other than Primary Amps, Background Amps, Primary Volts, Pulse Width, and "RESPONSE" dial settings are for information only, and these values may be changed as desired.

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/111199 Time: 11:59:S2 AM

Page 9 of 10

Page 8 of 9

WPS 03-43-T-801 Rev. 0

Layer 3
Technique Data Sheet for Third Temperbead Layer
(Applicable only to Layer 3)
BACKGROUND CURRENT

UPSLOPE TIME

PRIMARY CURRENT

DOWNSLOPE TIME

03
0-30 SEC

2602
0-300 AMPS 0-300 AMPS 0-30 SEC

TRAVEL START DELAY

TRAVEL SPEED

LOW PULSE FREQ

LOW PULSE WIDTH

SYNC PULSE

0 5
0-30 SEC

0 3 .0
0-20.0 IPM

12

.0

6 0
0-99%

OFPA
OFF
SYSTEM MODE

0-9.9 PPS

WIRE SPEED PRIMARY

I BACKGROUND

OPERATEsT

START DELAY

0 4
0-30 SEC OSCILLATOR AMPLITUDE

6,0
0-99 1PM

60
0-99 1PM
OFF FWDK REV MAN i5

OUT DWELL

EXCURSION TIME

IN DWELL
FIXTURE MODE

SAMPLED

0.99 INCHES

0.1-0.9SEC

0.1-0.9SEC

0.1--0.9 SEC

PRIMARY

BACKGROUND

1 0 .0
5.0-25.0 VOLTS

NA
5.0-25.0 VOLTS

RESPONSE

NOTES: Average Amperage=(Primary Amps*Pulse Width) + Background Amps*(1-Pulse Width) = 224 Amps Average Voltage-(Primary Volts*Pulse Width) + Background Volts *(1 -Pulse Width) - 6 Volts Heat Input Rate (Joules per inch) = (Average Amperage *Average Voltage *60) + Travel Speed = 26,880 J/In. Layer 3 heat input rates must be within the range 24,192 Joules per inch minimum through 29,568 Joules per inch maximum The "RESPONSE" dial shall remain set on "SAIPLED". Pulsed current shall be used. Values shown on this sheet other than Primary Amps, Background Amps, Primary Volts, Pulse Width, and "RESPONSE" dial settings are for information only, and these values may be changed as desired.

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/11199 Time: 11:S9:52 AM

Page 10 of 10

Page 9 of 9

WPS 03-43-T-801 Rev. 0

Remaining Weld Passes

Technique Data Sheet for Remaining Weld Passes
(Applicable to all weld passes installed after completion of Layers 1. 2, and 3)
BACKGROUND

