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Contents
1
GENERAL .................................................................................................................................................. 2 1.1 1.2 1.3 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4 4.1 4.2 4.3 5
ESTIMATED QUANTITY OF WELD CONSUMABLES ................................................................................................ 3 REFERENCES............................................................................................................................................... 3 WELDING PROCEDURE ................................................................................................................................. 4 CHEMICAL COMPOSITION OF MATERIALS .......................................................................................................... 4 MECHANICAL TESTS OF MATERIALS ................................................................................................................. 5 FILLER MATERIALS ....................................................................................................................................... 5 GAS AND GAS MIXTURES ............................................................................................................................... 5 WELDING PROCEDURE SPECIFICATION ............................................................................................................. 5 WELDING MATHOD ..................................................................................................................................... 6 QUALIFICATION OF WELDERS AND WELDING OPERATORS ..................................................................................... 6 STORAGE AND USE OF FILLER MATERIALS .......................................................................................................... 6 PREPARATION OF JOINT FACES ........................................................................................................................ 7 EXECUTION OF PRODUCTION WELDS ................................................................................................................ 7 REPAIRS ..................................................................................................................................................... 8 NON-DESTRUCTIVE TESTING .......................................................................................................................... 8
WELDING OF BOTTOM ............................................................................................................................... 10 WELDING OF SHELL ................................................................................................................................... 10 WELDING OF ROOF .................................................................................................................................... 10
MATERIALS .............................................................................................................................................. 4
WELDING PROCEDUREWELDING PROCEDURE .......................................................................................... 5
WELDING SEQUENCEWELDING SEQUENCE ............................................................................................... 9
WELDING RECORDWELDING RECORD .................................................................................................... 10
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1 GENERAL
This proposal describes on-site installation methods and steps for welding and ensuring pro-ject quality of two PTR storage Tanks, three KER storage Tanks, three TER storage Tanks and two SEK storage Tanks (main technical parameters see table 1) in HXA plant of HPC nuclear power station.
Table 1 Main technical parameters of storage tank
PTR tank ×2 Safety class ：3 Mechanical requirement:M3 Seismic requirement：NR Seismic function:- Design temperature:60℃ Minimum allowable pressure:- Material:316L Total /max usable volume: 1375/1200m3 Size:Dint=11.40m; h=13.5m Net weight:43.757t Tank internal piping system (1); manholes (2) set on the tank; water inlet (1), water outlet (1), overflow port (1), spare nozzles (2) , exhaust port (1), discharge port (1), equipment nozzles (4), anchoring parts(8), reinforcement ring, top frame, top angle steel, top platform and other accessories. KER tanks×3 Safety class ：3 Mechanical requirement:M3 Seismic requirement：NR Seismic function:- Design temperature:60℃ Minimum allowable pressure:- Material:316L Total volume/max usable vol-ume:800/750m3 Size: Dint=9.66m; h=12.0m Net weight:30.780t Tank internal piping system (1); manholes (2) set on the tank; water inlet (1), water outlet (1), overflow port (1), spare nozzles (3) , exhaust port (1), discharge port (1), equipment nozzles (6), anchoring parts(8), reinforcement ring, top frame, top angle steel, top platform and other accessories. TER tank ×3 Safety class ：3 Mechanical requirement:M3 Seismic requirement：NR Seismic function:- Design temperature:60℃ Minimum allowable pressure:- Material:316L Total volume/max usable vol-ume:800/750m3 Size: Dint=9.66m; h=12.0m Net weight:30.780t Tank internal piping system (1); manholes (2) set on the tank; water inlet (1), water outlet (1), overflow port (1), spare nozzles (3) , exhaust port (1), discharge port (1), equipment nozzles (6), anchoring parts(8), reinforcement ring, top frame, top angle steel, top platform and other accessories. SEK tank ×2 Safety class ：3 Mechanical requirement:M3 Seismic requirement：NR Seismic function:- Design temperature:60℃ Minimum allowable pressure:- Material:316L Total volume/max usable vol-ume:800/750m3 Size: Dint=9.66m; h=12.0m Net weight:30.780t UNCONTROLLED WHEN PRINTED
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Tank internal piping system (1); manholes (2) set on the tank; water inlet (1), water outlet (1), overflow port (1), spare nozzles (3) , exhaust port (1), discharge port (1), equipment nozzles (5), anchoring parts(8), reinforcement ring, top frame, top angle steel, top platform and other accessories. The configuration of storage tank shows below.
