ORNL-TM-2999.txt

 

OAK RIDGE NATIONAL LABORATORY

 

V operated by
UNION CARBIDE CORPORATION
N NUCLEAR DIVISION
-~ for the

U.S. ATOMIC ENERGY COMMISSION
ORNL- TM- 2999

 

COPY NO. -

DATE - April, 1970

QUALITY-ASSURANCE PRACTICES IN CONSTRUCTION AND MAINTENANCE
OF THE MOLTEN-SALT REACTOR EXFERIMENT

B. H. Webster

Abstract

At

T The MSRE was built at Oak Ridge National ILaboratory to demonstrate

the practicality of the molten-salt reactor concept. Site construction

and installation of auxiliary systems were by outside contractors, while

the primary reactor systems were installed by ORNL forces. Design, pro-

curement, construction, and maintenance followed ASME codes, ORNL

practices, and special procedures developed for the MSRE by the ORNL

Reactor Division group primarily responsible for quality assurance, This

report describes the program, the problems that were encountered, and the

lessons that were learned. Four years of reliable operation of the MSRE -~
proved the success of the quality-assurance program.

Keywords: reactors, fused salts, MSRE, inspection, construction,
maintenance, quality assurance, construction contractors, inspection
procedures, material control, cleanliness control, welder qualifications,
inspection of welds, leak testing.

&\f;

o NOTICE This document contains information of a preliminary nature
and was prepared primarily for internal use ot the Ook Ridge National
Laboratory. It is subject to revision or correction and therefore does
not represent a finel report.

DISTRIBUTION GFLIHIS DOCUMENT IS UNLIMITED

-~

e
- —— LEGAL NOTICE

 

 

 

This report was preparad as an account of Government sponsored work. Nejther the United States,

nor the Commission, nor any person acting on behalf of the Commission:

A. Makes any warranty or representation, expressad or implied, with respect to the accuracy,
completeness, or usefulness of the information contained in this report, or that the use of
any information, apparatus, method, or process disclosed in this report moy not infringe
privately owned rights; or

B. Assumes any licbilities with respect to the use of, or for damages resulting from the use of
any information, apparatus, method, or process disclosed in this report.

As used in the obove, ‘‘person acting on behalf of the Commission®’ includes any employee or

controctor of the Commission, or employee of such contractor, to the extent that such employee

or contractor of the Commission, or employee of such contractor prepares, disseminates, or
provides access to, any information pursuant to his employment or contract with the Commission,

of his employment with such contractor.

 

.
 

iid

CONTENTS
Page
Abstract
INTRODUCTION . . v v v v v v v v e e v e e e e e e e e 1
SITE CONSTRUCTION. ., ., . . v . v v v v v e e e e e . 1
Choosing the Location . . . . . . . . 1
Site Preparation. . . . . . e e . . 2
Major Building Modlflcatlons 2
Outside Modifications , . ., . . . C e e e L
Summary of Site Modification and Constructlon e e e 5
INSTALLATION OF EQUIRMENT AND SYSTEMS. . . . + v o & . . ., 2
Material Control, . . . . . . . v « « . . 5
Welder Qualification . . . . . . . . T
Duties of X-10 Inspection Engineering at the Constructlon
Site Covering Cost-Flus-Fixed-Fee (CFFF) Contract Work . . . T
Reactor Division Quality Control Activities . . T
Summary of Quality Control Procedures Used in Connectlon
With CPFF Work . . . . . . 8
ASSEMBLY AND INSTALLATION OF MSRE FUEL AND COOLANT SYSTEM. . . . . 8
Materials Control . . o v v v v v v o v v 4 4 0 e e e e 9
Welding . . . . . et e e e e e e e e e e e e e 9
Inspection for Cleanllness. e e e e e e e e e e e e e e e e e 10
Leaktesting of Components, Subassemblies, and Systems . . . . . 11

Assembly and Installation of Components and Piping. . . . . . . 12
Installation and Checkout of Electrical Wiring, Heaters,

and Bquipment. « ¢ « ¢ o v o v 0 0 e v 6 v e e 0w e e e e 13
Remote Maintenance Practice During the Construction Period. « . 14
Preoperational Testing of Auxiliary Equipment and Systems.. . . 1k

MATINTENANCE. + « v v o v v v v v v v v e s e v e e e e e v e e e s 15
Routine and Programmed (Preventive) Maintenance . . . . . . . . 15
Shutdown Maintenance. + + « v o « « « « « v o v s s e v v . .. 16

SU.WARY OF QUALITY COMOL BACTICES . . . . . . . . - . . - . s % 18

OVERALL CONCLUSIONS AND RECOMMENDATIONS. . « « v v v & « v o« « o+ & 18

APEENDICES

Appendix A -- Weld Inspection Report. . . . ¢« « « o o o o + & 21
Appendix B -- Welding Procedure Specification . . . .« . + . . . 25
Appendix C -- Non-Ferrous Materal Specifications. . . . . . . . 37
Appendix D -- Cleaning and Storing of Pipe and Fittings

to be Used in MSRE Constructicon. . « + « « + « . L1

 

LEGAL NOTICE
This report was prepared as an account of work
sponsored by the United States Government. Neither
the United States nor the United States Atomic Energy
Commission, nor any of their employees, nor any of
their contractors, subcontractors, or their employees, _
makes any warranty, express or implied, or assumes any e ‘fl,”’},?'R'ED
legal liability or responsibility for the accuracy, com- ey e TR TG :
pleteness or usefulness of any information, apparatus, ke : O LI;
product or process disclosed, or represents that its use
would not infringe privately owned rights,

 

 
iv

CONTENTS

(continued)

APIENDICES (continued)

Appendix E -- Control of Material After Delivery to

Building 7503 . . . .

Appendix F -- ORNL Operator’'s Quallflcatlon Test

Specification QTS-33 for Inert-Gas-Shielded

Tungsten-Arc Welding of INOR-8 Alloy Fipe,

Flate and Fittings to Inconel Material, , . . .
Appendix G -- Welding, Brazing, and Weld Inspection of

INOR-8 Components ., ., . . .
Appendix H -- Materials Which Have Been Analyzed for Use on

INOR-8 and Stainless Steel for the Molten-Salt

Reactor Experiment, . . . . . . . .

-

*

Appendix I -- Helium ILeak Test Procedure, . . . . +v v o o o o .
Appendix J -- Fixtures and Components During Assembly , . e .
Appendix K -- Check List — Reactor Cell Salt System |, . . .
Appendix L -- Fuel Drain Tank No., 2 in Jig , . .

Appendix

Check Off List for Main Blower Startup
QUALITY-ASSURANCE PRACTICES IN CONSTRUCTION AND MAINTENANCE
OF THE MOLTEN-SALT REACTOR EXTERIMENT

B. H. Webster
INTRODUCTION

The Molten=-Salt Reactor Experiment has been proved by four years of
operation to be a well-built, reliable reactor. This report describes the
quality-assurance program followed in the construction and maintenance of
the system. The intent is to describe the details involved in putting
together a sound, workable, relatively trouble-free system.

The report is divided into sections covering site preparation, in-
stallation of auxiliary systems and equipment, construction of the salt

systems, and maintenance along with conclusions and recommendations.
STTE CONSTRUCTION

Choosing the Location

The site chosen for the MSKE was an existing facility in which one
reactor had operated and in which preparations had been made for instal-
lation of another reactor. The facility was built for the Aircraft Reac-
tor Experiment (ARE), which was operated in 195Lk. It was later modified
for the Aircraft Reactor Test (ART), and at the time the Aircraft Nuclear
Propulsion Program was terminated, a considerable amount of electrical
equipment had been installed, the reactor cell had been built, and most of
the auxiliary equipment had been purchased.