UPSLOPE TIME

PRIMARY CURRENT

CURRENT

DOWNSLOPE TIME

S3
0-30 SEC

220
0-300 AMPS

10
0-30 SEC

0-300 AMPS

TRAVEL START DELAY

TRAVEL SPEED

LOW PULSE FREQ

LOW PULSE WIDTH

SYNC PULSE

0 5
0-30 SEC

3.0

.0

60
PA

0-20.0 IPM

0-9.9 PPS

0-99%

OFF

I START DELAY

WIRE SPEED PRIMARY

I BACKGROUND

SYSTEM MODE OPERATKYsT

9 9
0-99 IPM
OFF FWDK REV 15

0-30 SEC OSCILLATOR AMPLITUDE

0-99 IPM

.1

OUT DWELL

EXCURSION TIME

IN DWELL
FIXTURE MODE

0.99 INCHES

0.1-0.9SEC

0.1-0.9SEC

0.1-0.9 SEC

SAMPLED

PRIMARY

BACKGROUND

1 0 .3
5.0-25.0 VOLTS

NA
5.0-25.0 VOLTS

RESPONSE

NOTES: Average Amperage=(Primary Amps*Pulse Width) + Background Amps*(l -Pulse Width) = 244 Amps Average Voltage=(Primary Volts*Pulse Width)+ Background Volts*(1 -Pulse Width) = 6.18 Volts Heat Input Rate (Joules per inch) = (Average Amperage*Average Voltage*60) + Travel Speed = 30,158 J/In. Remaining passes' heat input rates must be equal to or less than 30,158 Joules per inch. The "RESPONSE" dial shall remain set on "'SAMPLED". Pulsed current shall be used. Values shown on this sheet other than Primary Amps, Background Amps, Primary Volts, Pulse Width, and "RESPONSE" dial settings are for information only, and these values may be changed as desired.

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/11199 Time: 12:26:00 PMl

Page 2 of 9

QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (See QW-201.2, Section IX, ASME Boiler and Pressure Vessel Code) Record Actual Conditions Used to Weld Test Coupon.
Company Name Procedure Qualification Record No.
WPS No. A043245

WELDING SERVICES INC.

A43256-52 Rev. (2) Gas Tungsten Arc Date June 16,1995

Welding Process(es) Types (Manual, Automatic, Semi-Auto.) JOINTS (QW-402)

Machine
Note 1: Filler Metal identified as UNS N06052 and considered as F43 inaccordance with ASME Section IX Code Case 2142, No SFA specification has been assigned. Inco 52 (N06052) Ht # NX8278JK P.O. 220562.

1 fZ-

Deposited Weld Metal: 1"

Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal or process weld.) POSTWELD HEAT TREATMENT (QW-407) BASE METALS (QW-403) N/A Temperature SB168 Material Spec. N/A Time UNS N06600 Type or Grade N/A Other 43 to P-No. 43 P-No.
Thickness of Test Coupon Diameter of Test Coupon 1

1/2"

Plate 112". > Pass No Other SB168 NO6600: Ht #NX7382 P.O. 220556 None
None

GAS (OW.408) Type of Gas or Gases Composition of Gas Mixture Argon (99.99%) Other

None
FILLER METALS (QW-404)

Argon - 35 CFH 99.99% Argon Welding Grade Backing gas utilized at a flow

rate of 2 CFH.
Weld Metal Analysis A-No. Size of Filler Metal Filler Metal F-No. SFA Specification AWS Classification N/A

.045"

43
None None

Note 1
Note 1 Note 1

ELECTRICAL CHARACTERISTICS (QW-409) DCEN Current

Polarity
Amps.

Straight
95-210 Volts

Other

No supplementary filler metal used.

Retainers not used.

8.6 to 9.3 Tungsten Electrode Size 1/8" EWTH 2% Maximum Heat Input: 37,088 JIn. Other

POSITION (QW-406) Position of Groove 1 G Weld Progression (Uphill, Downhill) None Other

Flat

TECHNIQUE (QW-410) 1.6 to 3.5 IPM Travel Speed Weave String or Weave Bead .04" to .29" Oscillation Multiple Multipass or Single Pass (per side) Single Single or Multiple Electrodes

PREHEAT (QW-406)
Preheat Temp.
Interpass Temp.

Other

1. Bare (solid) filler metal utilized.

2. No welding performed without filler metal.

65 Degree F (ambient) 400 Degree F

Other

None
,___,,,.,,,.__=_, _: .
1111 ,oum

4kf.,..

A~uIAC i'AZ : A7tk

FLUt. ., In. ,tr. ru

VR f haw~n
.,,u

MY

1(1017

(&/82)

Thius Torm~i tm.Uw"ni

may be 0018

~,.,...

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/11/99 Time: 12:26:00 PM

Page 3 of 9

QW-483 (Back) POR No. Tensile Test (QW-150)

Ultimate Ultimate Type of

A43256-52 Rev. (2)

Specimen No.

Width

Thickness

Area (in')

Total Load lb.