Figure1 The configuration of the tank
1.1 ESTIMATED QUANTITY OF WELD CONSUMABLES
Table 2--The details of welding
Part Bottom Shell Ceiling Bottom Shell Ceiling Total Type of tank PTR PTR PTR TER &KER &SEK TER &KER &SEK TER &KER &SEK The length of weld-ing 255m*2 530m*2 115m*2 100m*8 445m*8 90m*8 6880m The weight of filler material 45kg*2 135kg*2 20kg*2 20kg*8 100kg*8 15kg*8 1480kg Quantities of gas bottles 45 bottles*2 157bottles*2 12 bottles*2 22bottles*8 122bottles*8 9 bottles *8 1652bottles 1.2 REFERENCES
[1] BS EN 14015:2004: Specification for the design and manufacture of site built, vertical, cylindrical, flat bottomed, above ground, welded, steel tanks for the storage of liquids at am-bient temperature and above.
[2] BS EN 10204:2004: Metallic products — Types of inspection documents
[3] BS EN ISO 3581:2016: Welding consumables — Covered electrodes for manualmetal arc welding of stainless and heat-resisting steels —Classification
[4] BS EN ISO 14343:2009: Welding consumables— Wire electrodes,strip electrodes,wires and rods for arc welding of stainless and heat resisting steels — Classification
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[5] ISO 14344:2010: Welding consumables — Procurement of filler materials and fluxes [6] BS EN 10088-2:2005: Stainless steels —Part 2: Technical delivery conditions for sheet/plate and strip of corrosion resisting steels for general purposes
[7] HPC-CNENXX-AU-HXA-NOT-200871: UK6322-Book of Special Technical Specification of 9PTR, 9KER, 9TER, 9SEK tanks.
[8] Technical Specification Tanks for nuclear stations.
[9] UK EPR- BTR- Welding of equipment not subject to RCC-M rules.
[10] HPC-EDVAXX-U9-HXA-DRW-001261: Contract UK 6322 Guide Drawings for 09KER, 9SEK, 9TER & 9PTR TANKS WITHIN THE HXA TANK room (9HXA0203ZL).
[11] HPC-ECEIGX-U9-HVD-DRW-000248: Civil Work Guide Drawings of HXA/HVL and HVD Buildings.
The design drawings for tanks.
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1.3 WELDING PROCEDURE
[12] Procedure for qualification of welders and weld operators [13] Purchase technical specification for welding comsumable [14] Purchase technical specification for shielding gas [15] Installation and Assembly instructions [16] Special scheme for tank bottom [17] Special scheme for tank wall [18] Special scheme for tank ceiling [19] Inspection procedures-RT
[20] Inspection procedures-Visual and Penetrant [21] Inspection procedures and instructions [22] Welding procedure qualification record [23] Welding procedure specification [24] Inspection procedures-LT and soap test
2 MATERIALS
2.1 CHEMICAL COMPOSITION OF MATERIALS
The chemical composition of parent metal shall be accordance to the standard Ref [6] and the requirements of technical specifications for storage Tanks see table 3.