The basis for the decision to use this facility for the MSRE was
economic, Unfortunately several years had passed since the ARE and ART
programs had been terminated, and conseguently the records, drawings,
specifications, inspection reports, etc., on the building, equipment, and
services were scattered and some were lost. In order to make use of these
facilities for the MSRE, it was necessary for the project designers and

draftsmen to determine the condition of the equipment and the services, as
well as the various cells and buildings, in order to either design the
new system to fit in with the old or modify the o0ld in order to make it
fit in with the new system.

Needless to say, the assurance of guality in the adaptation of old
facilities to new systems is often a difficult task. Such was the case

for the MSRE.
Site Preparation

In May 1961, a small (~ $20,000) site preparation contract was awarded
to the H. K. Ferguson Company, who was at that time ORNL's prime CPFF con-
tractor. This contract included excavation for the fuel drain tank cell,
modification of the structure around the radiator cell, installation of a
new entrance into the east side of the reactor building, and removal of
unneeded piping conduit and equipment. The drawings and specifications
for this job were prepared by the ORNL Plant and Equipment Division (BE)
design group and approved by ORNL Reactor Division management. The P&E
Division supplied a construction inspector to ascertain that all specifi-
cations were met., The inspector kept a daily log, which is on record in
ORNL Laboratory Records Department. Since no high-quality welding,
pressure-vessel inspection, or other code work was involved, no other

records were keprt on this phase of construction.
Major Building Modifications

The prime contract for the major building modifications was awarded
to Kaminer Construction Company of Chamblee, Georgia. This phase of the
modification was started in September 1961. The design and specifications
were Pprepared by the P&E design group in cooperation with the Reactor Di-
vision (RD) design section and with special assistance on welding specifi-

cation and procedures from Metals and Ceramics Division (M&C) personnel.
Interpretation of Specifications

A short time after work had begun on the major building modifications,
a question arose concerning the intent of the specifications covering the

structural integrity of the reactor and fuel drain tank cells (classified
as secondary containment). The specifications had been written to cover
cases under the ASME Unfired Pressure Vessel Code, Section 8. At this
time certain changes were being made in this section to cover Nuclear
Vessel Code cases. After considerable discussion and negotiation between
representatives from RD, M&C, and Kaminer Construction Company, the fol-
lowing amendments were made in the specifications: Interpretation of ASME
Boiler and Pressure Vessel Code, Section 8, Special Cases 1177, 1270N,
1272N, and 12TLN.

Assuring the Use of Specified Materials

Stating the type materisl to be used in any given situation is ob-
viously only a beginning. In order to assure that materials meet the
specifications, testing and inspection must begin at the vendor's or in
some cases at the steel mills and fabrication plants. Once an acceptable
melt was established, heat numbers were assigned to all materials made
from this particular melt. This identification, showing the heat number
and inspection request number, was stamped on the material so that it was
identifiable even after installation. Records were kept on all materials
to cover identification, location in system, cleanliness, and weld-
inspection report that included welder's name, filler metal used, etc. (see
UCN Form 1149 in App. A). All records on materials, etc., noted above are
stored in the ORNL Laboratory Records Department.

Establishing Welding Procedures and Training and Qualification of Welders

Having established the procedure by which welding should be done, the
next task was toc "qualify" the procedure. This was done by the FE and
M&C weld-qualification groups (if a procedure to cover the specification
was not available). Welders were then trained and qualified to use the
procedure (see WPS-1402 and UCN-3312 for typical Weld Qualification Pro-
cedure, App. B)

Inspection of Welds, Material, and Equipment

Qualifying Inspectors. All inspection required to cover the work
performed by outside contractors (Kaminer Construction Company, Chicago

Bridge and Iron, etc.), as well as by manufacturers and vendors, was
performed by personnel from the ORNL Inspection Engineering (IE) group.
These people were usually chosen for a particular phase of work because
of their background in that field. 11 inspectors were required to go
through a training period in order to qualify for the tasks they were to
pverform. In general the curriculum for this training was taken fiom the
SNT (Society for Non-Destructive Testing) manual and was designed to cover
Section 8 of the ASME Code and the special cases noted previously. This
has since been revised to cover Section 3, Nuclear Vessel Code., With in-
creasing emphasis being placed on quality control, it is suggested that
CRNL should study the methods used for training inspectors, who should
be gualified and certified.

Inspection and Records of Work Performed by Kaminer Construction and
Subcontractors. Drawings and specifications were issued to the IE in-
spectors. FEach inspector worked closely with the FE construetion in-
spector and with supervisors and craftsmen of the contractor so that he
was constantly aware of all work planned or in progress on which his ser-
vices were required. The inspector had the responsibility to see that all
work within his jurisdiction was performed according to the specifications,
and he had authority through the constructicn inspector to reject any work
that did not meet these specifications. He also was responsible for main-
taining records on welds, stress relieving, heat treatment, leak-testing,

etc A1l such records are now in ORNL Laboratory Records Department,
Cutside Modificaticns

The contract for outside modifications and construction was awarded
to Hixon Construction Company of Knoxville, Tennessee. The outside work
consisted of construction of an offgas filter house and offgas stack,
installation of stack fans, and installation of the cooling tower, pumps,
and piping. The criteria for this phase of construction were established
by design groups from the Reactor and General Engineering Divisions. The
design was done by P&E. Inspection was performed by the GE construction
inspector, by representatives from Inspection Engineering, and by Reactor

Division ccordinators. A daily progress report and a log were kept by the

construction inspector, All records are now in the ORNL Laboratory Records

Department,

&
summary of Site Modification and Construction

In general the site preparation work went smoothly  One major problem
was a misinterpretation of the specifications. It appears that in the
future more thought should be given to specification writing, and a meeting
of the minds as to the interpretations of the specifications should be
reached insofar as possible before the work is started. In particular, the
inspection procedures for components purchased from outside vendors should
be clarified; since many of these components are only spot-checked, the
risk of inferior materials and workmanship is much greater. Also the over-
all quality control standards should be more detailed and -should be under-
stood and accepted by all groups involved.

As stated in the preceding descriptions, all inspection and quality
control work was done in accordance with the specifications and procedures
prepared by Reactor Division and P&E Division design groups. These draw-
ings, specifications, procedures, and records are located in the ORNL

Laboratory Records Department.

INSTALLATION OF EQUIEMENT AND SYSTEMS

The H. K. Ferguson Company was awarded a CPFF contract to install the
service and auxiliary systems and equipment., These included instrument
air compressors and piping; control room piping and equipment; leak de-
tectors; water, steam, and offgas piping and equipment; and all electrical
systems and equipment, including heater wiring up to the junction boxes
at the cell walls. The above work was started shortly after building

modifications were completed.
Material Control

A1l materials and equipment for the CPFF contract work were procured
by ORNL purchasing departments. All materials and equipment were more or
less standard items and were relatively easy to obtain, except for the

high-quality stainless steel piping used in some of the systems.
Procurement, Inspection, and ITdentification of Critical Materials

The critical material, whether fabricated into tanks, heat exchangers,
etc., by outside vendors or delivered to the laboratory as raw material,
was required to meet Metals and Ceramics Division Specifications (index
in App. C). The specifications were written through a joint effort of the
General Engineering, Metals and Ceramics, and Reactor Divisions. Inspec-
tion procedures were established by M&C, Reactor, and IE personnel, All
critical materials (Met Spec Material) were spot-checked at the vendor's
plant., Heat numbers of materials were etched or stamped at 12-in., inter-
vals on all materials, along with the inspection request number (IR No.).
The identification was maintained up to and through the installation period
and was noted on all weld inspecticn reports. Inspection, certifications,
and identification of all critical weld rod were accomplished by the same

procedure as that noted for pipe, fittings, etc.
Inspection of Critical Materials After Delivery to ORNL