Unit Stress psi

Failure & Location

0.5020

N/A N/A

0.1979 0.1995

19,300 18,800

97,500 94,000

Weld Metal Weld Metal

0.5040

Guided Bend Tests (QW-160)

Type and Figure No. Result

Side Bend, QW462.2 Side Bend, QW462.2 Side Bend, QW462.2 Side Bend, QW462.2

Acceptable Acceptable Acceptable Acceptable

Toughness Tests (QW-170)

Specimen No. None Notch Location Notch Type Test Temp. Impact Values Lateral Exp. % Shear Mile Drop Weight Break No Break

Rev. 2 - Added CFH gas flow rate and welding position.

Welders Name
Tests conducted by:

Randall A. Baker
Welding Services Inc./Applied Technical Svcs., Inc.

ClOCk No.

N/A

Stamp No. K40123 (N)

RAB5652

Laboratory Test No.

We certify that the statements in this record are correct and that the test welds were prepared, welded the requirements of Section IX of the ASME Code.
-

tested in accordance with

A
Manufacturer

/7
INC.

WLD

Date

.-

"12,T1'1J 7/.7//Vf

By
f tests r by the Code.)

(Detail of record of tests are illusbtative only and may be modified to conform to the type an num 6/82 (PQR00071.DOC)

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/'11199 Time: 12:26:00 PM

Page 4 of 9

PQR-03-03-T-801 Rev. 0 Page I of 6 Welding Services Inc. Company Name PQR-03-03-T-801 Procedure Qualification Record No. 0 Revision No. Preliminary WPS-03-03-T-801 WPS No. GTAW Welding Process(es) Machine Types (Manual. Automatic, Semi-Auto.) JO[NTS (QW402) 27.5" 12" 6.5" .5 eg. Original Issue Date: Revision Date: 04102/99 04/02/99

'
[) 3.5" 8.5" Typ.

1.25"

3.5" 2' Direction of Rolling

:" 0.5"

Ambient Temperature Temperbead Weld Installation

(Dashed lines indicate hardness traverse test areas) POSTWELD HEAT TREATMENT (QW-407) BASE METALS (QW-403) None Temperature SA533 to SA533 Material Spec. NA Time Grade B Class I to Grade B Class I Type or Grade PWHT was not performed. Other P3 Group 3 to P3 Group 3 P No. Post Weld Heat Soak was not performed. 3.5" to 3.5" Thickness Plate Diameter GAS (QW-408) Other Plate received 48 hours PWHT at 1125F prior to PQR Percent Composition welding. Plate heat no. is B6796. Welding was performed in Mixture Gas(es) accordance with draft ASME Code Case N-612. NA Argon Shielding No peening was performed. NA None Trailing (QW-404) FILLER METALS NA None Backing NA None SFA Specification (QW-409) CHARACTERISTICS ELECTRICAL NA ERNiCrFe-7 AWS Classification Filler Metal F-No. Filler Metal A-No. Filler Size Deposit Thickness:
Other

Flow Rate 35 CFH NA NA

F-43a) None 0.035" 1.25"

Solid Bare Wire

NA NA NA NA
NA

Current

Direct See attached pages

Straight Polarity Volts Amps. See attached pages Pulsed current was used. Other TECHNIQUE (QW-410)

POSITION (QW-405) Position of Groove 3G (Vertical) Uphill Weld Progression (Uphill, Downhill) None Other

Travcl Speed

See attached pages

Weave String or Weave Bead See attached pages Oscillation

Multipass or Single Pass Multipass Single Single or Multiple Electrodes

PREHEAT (QW-406) Preheat Temp. 69F 150 0F (Layers 1,2, and 3) Interpass Temp. 350 0 F (Remaining Layers)

Other

No pass exceeded 1/2" thickness.

Filler metal was added continuously (QW-404.14). Max. heat input rate: Sec attached pages Deposit thickness of layer I + layer 2 + layer 3 was > 1/8".

(D ERNiCrFc-7 filler material (inw 52) is classified as F-43 in accordance with ASME Code Case 2142.