Table 3 Chemical Composition
Number 1.4404 ω(C) ≤0.030 ω(Si) ≤1.00 ω(Mn) ≤2.00 ω(P) max ≤0.045 ω(S) ≤0.015 ω(Cr) 16.5～18.5 ω(Ni) ω(Mo) 10.0～13.0 2.00～2.50 ω(N) ≤0.11 UNCONTROLLED WHEN PRINTED Page 4 of 17
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2.2 MECHANICAL TESTS OF MATERIALS
Mechanical tests shall be carried out in accordance with the relevant standards for the type of material. These tests shall be carried out on deposited weld metal, in the as-welded condition, without dilution from the parent material.
Table 4 Mechanical property requirements
Number 1.4404 R m MPa 530～680 R p0.2 MPa 240 Minimum elongation % ≥45 2.3 FILLER MATERIALS
The filler materials used in the storage Tanks are showed in the table 5.
Table 5 Filler materials
Part Specification Disgnation Diameter CoverElectrode BS EN ISO 3581-A E 19 12 3 R 1 2 3.2mm 4.0mm SolidRod BS EN ISO 14343 W 19 12 3 L 1.6mm 2.4mm Solidwireelectrode BS EN ISO 14343 G 19 12 3 L 1.0mm 1.2mm The details of filler material specifications are regulated in the procedure Ref [13]. Before welding production welds, filler materials should have been accepted.
2.4 GAS AND GAS MIXTURES
The gas used in the storage Tanks are showed in the table 5.
Table 5 Gas and gas mixtures for HXA storage Tanks
Part Standard Designation Component Volume Welding processes Purpose Gas EN ISO14175 ISO 14175-I1 Ar (100%) 40L Tungsten arc welding (Process 141) Shielding, backing Gas mixtures EN ISO14175 ISO 14175-M12-ArC-5 5%CO2+Ar (95%) 40L Gas-shielded metal arc weld-ing (Process 13) Shielding The details of consumables specifications are regulated in the procedure Ref [14].
3 WELDING PROCEDUREWELDING PROCEDURE
3.1 WELDING PROCEDURE SPECIFICATION
The list of pWPS is shown in the Appendix A.
Before welding the storage Tanks, the welding process shall be qualified in accordance with the welding process specification. The certificaten shall be subject to third-party verification and approval.
Welding procedure qulification can be carried out in Britain or in China. WPS shall be edited in reference to WPQR. Welding procedure specifications see the procedure Ref [23].
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3.2 WELDING MATHOD
Different parts use different mathods showed in the table 6.
Tabel 6 Welding method
Parts BOTTOM BUTT SHELL BUTT BOTTOM TO SHELL ROOF LAP WELD ROOF TO SHELL OTHERS MAG × × × × Mathod SMAW × × TIG × 3.3 QUALIFICATION OF WELDERS AND WELDING OPERATORS
See the procedure Ref [12].
3.4 STORAGE AND USE OF FILLER MATERIALS
Filler materials shall be stored in an enclosed, dry and, if necessary, heated environment in accordance with the filler manufacturer’s recommendations.
The filler manufacturer shall be responsible for defining the recommended minimum temper-ature and maximum relative humidity required to keep the filler material in good condition. Stock control methods shall ensure full traceability of each product like table 7.
Tabel 7 Stock control method
Designation Dimentions E308L Φ3.2mm Date of entry Date of withdrawal Lot 36588 Quantity 100kg 03/12/2019 03/12/2024 Distribution and recycling methods shall ensure full traceability of each product like table 8.
Tabel 8 Distribution and recyling methods
Designation Dimentions E308L Φ3.2mm Date of distri-bution 03/04/2020 Quantity of distribution 5kg Date of re-cycling 03/04/2020 Quantity of recovery 0kg Lot 36588 Hydrogen controlled electrodes shall be baked / dried and stored in accordance with the filler Manufacturer's recommendations. After baking / drying, they shall bestored in suitably cali-brated heated containers or cabinets until required.
Each welder shall be issued with a heated quiver or sealed container to enable the elec-trodes to remain dry. Hydrogen controlled electrodes have been left at room temperature for more than 4 hours shall re-dried in accordance with the Manufacturer's recommendations. The welding parameters used (current, voltage, welding position etc.) shall be in accordance with the Manufacturer's recommendations.