Critical materials were delivered 1in care of the Inspection Engineering
Department. Upon receipt of this material, each item was inspected by one
or more of the following methods: dye-penetrant testing, ultrasonic exami-

nation, and radioagraph examination.
Material Cleaning Procedures

After certificaticn, all pipe, tubing, and fittings were delivered to
the 7000-area cleaning station, and cleaning was accomplished by the pro-
cedure of Appvendix D (Cleaning and Storing of Pipe and Fittings to be Used
in MSRE Construction). Records of cleaning results were maintained on
the form included in this appendix, The records are now on file in the

MSEE Maintenance Engineer's office.
Control of Material at 7503 Stores

With all the inspection, certification, and identifying of materials
that had gone before, there remained one very critical control point: how
to handle the receiving and issuing records at the construction site stores.
These problems were handled by the procedure in Appendix E (Control of Ma-
terials After Delivery to Building 7503).
Welder Qualification

All weld procedures to be used by H. K. Ferguson were already quali-
fied and are a matter of record. It remained only to qualify the welders
for the several procedures. This qualification was performed at the Y-12
test shop under the surveillance and instruction cof Y-12 Inspection Engi-

neering personnel.

Duties of X~10 Inspection Engineering at the Construction Site
Covering Cost-Plus-Fixed-Fee (CPFF) Contract Work

One or more inspectors from Inspection Engineering was assigned to
the construction site to handle inspection that came under their Jjuris-
diction. These duties included;:
1, inspection of all code welding (dye-penetrant, radio-graph, ete.),
2 witnessing all pressure and leak-testing of all code pipe and vessels,,
3. inspection of all materials before and during installation, and
L

record keeping on all the above activities.
Reactor Division Quality Control Activities

In addition to coordinating the efforts of the CPFF contractor with
design, Pprocurement, inspection, etc., the Reactor Division quality con-
trol group assumed the responsibility for and carried out the following:

1. Wrote cleaning and test procedures for systems not covered by
the Code, such as compressed air systems, water systems, etc. Formulated
check-off lists for equipment and systems to cover preoperational testing.

2. Worked with CPFF crafts and supervisors in carrying out the
cleaning, testing, and checkout of piping, wiring, and equipment.

3. Formulated, with help of P&E engineers, leak-test procedures
for testing vapor-suppression system. Worked with CPFF contractor per-
forming and documenting test.

L, Routinely checked piping and components during and after instal-
lation for cleanliness; notified craft supervision when additional cleaning
was required. Made daily checks on installed piping to assure ends were

closed; notified supervision of violations.
The problem of keeping the installed piping and components clean
and preventing foreign material getting into open-end piping and equipment
proved to be a major one. This area of quality control should be stressed

in future (and present) quality control procedures:!

Summary of Quality Control Procedures Used in
Connection with CPEFF Work

All critical piping, heat exchangers, tanks, etc., were fabricated
from materials certified to meet ASME codes and specifications formulated
from these codes. Critical piping and components were inspected and
tested according to ASME Codes provisions or approved procedures derived
from them. All work (critical and other) was inspected by Inspection
Engineering personnel and Reactor Division quality control personnel.
Check=-off lists were used to assure that wiring, piping, and equipment
were installed in accordance with drawings and procedures. All systems
were tested by acceptable procedures, and the test results were documented.
Records of weld inspection, material certification, leak and pressure tests,
preoperational tests, cleanliness, etc., are on file either in the ORNL

Laboratory Records Department or in the MSRE Maintenance Engineer's office.
ASSEMBLY AND INSTALLATION OF MSRE FUEL AND COOLANT SYSTEMS

All designs and specifications for the primary systems were either
formulated by the Reactor Division design group or were prepared under
their direct surveillance, Many of the designs, specifications, and pro-
cedures were derived from information furnished by the Reactor Division
development group.

Most of the major components were fabricated and tested in Y-12 shoPs.
All work on the primary and auxiliary systems inside the reactor cell,
coolant cell, and fuel drain cells was performed by ORNL craftsmen from

the P&E and I&C Divisions.
Materials Control

Procedures the same as those described in the foregoing section were
used to control the receipt, identification, storage, and issue of materials
used in the primary and auxiliary systems inside the coolant, reactor, and
fuel drain cells, This system apparently worked well, since there was no
known instance in which the wrong material was used in either the primary

or auxiliary systems.

Welding

The material used in the primary systems was INOR-8 (now known as
Hastelloy-N or Incoloy 806). Because there had not been much experience
with this material, it was necessary that welding procedures be specified
and tested. Welding Procedure Specification WES-1402 (App. B) was tested
and approved for welding INOR-8 materials. (See also form UCN-3312 in
App. B, which was used for recording the development information.) In
addition, several other '"mew'" procedures were necessary, such as those for
welding INOR-8 to Inconel, INOR-8 to stainless steel, etc. These pro-
cedures were developed by the EE weld inspection group and by M&C person-

nel and were carried out under their striect surveillance.
Welder Qualification

Welders were qualified to meet the above specifications per ORNL
Operators Qualification Test Specification QTS-33 for inert-gas-shielded
tungsten-arc welding of INOR-8 alloy pipe, plate, and fittings to Inconel
material. (See QIS-33, App. F, which is typical of all procedures.)

Weld Inspection

P&E inspectors were used exclusively on welding performed by ORNL
craftsmen. All inspectors were required to be qualified; that is, they
were required to actually perform the type of welding they were to in-
spect. This had distinct advantages, because when an inspector who is not
a qualified welder looks at a completed weld, he can usually only say
"The weld is good" or "The weld is bad," Rarely will he be qualified to

instruet the welder in what he should do to make corrections if the weld
10

does not meet the specifications. On the other hand, an inspector who is

a qualified welder can usually spot the improper technique while the welding
is in progress. Corrections can then be made with a minimum of delay. It
seems clear that much time and effort could be (and was) saved by these
highly competent inspectors.

Inspection techniques were formulated with the several ASME and ASTM
codes as guide lines. ORNL Inspection Emgineerihg and Metals and Ceramics
personnel then categorized these several procedures into six classes (A
through F) with respect to the quality requirements of the welds. For
example, Schedule B inspections required inspection of fit-up, inspection
of the root pass before final closure, dye-pPenetrant inspection on each
pass, and a radiograph of the completed weld; whereas Schedule F required
only visual inspection. The designer specified on each drawing the in-
spection schedule, and a copy of each drawing was issued to the welding

inspectors (see table of inspection schedules in App. G).
Stress Relijeving of Welds

All TNOR-8 welds and adjacent piping were stress relieved by a pro-
cedure based on ASME Boiler and Pressure Vessel Code, Section III N-532.
The welding inspector was responsible for inspecting the preparation for
the stress-relieving operation and recording the information. The records
of all stress-relieving cperations are on file in the MSRE Maintenance