From: Bruce Newton 770 209 96B4 To: Scott Presler

Date: 11/111/99 Time: 12:26:00 PM

Page 5 of 9

PQR-03-03-T-801 Rev. 0 Page 2 of 6 QW-483 (Back) Tensile Test (QW-15O) Specimen No. I 2 Width (In.) 0.748 0.758 Thickness (In.) 1.304 1.253 Area (In. ) 0.975 0.949 Guided Bead Tests (QW-160) Type and Figure No. Side Bend No. I (QW-462.2) Side Bend No. 2 (QW-462.2) Side Bend No. 3 (QW-462.2) Side Bend No. 4 (QW-462.2)
Toughness Tests (QW-170)
2

Ultimate Total Load lb. (PSI) 85,600 85,000

Ultimate Unit Stress (PSI) 88,000 89,500

Type of Failure & Location Ductile (Weld) Ductile (BM)

Result Acceptable Acceptable Acceptable Acceptable Impact Values % Shear 58 73 100 77 100 100C) 100
100

Specimen No. BM- I BM-2 BM-3 BMAverage HAZ- I HAZ-2 HAZ-3

HAZAverage
W

Notch Location BM BM BM HAZ HAZ HAZ

Notch Orientation See Note See Note See Note See Note See Note See Note

Test Temp. (oF) 0 0 0 0 0 0

Ft. Lbs. 142 160 t84 162 246 >300 () 234

260

Mils 84 100 96 93.3 90 126 Q 82

99.3

Drop Weight Testing Base Metal Break No Break -80*F -400 F -60*F -40*F 0 -50 F

the thickness of the deposited we metal. Impact testing of lnco 52 filler material is not required. Plate direction of rolling is parallel to the axis of the weld. Three full-size 10 mm x 10 mm specimens were tested. Test samples were removed in accordance with draft ASME Code Case N-612, Figure 1. (D Impact specimen HAZ-2 did not break, as a result of its exceptional toughness. The listed value of 100% shear is estimated, based on the fact that HAZ specimens I and 2, both of which broke during Charpy testing, exhibited 100% shear. 126 mils lateral expansion is calculated by extrapolation, using the absorbed energy values from HAZ specimens I and 3 and the corresponding lateral expansion values. This extrapolation incorporates a measure of conservatism in that it assumes breakage at 300 ft-lbs., whereas actual absorbed energy was greater than the test machine's 300 ft-lb. capacity.
Area Depth (In.) 0.250 0.200 0.150 0.100 0.050 Interface W Tempered Zone 0 0.050 Hardness Tests (D Line No. 1 (0) 95 HRB 99 HRB 97 96 30 37 95 91 HRB HRB HRC HRC HRB HRB Line No. 2 (2) 91 HRB 91 HRB 93 95 38 30 97 95 HRB HRB HRC HRC HRB HRB Line No. 3 Z 97 HRB 20 HRC 97 HRB 22 ItRC 30 HRC

t.IAZ impact specimens were removed from a location as near as practical to a depth or I/

BASE METAL

3 OHRC
91 HIRB 87 HRB

(I) * (*) 9)

0.100 93 HRB 24 HRC 91 HRB 0.150 95 HRB 99 HRB 82 HRB 0.200 94 HRB 96 HRB 94 HRB 0.250 98 HRB 96 HRB 87 HRB Testing was performed in accordance with ASTM E384-89 (97), with values converted to Rockwell per ASTM E140-97. Microhardness testing was performed on the weld/base material cross section in the three locations shown in the sketch on page 1. Measurements were taken on base metal, at a location 0.010" from weld/base metal interface. Measurements taken in the center of the tempered zone of the weld material.

WELD

Welder's Name and ID Number: Oscar Lane (StomD OL-3745)

Trests Conducted by: Aimlied Technical Services requirements of the 1998 Edition of Section IX of the ASME Code.

