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Welding and Inspection IV-6 4 LEGAL NOTICE This report was prepared solely for use (including release to the Public Document Room) by the U. S. Atomic Energy Commission in considering the application filed by Northern States Power Company (pursuant to the Atomic Energy Act of 1954, as amended, and Title 10 Part 50 of the Code of Federal Regulations) for a construction permit and operating license for a boiling water reactor nuclear generating plant to be located at Monticello, Minnesota. Use of this report or the information contained herein by any one other than the Atomic Energy Commission or for any purpose other than that for which it is expressly intended is not authorized. With respect to any unauthorized use neither Northern States Power Company, the General Electric Company, Chicago Bridge & Iron Company nor the individual authors: A. Makes any warranty or representation, expressed or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information disclosed in this report may not infringe privately owned rights; or B. Assumes any responsibility for liability or damage which may result from the use of any information disclosed in this report. A2A TABLE OF CONTENTS I. SUMMARY AND INTRODUCTION 1. 1 Summary I-1 1. 2 Study I-1 II. FEASIBILITY OF SHIPPING SHOP-ASSEMBLED VESSEL TO MONTICELLO SITE 2. 1 General H1-1 IIL REACTOR VESSEL DESIGN 3. 1 Design Requirements III-1 3. 2 Performance of Reactor Vessel Design Analysis 111-3 3. 3 Material Selection 111-6 3. 4 Appendix Material 111-6 IV. VESSEL FABRICATION AND ASSEMBLY 4. 1 Division of Work and Project Organization IV-1 4. 2 Shop Fabrication and Sub-assembly Work IV-1 4. 3 Site Sub-assembly and Erection IV-3 4. 4 Details of Welding and Inspection IV-6 4. 5 CB&I Quality Control Plan IV-8 V. GENERAL ELECTRIC REVIEW AND EVALUATION OF CB&I PROCEDURES 5. 1 General V-1 5. 2 Types of Procedures to be Reviewed V-1 5. 3 Differences in Fabrication Procedures and Criteria for Acceptance V-2 VL GENERAL ELECTRIC QUALITY CONTROL PLAN 6. 1 General VI-1 6. 2 Organization VI-1 6. 3 Typical Experience VI-1 6. 4 Quality Control Plan VI-2 6. 5 General Electric Quality Control Activity VI-2 VII. FIELD ORGANIZATION VIII. QUALIFICATION OF VENDOR 8. 1 General Electric Experience VIII-1 8. 2 CB&I Experience VIII-1 ILL APPENDICES APPENDIX A Task Force Study (Field Assembly vs. Shop Assembly of Reactor Vessels) APPENDIX B Feasibility of Shipping Shop-Assembled Vessel to the Monticello Site APPENDIX C General Electric Engineering Requirements for the Monticello Vessel APPENDIX D Erection Sequence Illustrations APPENDIX E Training of Welding Supervisors APPENDIX F CB&I Quality Control Procedures and Records APPENDIX G Fabrication, Inspection and Test Procedure Requirements APPENDIX H Review of Radiographic Inspection Procedures APPENDIX J General Electric Reactor Vessel Quality Control Plan APPENDIX K Chicago Bridge and Iron Company Experience K1 CB&I Personnel Code Committee Assignments K2 Field Stress Relieving of Large Field-Erected Vessels (Reprint from Welding Journal) K3 CB&I Containment Experience Bulletin No. 8500 K4 Site Assembly (Reprint from Nucleonics) iv LIST OF ILLUSTRATIONS No. TITLE III-1 Comparison of Review and Approval Process 111-2 Field Erection Vessel Support Structure 111-3 Final Vessel Support Structure IV-1 Project Organization Chart IV-2 Site Assembly Area IV-3 Composite Reactor and Pressure Vessel IV-4 Shop-Assembled Shipping Pieces IV-5 Shroud Support Details IV-6 Stainless Steel Overlay of Pressure Vessel IV-7 General Plan of Vessel IV-8 Post Weld Heat Treatment of Longitudinal Welds IV-9 Post Weld Heat Treatment of Bottom Head and Skirt Welds IV-10 Post Weld Heat Treatment of Top Head to Flange Weld IV-11 Establishing Reactor Centerline IV-12 Top Head Flange Drilling IV-13 Top Head Flange Machining IV-14 Boring Bar Cutter Drilling Control Rod Drive Sleeves IV-15 Post Weld Heat Treatment of Girth Weld in Position IV-16 Vessel Closing Flange Drilling IV-17 Vessel Closure Flange Machining IV-18 Category A & B Joint Detail IV-19 Category D Joint Detail IV-20 Category B Joint Weld Sequence IV-21 Category A Joint Weld Sequence IV-22 Weather Protection for Welders IV-23 Typical Field Pre-Heating Arrangement IV-24 Typical Stainless Steel Overlay Manual IV-25 Shroud Support Buildup Control Rod Penetration Sleeves IV-26 Skirt Knuckle Weld Buildup on Bottom Head Knuckle IV-27 Typical Field Radiographic Setup VI-1 General Electric Quality Control Organization VI-2 Direct-to-Site Procurement VII-1 Field Organization - Reactor Vessel Assembly and Erection V LIST OF ILLUSTRATIONS (Cont) No. TITLE VIII-1 Site-Erected Hydro-cracker Pressure Vessel VIII-2 CB&I-Constructed Heavy Wall Vessels VIII-3 Field Machining Drywell Flange VIII-4 Basic Oxygen Furnaces, Sheet 1 VIII-5 Basic Oxygen Furnaces, Sheet 2 VM-6 Basic Oxygen Furnaces, Sheet 3 VIII-7 Site Boring 32" 0 trunnion ring VIII-8 Summary Post Weld Heat Treatment VIII-9 Welders 100% X-Ray Examination Record VIII-10 Welding 2 5/8" Thick Drywell Transition Knuckle Vf-11 Hot Pressing 7" Thick Plate VIII-12 Shop Assembly of Thick Wall Vessel Vm-13 Site-Assembled Refinery Reactors in Canada VIII-14 Comparative Data: Dresden 2, Monticello and Vessels CB&I is currently assembling VII-15 Gamma Radiograph Setup VIII-16 Site X-Ray Processing Unit A-1 Typical Sub-assembly Sequence A-2 Comparison Schedule - Field vs. Shop-Assembled B-1 Minneapolis - St. Paul B-2 Proposed Route C-1 Reactor Vessel C-ia Reactor Vessel Details, Sheet 1 C-1b Reactor Vessel Details, Sheet 2 C-1c Reactor Vessel Details, Sheet 3 C-2 Loads and Nozzle Reactions C-3 Nozzle Thermal Cycles C-4 Seismic and Jet Forces C-5 Vessel Flange Bolting C-6 Nozzle End Preparations C-7 Insulation Support Brackets C-8 Thermal Mounting C-9 Charpy Impact Specimens C-10 1/4" Tensil Test Specimen C-11 Test Plate - Base Metal Specimens vi LIST OF ILLUSTRATIONS. (Cont) No. TITLE C-12 Test Weld for Weld and Heat-Affected Zone Specimen C-13 Base Metal Charpy and Tensil Specimens Location C-14 Weld Charpy C-15 Weld Tensil C-16 Heat-Affected Zone Tensil C-17 Heat-Affected Zone Charpy D-1 Bottom Head Together D-2 Bottom Head to Skirt Extension D-3 Reactor Skirt D-4 Skirt Extension to Skirt D-5 Shell Sections Together D-6 #1 Shell Ring to Bottom Head D-7 #2 Shell Ring to #1 Shell Ring D-8 #3 Shell Ring to #2 Shell Ring D-9 Shell Flange to #4 Shell Ring D-10 #4 Ring to #3 Ring D-11 Head Flange to Top Head D-12 Machining Top Head Flange D-13 Drilling Holes in Top Head Flange D-14 Control Rod & In-Core Penetrations D-15 Machining Shell Flange D-16 Drill & Tap Shell Flange D-17 Shroud Support Installation E-1 Classroom E-2 Specimen Binder E-3 Welding Defects E-4 Radiography Reading E-5 Radiographing E-6 Film Developing and Reading E-7 Catastrophic Failure of Oil Storage Tank E-8 First Ring Failure by Cleavage Square Cut Failure E-9 Catastrophic Failure During Hydrostatic Test E-10 Notch That Triggered Failure E-11 Notch Failure Demonstration Skitch E-12 Stress Concentration Design E-13 Instructor Checking Prospective Supervisor E-14 Using the Carbon Arc Gauges vii LIST OF ILLUSTRATIONS (Cont) No. TITLE E-15 Submerged Arc Welding Instruction E-16 Automatic Girth Welding Instruction E-17 TIG Welding E-18 MIG Torch Welding E-19 CO2 or Innershield Welding E-20 Automatic Veritcal Welding E-21 Magnetic Particle Testing E-22 Dye Penetrant Testing E-23 Ultrasonic Testing E-24 Tensil Testing E-25 Charpy Vee Notch Specimen Testing E-26 Drop Weight Testing E-27 Drop Weight Test Specimens E-28 Basic Structure Study E-29 Final Exam F-1 Cold Forming Affect on A533 Material (Page 1) F-1 Cold Forming Affect on A533 Material (Page 2) F-1 Cold Forming Affect on A533 Material (Page 3) F-1 Cold Forming Affect on A533 Material (Page 4) F-2 Cold Forming Procedure (Page 1) F-2 Cold Forming Procedure (Page 2) F-2 Cold Forming Procedure (Page 3) F-3 Post Forming Welding Heat Treating Procedure (Page 1) F-3 Post Forming Welding Heat Treating Procedure (Page 2) F-3 Post Forming Welding Heat Treating Procedure (Page 3) F-4 Ultrasonic Examination Procedure for Plates (Page 1) F-4 Ultrasonic Examination Procedure for Plates (Page 2) F-4 Ultrasonic Examination Procedure for Plates (Page 3) F-4 Ultrasonic Examination Procedure for Plates (Page 4) F-5 Liquid Penetrant Testing Procedure (Page 1) F-5* Liquid Penetrant Testing Procedure (Page 2) F-6 Magnetic Particle Testing Procedure (Page 1) F-6 Magnetic Particle Testing Procedure (Page 2) F-7 Plate Material Specification (Page 1) F-7 Plate Material Specification (Page 2) F-7 Plate Material Specification (Page 3) LIST OF ILLUSTRATIONS (Cont) No. TITLE F-8 Ultrasonic Test Procedure UT-B2 (Page 1) F-8 Ultrasonic Test Procedure UT-B2 (Page 2) F-8 Ultrasonic Test Procedure UT-B2 (Page 3) F-8 Ultrasonic Test Procedure UT-B2 (Page 4) F-8 Ultrasonic Test Procedure UT-B2 (Page 5) F-8 Ultrasonic Test Procedure UT-B2 (Page 6) F-9 Traveler Card (Page 1) F-9 Traveler Card (Page 2) F-10 Thermal History F-li Quality Control Spread Sheet F-12 Radiography Work Order F-l3 Ultrasonic Test Report F-14 Magnetic Particle Inspection Record F-15 Liquid Penetrant Inspection Record H-1 Requirements for X-Ray Energy ix LIST OF TABLES No.
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