Engineer's office.
Inspection for Cleanliness

In addition to the cleanliness control described in Appendix D,
INOR-8 required cther more stringent controls. INOR-8 (Hastelloy-N)
is a high-nickel alloy which will alloy at the MSRE operating temperature
of approximately 1200°F with any metal or alloy having a low melting point;
fcr example, sluminum, zine, lead, etc, In addition, sulphur-bearing
compounds are incompatible with INCR-8 at elevated temperatures., Many of
the lubricants normally used in machining metals were known to have high
sulphur content. Therefore because of the contamination potential associ-

ated with machining, fabricating, and assembling the piping and components,
11

rigid safegfiards were established, Several different types and brands of
lubricants, marking materials, permanent and temporary insulation, etc.,
were analyzed for the metals and compounds listed above. (See App. H for
results of these analyses.) The reactor site storekeeper was instructed
to refrain from storing materials that were noct compatible with INOR-8 or
stainless steel. Lists of materials compatible with INOR-8 and with stain-
less steel were prepared from the analyses and issued to the craft super-
visors. A constant vigil was maintained by the weld inspectors and by
Reactor Division quality control personnel. All INOR-8 vessels and piping
were carefully surveyed for evidence of contamination. All surfaces were
carefully cleaned immediately prior to installation of heaters and insu-
lation, regardless of lack of evidence of contamination, This strict and
seemingly expensive operation apparently was worthwhile, since there is

no evidence of damage to the materials in the system after years at ele-

vated temperatures.
Leaktesting of Components, Subassemblies, and Svstems

Components such as the reactor vessel, heat exchangers, pumps, and
fuel drain tanks were leaktested at the Y-12 fabrication site. Much of
the piping for the primary and auxiliary systems was prefabricated and in
many cases leaktested before installation. Leaktest specifications (i.e.,
type of test to be performed) were noted on the drawings. Detailed pro-
cedures and record forms were written by the Reactor Division quality con-
traol group located at the MSRE construction site. Flow diagrams were
"color-coded" to indicate the leaktest status and type of test performed.
These flowsheets are a part of the permanent record, along with the test
results noted on the leaktest forms. All leaktests were witnessed by
Reactor Division quality control personnel.

All primary-system piping was leaktested by using the mass-spectrometer
method (helium leaktest). Wherever possible the piping was evacuated, en-
cased in plastic, and flooded with helium. The leaktest was then performed
and recorded per procedure MSRE-SK-216 and form UCN-5113 (see App. I) with
a consolidated leak-detector machine. In some cases it was necessary to

pressurize the piping and move the leak-detector probe over the welds and
12

surface of the pipe, after which the assembly was enclosed in plastic and
the probe inserted into the bag at the highest point. If no leak was
indicated, after walting for some predetermined length of time, an amount
of helium equal to the allowable leak was injected into the bag at the
lowest point to check the sensitivity of the leak-detector machine., The
results of these tests are recorded and are a part of the permanent record.

Hydrostatic and other pressure and leak tests were performed as in-
dicated on the design drawings. The form (App. I) was used to record the
results of all such tests.

Valid leak tests were performed on all piping systems. Leak testing
was performed by craftsmen and witnessed by Reactor Division quality con-
trol personnel. Helium leaktesting was guite time-consuming because of
the shortage of trained craftsmen. It would appear to be desirable to

consider instituting a training program in this field as soon as practical.
Agsembly and Installation of Components and Piping

One of the major objectives of the MSRE was to prove that it could
be maintained. To make this possible it was necessary to assemble the

equipment so that exact duplicates could be fabricated if the need arose,
Reactor Cell Component Assembly

A fixture was designed to support the components in the same position
relative to each other as they would be after they were installed in the
reactor cell., The elevations and center lines of the components and the
slopes and angles of the piping and flanges were established by a group
of civil engineers with precision optical tooling. Some of the people
involved in formulating the assembly procedures attended a school con-
ducted by the Brunson Cptical Instrument Co. for training in the use of
Precision optical instruments.

When installed in the cell, the components fitted together with re-
markable accuracy. A photograph of ccmponents while on the fixture and
after installation in the cell is shown in Appendix J.

All dimensions were recorded on as-built drawings and are on file in
the MSRE Maintenance Engineer's office. One major side benefit from this

method of assembly was the easy access for welding and other associated work.
13

In addition, with the major components being assembled outside the
cell, the in-cell installation of auxiliary piping, electrical, and thermo-
couple leads, etec., was simplified. A check list indicating the care that
was taken to assure that all was in order before the assembly was installed
ig reproduced in Appendix K., This type of final check is an important

part of any quality-assurance progranm,
Fuel Drain Cell Components Assembly and Installation

The general procedures noted above were also used to assemble the
two fuel drain tanks, steam domes, and the fuel flush tank. The center
lines, elevations, etc., were established on the tanks, steam domes, etc.,
and the fixture was then made to fit the critical points noted on the in-
stallation drawings. The photograph in Appendix L shows the drain tank
assembly located on the fixture.

All dimensions were recorded on as-built drawings. The assembly was
lowered into the cell and a cutting platform was fitted to the salt inlet
and outlet lines (no flanges in these lines). The location of the cutting
platform relative to the tank was noted on the as-built drawings. In case
it should become necessary, the steam dome or the drain tank, or the two
items together, may be removed and an exact duplicate fabricated and in-

stalled by remote and semiremote methods.

Installation and Checkout of Flectrical Wiring,
Heaters, and Equipment

As in the case of the auxiliary piping, the installation of the elec-
trical systems was a Jjoint effort between the CPFF contractor and the IE
crafts. Installation of motors, switchgear, wiring, and thermocouple leads
outside the fuel cells and up to the final junction at the cell walls was
performed by the contractor. The heaters, electrical leads, and thermo-
couple leads inside the cells were installed by P&E craftsmen. The equip-
ment outside the cell was checked out, and the motors were '"bumped™ for
proper rotation by the contractor. Heater leads and thermocouple leads
were "run out," tested for grounding, and identified at the cell walls by

the contractor. The heaters, heater leads, and thermocouple leads inside
14

the cells were installed and checked out by P&E craftsmen, after which
tie-ins were made at the cell walls and the total system was checked out
from the control panels.

Records were kept on the above tests and are now located in the equip-
ment files in the MSRE Maintenance Engineer's office., This part of the
work was well coordinated and very little trouble or confusion was en-

countered.
Remote Maintenance Practice During the Construction Period

The remote maintenance development group was in constant communication
with the system design and construction groups. During the design and con-
struction period, procedures were written, and tools and equipment were
designed, fabricated, and tested. In order to check out some of the tools
and procedures, maintenance equipment was set up, and several pieces of
equipment were removed and reinstalled. These practice runs were helpful
in establishing the procedures and technigues to be used later in per-
forming the remote maintenance. The fuel pump rotary element and motor,
the primary heat exchanger, one of the cell space coolers, and several

heater assemblies were removed and replaced remotely.

Preoperational Testing of Auxiliary
Egquipment and Systems

Cleaning and test procedures were written for each system or sub-
system before and during the construction period by the Reactor Division

quality control group.

Water System

As sections of the cooling-water systems were completed, the piping,
valves, pumps, flowmeters, etc., were flushed out, leaktested, and given
a preliminary check for pump ocutput, etc. by CPFF craftsmen and witnessed
by Reactor Division quality control personnel. When the entire water sys-
tem was completed, the total system was given a preliminary checkout.
After preliminary testing, the system was turned over to the MSRE opera-

tions group.
15

Instrument Air System

After completion of the instrument system, each line was taken loose
from the instrument and the entire piping system was blown down. The
filters were changed and the piping was reconnected. A leak test was then
performed on the total system. Flowmeters, pressure switches, etc., were
tested for performance and accuracy. The preoperational testing was per-
formed by CIPFF craftsmen and witnessed by the Reactor Division quality
control people who wrote the test procedures. Test results were docu-
mented and records are on file in the MSRE Maintenance Engineert's office.