All welding products shall be clearly identifiable at any stage of their use.
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3.5 PREPARATION OF JOINT FACES
The weld preparation and joint fit-up tolerance are in accordance with the specified WPS or showed in weld drawings.
Tack welding shall be controlled in the same way as all other welding operations. They shall be made by a qualified welder, using a qualified WPS.
Before welding, the joint preparation and any tack welds are free from visible defects and all surfaces to be welded are clean, dry and free from contaminants (i.e. rust, grease, oil, paint etc.) that could adversely affect the quality of the finished weld.
The surface finish of the weld preparation and areas adjacent to the joint to be welded shall be suitable for subsequent non-destructive testing.
3.6 EXECUTION OF PRODUCTION WELDS
When using manual welding processes, the earth return clamp shall be positioned as close as possible to the joint to be welded.
Welding shall not be permitted if the ambient temperature is Iess than - 10°C. The workpiece shall be kept at a temperature no less than + 5°C. AIl welding operations shall be adequately protected against the effects of the weather through isolating the work area by water proof cloth. Details see Special scheme Ref [16], Ref [17] ,Ref [18].
All welding, including repair, tack or attachment welding, shall be carried out in accordance with approved welding procedures, and shall be carried out by approved welders.
Tack welds shall not form part of the joint and shall be removed before or during welding ofthe joint. However on joint configurations where removal of the tack welds is not possible, they shall form part of the weldjng procedure and the corresponding qualification tests. Tack welds that are to be incorporated into the finished weld shall have their ends finished by grinding in order to facihitate subsequent welding operations. The peening of welds is generally not permitted.
The welding of temporary attachments shall be subject to the same qualification rules as those welds for the main equipment/components.
After welding, the surface of the finished weld and adjacent areas shall be suitable for the required non-destructive examination. The weld and adjacent surfaces shall be cleaned to remove allI traces of weld spatter, oxide, scale, grease, etc. likely to hinder the examination process.
Temporary welds used for the positioning of parts during assembly shall be made in full con-formity to an approved welding procedure (see Ref [23])
The welding consumables shall be those specified in the approved welding procedures.
3.7 TOLERRANCES ON ALIGNMENT OF PLATE AND ON SHAPE OF WELDED JOINTS
Vertical joints
Tabel 9 Misalignment at vertical joints
Shell plate thickness(e,mm) e≤8 Misalignment(mm) 18% of e Horizontal joints
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When alignment between the internal surface of the plates is specified on the drawing, the deviation between the surface of plates shall not exceed 20 % of the thickness of the upper plate, with a maximum of 3 mm.
Tabel 10 Tolerances on shape of welded joints
Plate thickness(e,mm) e≤12.5 Tolerance(mm) 10
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3.8 REPAIRS
Welding repairs shall be carried out in accordance with an appropriate WPQR. Only two attempts at weld repair may be carried out at the same location.
Do not attempt further repair until preparing a report analyzing the cause of these successive repairs and submitting it to EDF for approval. The same shall applly to repairs which occur too regularly or to the detection of defects which might invalidate the conditions of applica-tion of the procedure, or the welding procedure qualification itself.
If the repairs made on a weld by an automatic process are likely to exceed one fifth of it-slength over at least one haif of its thickness, the weld shall be completely re-made and then re-examined.
For single sided welds, providing the material is thick enough to allow for a repair to beun-dertaken in accordance with regulation requirements, repairs may be made from oneside so as to maintain an acceptable weld root.
3.9 NON-DESTRUCTIVE TESTING
For full penetration welded joints, radiographic examination shall be made by spot checking. Joints to be examined for each vessel shall be grouped into homogeneous batches (same operating procedure, same thickness, the same welder/operator).
An examination shall be carried out on each batch on at least 10% of the total length of the welded joints, and also an inspection of at least one T-junction out of ten shall be carried out. The joint section inspected at the same time as the T-junction shall not be considered as a common inspection.