Laboratory Test No. D92460

We certify that the statements in this record are correct and that the test welds were prepared,. welded, and tested in accordance with the

Manufacturer Weldinp Services loi. Date April 7, 1999 By LftZ!1 I

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/111199 Time: 12:26:00 PM

Page 6 of 9

PQR-03-03-T-801 Rev. 0 Page 3 of 6

Layer I
Technique Data Sheet for First Temperbead Layer
(Applicable only to Layer 1)
BACKGROUND CURRENT

UPSLOPE TIME

PRIMARY CURRENT

DOWNSLOPE TIME

0-30 SEC

3Io S

W2il4 0
0-300 AMPS 0-300 AMPS

D3 S
0-30 SEC LOW PULSE WIDTH

TRAVEL START DELAY

TRAVEL SPEED

[0iZIIo]
0-20.0 IPM WIRE SPEED PRIMARY 0-99 IPM

LOW PULSE FREQ

SYNC PULSE

0-30 SEC

0-9.9 PPS

0-99%

PA QO
SYSTEM MODE OPERATE UST

I
START DELAY

I BACKGROUND

0-30 SEC

0-99 IPM

OSCILLATOR AMPLITUDE

11311
0.99 INCHES PRIMARY

OUT DWELL

EXCURSION TIME

IN DWELL

OFF FWDOREV MAN Is

0.1-0.9 SEC

0.1-0.9 SEC

0.1-0.9 SEC

FIXTURE MODE

PREPURGE

SAMPLED LOCK CONT

EIP1.0o
5.0-25.0 VOLTS

BACKGROUND

5.0-25.0 VOLTS
NOTES:

RESPONSE

Average Amperage=(Primary Amps*Pulse Width) + Background Amps*(l-Pulse Width) = 220 Amps Average Voltage=(Primary Volts* Pulse Width) + Background Volts*(l -Pulse Width) = 5.4 Volts Heat Input Rate (Joules per inch) = (Average Amperage*Average Voltage*60) Travel Speed = 23,760 J/In.

From: Bruce Newton 770 209 9664 To: Scott Presler

Date: 11/11199 Time: 12:26:00 PM

Page 7 of 9

PQR-03-03-T-801 Rev. 0 Page 4 of 6

Layer 2
Technique Data Sheet for Second Temperbead Layer
(Applicable only to Layer 2)
BACKGROUND CURRENT

UPSLOPE TIME

PRIMARY CURRENT

L1IE1
0-300 AMPS TRAVEL SPEED 0-20.0 IPM

DOWNSLOPE TIME

EIII
0-99%

0-30 SEC

0-300 AMPS

0-30 SEC

TRAVEL START DELAY

IZE.E1 [: -01
0-9.9 PPS

LOW PULSE FREQ

LOW PULSE WIDTH

El o

SYNC PULSE AP

0-30 SEC

WIRE SPEED

SYSTEM MODE BACKGROUND OPERATE UTT 0-99 1PM OFF FWDOREV MAN 15

START DELAY

PRIMARY

6 1PM
0-30 SEC 0--99 IPM

OSCILLATOR AMPLITUDE

OUT DWELL

EXCURSION TIME

IN DWELL

FIXTURE MODE 0.99 INCHES

0.1-0.9 SEC 0.1-0.9 SEC 0.1-0.9 SEC SAMPLED

PREPURGE

LOCKdjCONT PRIMARY
BACKGROUND

RESPONSE 5.0-25.0 VOLTS

5.0-25.0 VOLTS NOTES: Average Amperage-(Primary Amps*Pulsc Width) + Background Amps*(l-Pulse Width) = 224 Amps Average Voltage=(Primary Volts*Pulse Width) + Background Volts*(l-Pulse Width) = 6.18 Volts Heat Input Rate (Joules per inch) = (Average Amperage*Average Voltage*60) + Travel Speed = 27,686 J/In.