Preoperational testing of other auxiliary systems was performed in

essentially the same manner,

MATNTENANCE

Maintenance 1is a vital part of any facility and was especially so in
the Molten-5alt Reactor Experiment. As mentioned earlier in this report,
one of the major objectives of the MSRE was to demonstrate its maintain-
ability so that reactor downtime could be kept to g minimum. Because of
this, planning, scheduling, procurement, and necessary design changes

Played a vital role in the overall operation.
Routine and Programmed (Preventive) Maintenance

Just prior to the completion of the MSRE, ORNL had set up a mainte-
nance system called "Programmed Maintenance.' This required that mainte-
nance to be performed on a piece of equipment be specified and fed into
the K-25 TEM computer. At a predetermined frequency, IBM cards were de-
livered to the foreman who was to perform the work. After considering the
alternate maintenance programs, it seemed advisable to make use of this
program.

Accordingly a master list of all equipment in the MSRE system was
compiled, and in cooperation with the operations group, an estimate was
made on the percentage of time the equipment would be in use. Then, with

the manufacturer's maintenance manual as a guide, a maintenance program
16

for each piece of equipment was listed and fed into the IEM computer.
This listing included a description of the eqguipment, frequency of service,
maintenance to be performed, type of lubricant, etec.

The maintenance cards were delivered (approximately one week in ad-
vance of the scheduled maintenance date) to the MSRE Maintenance Engineer,
who initiated a work request. The work request, with the TEM card at-
tached, was directed to the E&E Craft Supervisor. A copy of the work re-
quest and the maintenance card were issued to the operations Shift Super-
visor. The Shift Supervisor shut down and tagged out the equipment at
the request of the FE supervisor. The maintenance was performed by the
craftsmen, and in most cases, depending on the nature of the job, was
witnessed by a representative of the Reactor Division quality control
group or by the craft foreman. (Examples of this were the witnessing of
the preventive maintenance performed on the component cooling blowers;
the lubrication and tensioning of the drive belt; and the leaktesting of
the dome flange. All this work was performed according to predetermined
procedures.) Adjustments were made from time to time of frequency, type
of lubricant, etc.

According to the feedback received from those who used the mainte-
nance cards, the program appears to be relatively economical. Many pro-
blems were noted in time to prevent major breakdown and repairs; however,
it appears more refinement of the program is needed, especially with re-

spect to freguency.
Shutdown Maintenance

For the most part, MSRE shutdowns were preplanned and scheduled. The
following describes the planning and scheduling methods used. 1In general,

the same methods were followed for nonscheduled shutdowns.

Planning

Trmediately after a reactor startup, planning was started for the
next shutdown. In most cases, a target date was set for completion of a
run based on the need for inspection of the core specimens. As operating
experience dictated, proposed changes and modifications were added to the

list. Equipment repairs were added as the occasion warranted.
L7

Procurement and design were started as soon as practical after the
need arose. Procedures or Jjob descriptions were written well in advance
of the shutdown to allow time for everyone involved to become familiar
with the tasks to be performed.

Information and planning mettings were held with the craftsmen and
supervisors., For some remote maintenance tasks, mockups were built, and
training and practice sessions were held with craftsmen, supervisors, and

Reactor Division quality control representatives.

Scheduling

The list of work to be performed was detailed and firmed up as far
in advance of the shutdown as possible. The critical path method was used
for showing the sequence and estimated duration of each task, such as
design, procurement, writing of procedures, practice sessions, installa-
tion, and testing., The sequences of work were established as a joint
effort of the operations and maintenance group. Estimates of job duration
were made by the EFE supervisors.

As work progressed, more tasks were usually added to the list, and
because of this the schedule was updated periodically. This method of
scheduling proved to be very satisfactory, and the estimates became more
accurate as time progressed. On the last few shutdowns, estimates were

correct to within approximately 5%.
Witnessing the Critical Shutdown Work

Critical tasks, such as remote maintenance, repairs or modifications
to component cooling pumps, main blowers, radiator door lifting mechanism,
etc., were observed and coordinated by Reactor Division guality control
personnel, Procedures and job descriptions were modified as required so
that they reflected the actual work performed and therefore were more
nearly accurate for similar future tasks. A checkoff list was used to
assure that all was in order before equipment or systems were reacti-

vated after each maintenance period (see example in App. M).
18
SUMMARY OF QUALITY CONTROL PRACTICES

Quality control procedures were formulated for all critical work not
covered by existing codes and procedures, and record forms were designed,
if they did not exist, for documenting critical inspection and testing.
Inspectors were traired (to some degree) for following and documenting
the work. Coordination of quality control and craft effort was difficult

in the early stages but improved as the job progressed.
(VERALL CONCLUSIONS AND RECOMMENDATIONS

Basic quality control procedures should be standardized for the whole
laboratory as soon as practical, Specific procedures for a project should
be formulated and agreed upon as soon as possible after criteria and speci-
fications are written. The project quality control director should be
intimately involved in formulating specific procedures not covered by the
various codes. Assembly of the quality control procedures incorporating
existing codes and specific detailed procedures should be accomplished
through the joint efforts of the several quality control groups and the
designer and specification writers, All quality control procedures and
specifications should be ircorporated into one manual. Adequate forms
for documenting quality contrel should be designed prior to the beginning
of work.

The quality control rersonnel (inspectors) should be responsible to
the project gquality control director, and they should have authority to
direct craft superviscrs to stop work not being performed according to
the specifications. If the standards specified in quality control pro-
cedures are to be met, those who perform the work and those who witness
that performance must be adequately trained. To accomplish this, quality
control inspectors should be formally trained, tested, and certified, and
craftsmen and craft superviscrs should receive basic training in quality
control procedures and practices.

If this phase of the effort is viewed with the respect it is due,
there is every reason tc believe that the construction and tesfing of a
reactor system can be performed smoothly and efficiently and that the

startup of the reactor should be relatively trouble-free,
#\

19

APEENDICES
st

21

Appendix A

Weld Inspection Report
WELD

DISTRIBUTION:

INSPECTION REPORT

23

Report No.
DRAWING NUMBER
WORK ORDER NUMBER

DATE

 

COMPONENT TITLE

WELD NUMBER

 

WELDING SPECIFICATION

"WELDING PROCESS

 

TYPE JOINT

 

INSPECTION SPECIFICATION

 

INSPECTION SCHEDULE

 

BASE

MATERIALS

FILLER METAL

 

TYPE

|

 

IR

 

HEAT

 

 

MFG,
LOT NQ.

FORM

ITEM

 

PIECE

 

SIZE

 

 

 

 

 

 

 

 

 

 

 

 

 

WELDER'S NAME

 

FITTER'S NAME

 

i
I

INSPECTION

I'coverGas ~

BACK-UP GAS

A

A He

 

DISPOSITION

APPROVED

 

'CLEANLINESS
FIT-UP

RCOT PASS

 

 

PENETRANT: DEFECTS

 

 

INTERMEDIATE PASSES

PENETRANT: DEFECTS

 

FINAL PASSES

 

 

PENETRANT: DEFECTS

 

RADIOGRAPHY

 

UL TRASONIC

 

WELDING VARIABLES

VAOLTS

 

AMPS

 

INTER PASS TEMP.