A dye penetrant examination by spot checking shall be made for all welded joints. Joints to be examined for each vessel shall be grouped into homogeneous batches (same operating procedure, same thickness, the same welder/operator). An examination shall be carried out on each package on at least 10% of the total length of the welded joints, and an inspection of at least one node out of ten shall be carried out. The joint section inspected at the same time as the T-junction shall not be considered as a common inspection
When an assembly is made from a single-pass lap joint on one side, a vacuum box inspec-tion shall be made over 10% of the total length thus welded. The procedure and acceptance criteria shall be submitted to EDF.
When a defect outside criteria is revealed, the inspections shall be extended as follows:
➢ Automatic or mechanised weld: extension to 100% of the corresponding batch.
➢ Manual welding: extension of the inspections to two welds in the same batch, and if
it is demonstrated that at least one defect in one of the two welds submitted to ex-tended inspection is outside the criterion, a 100% inspection of the batch shall be required.
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The type and extent of examination of welds shall depend on the type of assembly, its loca-tion andthe materials used, and shall be to Appendix B. Imperfection acceptance criteria
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shall be to Appendix C-1 / C-2 / C-3 / C-4. Visual testing should obay with Ref [21].
Liquid penetrant testing should obay with Ref [21]. Vacuum boxtesting should obay with Ref [24]. RadiographyTesting should obay with Ref [19].
4 WELDING SEQUENCEWELDING SEQUENCE
Construction process flow chart
STARTAcceptance Acceptance Temporary support check for Survey on the installation for materialplinthcheck of ground and plinthceilingScaffolding Bottom Supports and installationinstallation NDTlifting equipment Ceiling isnallatonstructure installationThe 5th layer and accessories installation，NDT，Pickling and passivationCeiling and accessories installation，NDT，Lifting the 5th pickling and passivationlayerThe 4th layer and accessories installation，NDT，Pickling and passivationCeiling and platform installation，NDT，Pickling and passivationThe other layers installation Support Welding between shell and Internal removalbottom，NDT，Pickling scaffolding and passivationremovalBottom pipe installation, Lifting DNT, pickling and equipment passivationremovalHydraulic testFINISH UNCONTROLLED WHEN PRINTED
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4.1 WELDING OF BOTTOM
See document Ref [16].
4.2 WELDING OF SHELL
See document Ref [17].
4.3 WELDING OF ROOF
See document Ref [18].
5 WELDING RECORD
Records describe the execution of welding related activities,and could provide traceability of welders or operators to specific welded joints and traceabilitu of filler material. Details see Appendix D.
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Appendix A
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Appendix B
Part of tank Bottom plates Bottom to shell shell Roof to shell Type of assembly Butt weld Fillet weld Fillet weld Butt weld Fillet weld Butt weld Fillet weld Roof Butt weld Nozzle to shell or insert and nozzle with reinforcing Plate Nozzle to shell Nozzle to reinforcing plate Reinforcing plate to shell After remov-al of the brack-et Fillet weld Main butt welds in stiffenting rings Fillet weld 100 100 100 100 Visual examination % 100 100 100 On both sides 100 100 100 100 Dye penetrant test % 100 100 100 100 100 Vacuum box test % 100 100 100 On one side 100 On one side 100 On one side 100 On one side Radiograpgy Soap bubble examination examination% % 100 10% T joint 25% 100 Temporary Permanent bracket and pad plates Stiffening rings 100 100 100 100 100
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Appendix C-1
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Appendix C-2
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Appendix C-3
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Appendix C-4
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Appendix D
Technical welding sheet Name of welders or operators Sheet No. Repair Part Welding No. Length Joint WPS No. Weld data package Remark Filler material brand and Lot No. Automatic welding machine Identification of the equipment RECORD： QC： NNB: UNCONTROLLED WHEN PRINTED Page 17 of 17
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