Note: The outermost bead on layer 2 was located 3/16" (1/16") from the point where the edge of layer I contacts the base material surface. No subsequent layers extended past the outer edge of layer 2.

From: Bruce Newton 770 209 9684 To: Scott Presier

Date: 11111/99 Time: 12:26:00 PM

Page 8 of 9

PQR-03-03-T-801 Rev. 0 Page 5 of 6

Layer 3
Technique Data Sheet for Third Temperbead Layer
(Applicable only to Layer 3)

UPSLOPE TIME

[I3

PRIMARY CURRENT

BACKGROUND CURRENT

DOWNSLOPE TIME

1 0
ECl 0-30 SEC SYNC PULSE 0-99%

0-30 SEC

0-300 AMPS

0-300 AMPS

TRAVEL START DELAY

TRAVEL SPEED

ZEP]
0-20.0 IPM WIRE SPEED

LOW PULSE FREQ

E.ll L ]2
0-9.9 PPS

LOW PULSE WIDTH

0-30 SEC

PA QO
SYSTEM MODE

I START DELAY

PRIMARY

BACKGROUND

OPERATE,

0-30 SEC

0-99 IPM
OUT EXCURSION

0-99 IPM
OFF IN

OSCILLATOR AMPLITUDE

LLoY

FWD

REV
MAN

DWELL

TIME

DWELL

0.99 INCHES

0.1-0.9 SEC

0.1-0.9 SEC

0.1-0.9 SEC

PREPURGE SAMPLED

PRIMARY

BACKGROUND

15 0 VOLT
5.0-25.0 VOLTS

LEZIZO
5.D-25.0 VOLTS
NOTES:

RESPONSE

Average Amperage=(Primary Amps*Pulse Width)+ Background Amps*(l-Pulse Width)= 224 Amps Average Voltage=(Primary Volts*Pulse Width) + Background Volts*(-Pulse Width) = 6.0 Volts Heat Input Rate (Joules per inch) - (Average Amperage*Average Voltage*60) + Travel Speed = 26,880 J/In.

From: Bruce Newton 770 209 9684 To: Scott Presler

Date: 11/11/99 Time: 12:26:00 PM

Page 9 of 9

PQR-03-03-T-801 Rev. 0 Page 6 of 6

Remaining Weld Passes

Technique Data Sheet for Remaining Weld Passes
(Applicable to all weld passes installed after completion of Layers 1, 2, and 3)
UPSLOPE TIME
PRIMARY CURRENT

BACKGROUND CURRENT

DOWNSLOPE TIME

321o01M
0-30 SEC
0-300 AMPS

0-300 AMPS

0-30 SEC

TRAVEL START DELAY

TRAVEL SPEED

EliI.o
0-20.0 IPM WIRE SPEED PRIMARY

LOW PULSE FREC

2 I.0E
0-99 IPM

LOW PULSE WIDTH

SYNC PULSE

0-30 SEC

0-9.9 PPS

0-99%

SYSTEM MODE
BACKGROUND

START DELAY

OPERATE

0-30 SEC OSCILLATOR AMPLITUDE

0-99 IPM

OFF OUT DWELL EXCURSION TIME IN DWELL FWD EV FIXTURE MODE 0.99 INCHES 0.1-0.9 SEC 0.1-0.9 SEC 0.1-0.9 SEC

MAN

PREPURGE SAMPLED LOCK CONT

PRIMARY

BACKGROUND

N5 IV OL
50-250 VOLTS 5.0250 OLS NOTES:

RESPONSE

Average Amperage=(Primary Amps*Pulse Width) + Background Amps*(I-Pulse Width) = 244 Amps Average Voltage-Primary Volts*Pulse Width) + Background Volts*( I-Pulse Width) = 6.1g Volts Heat Input Rate (Joules per inch) = (Average Amperage*Average Voltage*60) + Travel Speed - 30,158 JtIn,