 

REMARKS:

 

INSPECTOR'S SIGNATURE

DATE

FINAL ACCEPTANCE

 

DATE

 

 

 

UCN-1149A
(238  9-84)
Appendix B

Welding Procedure Specification
N

OAK RIDGE NATIONAL LABORATORY
OPERATED BY
UNION CARBIDE CORPORATION
NUCLEAR DIVISION

UNION
(2 1z401)3

POST OFFICE BOX X
OAK RIDGE, TENNESSEE 37830

WELDING PROCEDURE SPECIFICATION WPS-1402

GAS TUNGSTEN-ARC WELDING OF NICKEL-MOLYBDENUM-CHROMIUM-IRON
(HASTELLOY-N OR INOR-8)

SCOPE

This Procedure Specification covers welding of Nickel-Molybdenum-
Chromium-Iron within limits summarized below.

Base Metal: WNi-Mo-Cr-Fe (Hastelloy-N, INOR-8), 0.020- to 1l.0-in.
thick, in any form.

Filler Metal: Ni-Mo-Cr-Fe bare welding rod.
Welding Process: Gas tungsten-arc, Ar shielded.
Equipment and Control: Manual.

Positions: All.

PROCEDURE QUALIFICATION

 

This Procedure Specification was qualified by Fabrication Department,
P&E Division, in accordance with ASME Code Section IX, Welding
Qualifications. This Procedure Specification supplements, but does
not repeat, the Code rules that apply to fabrication by welding.

PERFORMANCE QUALIFICATION

Determine that the welder is currently qualified in accordance with
ORNL Performance Qualification Specification PQS-1402. Refer to the
latest Welder Qualification Status Report issued by Fabrication
Department.

Revision 0

Date
Page

8-13-638

1 of 8
28

BASE METAL

Ni-Mo-Cr-Fe (Ni-16.5Mo-7Cr-5Fe) that conforms to Code Cases 1315 and
1345, or to applicable ORNL Specifications.

Trade Name: Hastelloy-N. ORNL Designation: INOR-8.

Base Metal may be in any form and should be solution heat treated and
descaled.

FILLER METAL

Bare welding rod that conforms to Code Case 1345, Code Specification
SB~304, and applicable ORNL Specifications.

Trade Name: Hastelloy-N. Approved equal may be used,.
Use only welding rods from original unit container that has complete
original identification marks. Keep container sealed when welding

rods are not being used.

Discard rods that do not have a bright smooth surface, free of pits,
grooves, oxide and foreign material. '

SHIELDING GAS

Ar 99.995% (min) pure for arc shielding and for backing gas on root
side of joint.

BACKING STRIP

Do not use backing strip or ring.

WPS-1402
Revision 0

Date
Page

8-13-68

2
29

PRECAUTIONS

For preparing and cleaning base metal and weld beads, use cutting
tools, hand tools, grinding wheels, and stainless steel wire brushes
that are free of foreign material and that have not been used on
low-melting metals (Zn, Sn, Pb, etc.), and alloys (brass, brazing
alloys, solder, etc.) that contain these metals.

Use suitable clean solvents that conform to job specifications. Do
not use marking paint or crayon, temperature-indicating crayon, and
cutting fluid containing sulfur.

PREPARATION OF BASE METAL

Produce the weld joint geometry shown in the applicable detail on
Joint Welding Schedule and drawing.

Before preparing a weld joint surface on arc-cut or oxygen-cut base
metal, machine or grind to remove irregularities and 0.100 in. add-
itional metal from the cut face.

Remove burrs, laps, gouges, and other defects from shearing, sawing,
etc. to produce smooth weld joint surfaces.

Remove scale and oxide within 1 in. of each edge of the weld joint.
Remove o0il, moisture, chips, and other foreign material from weld
joint and from base metal within 10 in. of each side of the joint.

Heat treat to stress relieve severely cold worked base metal. Contact
engineer if heat treatment procedure is not covered in job specifi-
cation.

Immediately before welding, inspect joint for foreign material by
wiping with clean white cloth, damp with solvent. Reclean as required.

ASSEMBLY AND FIXTURES

 

Provide suitable fixtures to support and align parts during weld-
ing without excess restraint on the weld. Use welded-on temporary
attachments only where necessary.

Clean fixture within 10 in. of each side of weld joint.

Set up parts as shown on Joint welding Schedule and drawing.

Provide suitable baffles on root side of joint to confine and prevent
contamination of the backing gas.

WSP-1402
Revision 0

Date
Page

8-13-68

3
30

Tack weld by depositing short small beads equally spaced along joint.
Remove oxide and defects. Grind tacks if necessary to produce tapered
ends and flat or concave surface.

Shield weld area to exclude moisture, foreign material, and drafts
that contaminate inert gas shielding.

WELDING POSITION

 

All positions.
WELDING PROCESS, CURRENT AND SCHEDULE

Process: Gas tungsten-arc.
Process Control: Manual.
Current: Direct current, electrode negative (straight polarity).

Schedule: Follow Joint Welding Schedules in this Procedure.
WELDING EQUIPMENT

Current Source: Rectifier or generator having drooping volt-amp
characteristic, and foot control to permit continuous control of weld-
ing current, and upslope and downslope of current over a 10-to-l1 range.

Arc Starter: High-frequency oscillator if available, ON during start
only.

Welding Torch: Hand-held gas tungsten-arc torch adaptable to the
joint and suitable for amperage, electrode, and gas nozzle specified
in Joint Welding Schedules.

Electrode: Thoriated tungsten welding electrodes that conform to
ASTM-B297, Classification EWTH-2.

Flow Meters: Ar and He flow meters, as required, calibrated at speci-
fied flow rate.

Gas Lines: Use metal or plastic. If necessary, backing gas lines may
be latex rubber tubing in new condition.

PREHEAT AND INTERPASS TEMPERATURE
Preheat Temperature: 60°F (min), to 10 in. from weld joint.

Interpass Temperature: 200°F (max).

WPS-1402
Revision 0
Date 8-13-68
Page 4
31

WELDING TECHNIQUE

Before welding, use at least 5 volume changes of Ar backing gas to re-
move air. Continue flow until weld thickness is sufficient that
the underside is not heated to oxidizing temperature during welding.

Place torch in welding position, start Ar preflow and purge air from
gas lines, torch, and arc-strike area.

Strike arc by means of high-frequency spark or by light touch of
electrode in weld groove or on a copper block. Start arc at low
current; when arc is stable, upslope current to welding level.

Hold torch perpendicular to joint or slightly slanted (0-15°), with
electrode pointed normally in direction of travel. Move torch at a
constant rate in direction of travel with minimum oscillation if
necessary. Maintain short arc length. Regrind or replace electrode
when necessary to maintain required tip shape and to remove metal
pickup and oxide.

Wipe welding rod with clean cloth and solvent. Hold rod 10-30° from
base metal. Begin adding welding rod as soon as a small weld pool

is present. Add rod at a constant rapid rate into the leading edge
of the pool. Do not fuse base metal or weld metal without adding rod.
Deposit string beads. Keep end of rod in the shielding gas. Remove
oxidized ends of used rods.

Travel upward when axis of weld is not level.

Before breaking arc, fill crater and reduce weld pool to smallest
possible size by downsloping current.

Maintain postflow until weld bead is below oxidizing temperature.
CLEANING OF WELD BEADS

Remove all oxide (particles and film) from crater, weld beads, and

base metal in the line of arc travel, before depositing each section

of bead and from each completed weld bead.

PEENING

Do not peen weld beads or base metal.

WPS-1402
Revision 0
Date 8-13-68
Page 3
32

DEFECTS ~

Examine each weld bead and each crater for cracks, pin-holes, incom-
plete fusion, incomplete penetration, overlap, undercut, narrow
grooves, tungsten inclusions, heavy oxide or scale, and other defects.

Check that fillet size and butt weld reinforcement conform to job ®
specification. Check that all beads have normal smooth surface and
contour, and merge smoothly with each other and with base metal.

Remove weld defects by grinding, filing, or machining.

Before depositing each bead, examine weld groove and adjacent base
metal for cracks, laminations, holes, and other defects.

Report to Foreman defects in base metal and any other condition that
might reduce weld quality.

BACK-GROOVING

Before welding the second side of double-welded joints, machine or
grind the back of the root to remove defects.

POSTWELD HEAT TREATMENT
Postweld heat treatment was not incorporated in procedure qualification.
WELDER IDENTIFICATION

Record welder identification for each weld. Do not die stamp base
metal or weld.

INSPECTION

When the Welding Inspector believes inspection necessary, he will
examine base metal or welds at any stage of fabrication; and when

he has reason to question that this Procedure is being followed,

the ability of the welder, or weld quality, he may require supple-
mental inspection, corrective action, or requalification of the welder.

D. R. Frizzell
Chief Welding Technologist
P& Division

C. H. Wodtke
Welding Engineer
M&C Division -

WPS-1402
Revision 0
Date 8-13-68
Page 6
33

JOINT WELDING SCHEDULE
ELECTRODE DATA For 2% THORIATED TUNGSTEN

 

TIP DIMENSIONS

PREFERRED OPTIONAL #

60°

 

  

 

ELECTRODE EXTENSION

 

1

 

 

 

MIN. RADIUS _—IQ 1/4 ~3/8
2
#FOR FILLER BEADS ONLY AT IO AMPS MIN. GAS CUP
CURRENT RANGES
ELECTRODE DIA. (INCHES) AMPS, DC ELECTRODE NEG.

020 - — — - — — - —_—— — — 5-20
040 — e 15-80
e - - - _ 70-150
3/32 — e 150-250
Ve — __ — e 250-400
5/32 — — 400-500
MO o e e e — 500-800

 

WPS & PQS_____1402
REVISION 0
DATE 8-13-68
PAGE 7
JOINT WELDING SCHEDULE
BUTT JOINT, SINGLE WELDED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

JOINT DETAIL" WELDING SCHEDULE
450 ROD TUNGSTEN | CUP | SHIELD GAS | BACKI
X8 I~ JOTE | ponammon praM. | “URRENT | prpCTRODE | DIAM. FLOW FLOW
!_5 \ /- + p! > LAYER { BEAD IN. DIAM. IN.| IN. [ TYPE |CFH | TYPE | CFH
T “‘"—L*%g,g“, 0.020 ALL L 1_[0.035 12 1/16 0.5 Ar 15 | Ar 10
SHEET-1/32™-+0,0[0" 'S ! 0.045 ALL 1 1 0.045 24 1/16 0.5 Ar 15 AL 10
k < ) 1 [0.065 ALL 1 1 |0.062 42 1/16 0.5 Ar 15 | Ar 10
i 0.100 ALL 1 1 1/16 35 1/16 0.5 | Ar 15 | Ar 15
e '- 2 2 [ 1/16 40 1/16 0.5 | Ar | 15 | Ar 15
>\-o 0.187 ALL 1 1 3/32 50 3/32 0.5 Ar 20 Ar 20
2+ 2+ | 3/32 75 3/32 0.5 | ar | 20 | Ar 20
T 0.250 ALL 1 1 3/32 55 3/32 0.5 | Ar | 25 | Ar 25
;} N\ /1 1 2 2-3 | 3/32 80 3/32 0.5 | Ar | 25 | Ar 25
r 3/32“—"“—-‘_0'04?" 3+ 44+ 1 3/32 110 3/32 0.5 Ar 25 Ar 25
Jjes" *0 5" 0.375 ALL T 1 3732 65 3732 0.5 Ar | 25 | Ar 25
TEo— to 2 1 2-3 [ 3/32 ] 9 1/8 0.5 | Ar | 25 | Ar | 25
o 0.500 3 4t | 1/8 125 1/8 0.5 Ar | 25 | Ar 25 0
b S 1
250 0.375 ALL 1 1 3/32 65 1/8 0.5 | Aar | 25 | Ar 25
125 ’- 2 2-3 | 3/32 95 1/8 0.5 At | 25 | Ar 25
3+ 4+ | 1/8 130 1/8 0.5 | Ar | 25 | Ar 25
Qo 0.500 ALL 1 1 | 3/32 65 1/8 0.5 | Ar [ 25 | Ar 25
2 2-3 | 3/32 100 1/8 0.5 | Ar | 25 | Ar 25
3+ 4+ | 1/8 170 1/8 0.5 Ar | 25 Ar 25
0.750 ALL 1 1 3/32 70 1/8 0.5 | Ar | 25 Ar 25
to 2 2-3 | 3/32 105 1/8 0.5 | Ar | 25 | Ar 25
1.000 3+ 4+ | 1/8 190 1/8 0.5 | Ar | 25 | Ar 25
WPS- 1402 1. Misaligmment tolerance: 0.10T but not over 0.032 in. offset or mismatch.
Revision O Other joint details are covered in Joint Detail Standard MET-WS-1.
Date _8-13-68 2, Range: Stated current * 10% depending on joint conditions

Page 8
DEYELOPMENT RECORD OF WELDING PROCEDURE

 

DATE

 

 

 

PRCCEDURE

POSITION OF WELD WELDING GPERATOR

 

 

 

 

BUILDING NO, WORK ORDER NO,

 

 

 

 

 

MATERIAL [CJPiPE < PLATE [ ]|SPEC. NUMBER ALLOY OR GRADE MANUFACTURER TTHEAT NUMBER
OTHER -

MATERIAL [C]FIPE - PLATE[ ]|SPEC. NUMBER ALLOY OR GRADE MANUFACTURER HEAT NUMBER
OTHER = '

FILLER METAL 1roD SPEC, NUMBER AWS CL ASS. MANUFACTURER "LGT OR HEAT NO.
[] ELECTRODE

FILLER METAL []roD SPEC. NUMBER AWS CLASS! " IMANGFACTURER LOT OR REAT NO.
[[]ELECTRODE

 

 

 

 

 

 

WELDING PROCESS
E:l METALLIC

C1mie
CIwmiae

1FiLING

MATERIAL PREPARATION
[C1MACHINING

[_]1GRINDING

 

 

CLEANING
SURFACE FINISH [jvaroRr [C]HAND
[soLvVENT T TDETERGEMT
I

 

 

INERT GAS COVER
TORCH % PUR
[ JARGONM
[ JHELIUM

E PURGE

[C] arGON
[ClHELIUM

% PURE

Ko

[C]vEs

 

GRINDING BETWEEN PASSES
METHOD

lMACHlNING COOLANT
ABRASIVE |[INO
- 1

COOLANT USED

iC}YEs

 

P ASS
NO.,

PRE~
HEAT

INTER PASS CURRENT

FILLER

WELDING TIME POST- LiQuIiD RADIO~

 

VOLTAGE

TEMPERATURE AMPS,

DIA.

VISUAL

LENGTH MINUTES HEAT PENETRANT GRAPHY

 

 

 

()

 

 

 

 

 

 

 

 

 

 

 

o

 

 

 

 

0.0

 

 

 

 

 

 

 

 

 

 

 

14

 

 

LAND WAS CUT OFF

 

MAT'L: MAT'L;

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(COMPLETE SKETCH AS REQUIRED)

 

REMARKS:

 

UCN+3312
(3 1z2-61)

[ INSPECTOR

 

 

 
37

Appendix C

Non Ferrous Mgterial Specifications
MET-RM-1

MET-RM-2

MET-RM=-3

MET-RM-L

MET-RM-5

MET~RM-6
MET-RM-B 10
MET-RM-B 163
MET-RM-B 167
MET-RM-B 30k
MET-RM-B 332 -
58 T

MET-RM-B 33k

MET-RM-B 336
MET-RM-C 300

MET-RM-C301

39

Appendix C

NONFERROUS MATERTAL SPECIFICATIONS

Rev.

0 5-10-61
1 8- 1-61
1 8- 1-61
1 8- 1-61
0 12-23-60
1 11-22-61
0 9- 9-63
0 h-19-61
0 L-19-61
0 L-19-61
0 7=14=60
0 h-27-61
0 h-27-61
0 T-22-61
1 9-21-62

Graphite Bar
Nickel-Molybdenum-Chromium Wrought
Alloy Forged or Rolled Pipe Flanges,
Forgings, and Forged Fittings and
Valve Parts

Nickel-Molybdenum~Chromium Wrought
Alloy Welded Pipe

Nickel-Molybdenum-Chromium Wrought
Alloy Welded Fitting

Gold-Nickel Brazing Filler Metal

Nickel-Molybdenum-Chromium Alloy
Formed Heads

Nickel-Molybdenum=Chromium Alloy
Plate and Sheet

Nickel-Molybdenum-Chromium Alloy
Seamless Heat-Exchanger Tubing

Nickel-Molybdenum-Chromium Alloy
Seamless Pipe and Tubing

Nickel and Nickel-Base Bare Welding
Filler Metal

Nickel-Molybdenum-Chromium=-Iron
Alloy Castings

Nickel~Molybdenum~-Chromium Alloy
Plate and Sheet

Nickel-Molybdenum-Chromium Alloy Rod
Boron Carbide Control Rods

Gadolinium Aluminum Oxide Cylinder
L1

Appendix D

Cleaning and Storing of Pipe and Fittings
To be Used in MSRE Construction
INTRA-LABORATORY CORRESPONDENCE
Oak Ridge National Laboratory
October 19, 1962

MSR-62-80

To: Distribution
From: B. H. Webster

Subject: Cleaning and Storing of Pipe and Fittings to be Used in MSRE
Construction

The pipe and fittings will be stored in B.M. Stores at X-10, Attention:

E. A. Wallace. At a later date part of the material will be stored at 7503
Building. Upon receipt of the material, the B.M. storekeeper will notify

the 7000 Area pipe shop foremen who will furnish craftsmen to clean, cap,

and return the material to Stores. The shop foreman will notify Inspection
Engineering in order that they may witness the cleaning. Inspection Engineering
will furnish and fill out a cleaning inspection form¥* and will forward copies

to J. T. Beall, E. A. Wallace, and B. H. Webster. The material will be cleaned
at the 7000 Ares Cleaning Facility by the focllowing method:

Cleaning Procedures for Pipe and Fittings to be Used in MSRE
Construction

Upon receipt of material at the Cleaning Facility, it is visually
inspected for cleanliness. If grease, oll, or dirt is present, the
material is washed with acetone, hot water, or blown with air to
remove the excess.

The material is then lowered into a vat of five per cent tri-sodium
phosphate (100 pounds of technical grade TSP to 280 gallons potable
water) at 80°C. This solution is cireculated through the vat at 60
gallons per minute. The inlet line is arranged so as to allow maximum
flow through pipe being cleaned. The material is to remain in this
solution for one-half hour minimum.

The material is then lowered into a vat of cold potable water. The
potable water flows through the vat at 50 gallons per minute and is
continuously discharged to waste. The material is rinsed in this vat
for one-half hour.

The material is then lowered into a vat of hot circulated potable
water (80°C) at 20 gpm for one-half hour. It is then removed to a
rack where it is air dried with 90°C filtered air.

¥ Form No. 1 - MSRE Cleaning and Inspection Form
See Attached Form
L

Distribution -2- October 19, 1962

The material is then finally inspected for cleanliness and remarked
if the identification was removed during cleaning. Material is to
be remarked by etching, pipe is to be marked on twelve inch (12")
centers, and fittings marked in two places.

If possible, the material will be delivered to E. A. Wallace or to
7503 Stores the same day it is cleaned.

All materials that pass through the Cleaning Facility are logged
in and out. The following information is recorded in the operations
log:

(a) Inspection request of store stock item number of the
material

(b) Description of material

(¢) Quantity of material

(d) Date cleaned

(e) Type cleaning

(f) Cleaning solution and rinse sample numbers

(g) Records are maintained on the date that the cleaning

solution is mixed and the nmixture.

All cleaning solutions and rinse waters are sampled once daily and
a sample log is maintained. The solutions are analyzed for sulphur,
lead, mercury, chloride.

The TSP solution is dumped twice weekly unless the analysis indicates

it should be discarded sooner. Solution is to be discarded if chloride
is 10 ppm or more or if 250 ppm of lead, mercury, or sulphur is detected.

Packaging for Return to Stores

 

For pipe - use plastic end caps or cover ends with aluminum foil and
masking tape.

For valves and fittings - use plastic bags, closing bags with aluminum
wire or use aluminum foil for larger items.

Issuing Material

After cleaning, the material is to be returned to B.M. Stores for use
in 7000 Area Shops and 7503 Field Shop. The material will be issued
only under the following conditions: '

1. The B.M. Storekeeper has in his possession a signed copy of the
Cleaning Inspection report showing the material has been cleaned
according to this procedure.

~
45

Distribution -3 October 19, 1962
2. The Storekeeper has in his possession the material
certification report from the vendor (to be turned over
to Storekeeper by J. W. Teague or C. K. MeGlothlan.
5. A Bill of Material form* properly filled out and signed by
one of the following: J. T. Beall, J. P. Jarvis, W. B. McDonald,
L. P. Pugh, J. W. Teague, B. H. Webster, C. K. McGlothlan,
F. T. Anderson, H. J. Klemski, R. 8. Jackson, W. D. Todd.
* See Attached Form
BN AT
B. H. Webster

BHW: jc

Attachment

Distribution

MSRP Director's Office R. B. Lindauer

J. T. Beall (3) H. G. MacPherson

S. E. Beall W. B. McDonald

E. S. Bettis H. F. McDuffie

F. F. Blankenship C. K. McGlothlan

C. E. Childress (%) R. L. Moore

A. J. Cook L. P. Pugh

D. E. Ferguson D. Scott

C. D. Greenway (3) I. Spiewak

W. R. Grimes A. Taboada

T. R. Housley (5) J. R. Tallackson

J. P. Jarvis (5) J. W. Teague

B. H. Webster (2)
 

DATE

MSRE BILL OF MATERIAL

 

 

 

E & M WORK ORDER NUMBER

WORK ORDER NUMBER - SKETCH NUMBER T T Iwork BY
L —_

 

 

‘JoB DESCRIPTION

 

ITEM NO. QUANTITY ‘ STOCK NO. i INSP. REQUEST NOC. i BESCRIPTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

£
— | ——— — e _ i'” e
|
— ————— —_— —_ — —— . — — T—-v —— -
| }
_— —_— — _— - —_— ——f — —— —_— e
_ [ [ S — - — — e e—— e - - —— -
T :
\ !
[ — e —_ — e — — — S
———— - e ————
[ e —_— ——
— = el e S — ——= —=mE—y ] T —
SIGNED BY
UCN-384C ;
(3 15-82} i
CLEANING PROCEDURE FOR MSRE

PIPE AND FITTINGE

 

 

DATE .
TRI-SODIUM  [COLD WATER|HOT HxO
PHOSPHATE RINSE AT |RINSE AND|FINAL VISUAL INSPECTION| PIPE FITTINGS
IR ITEM| QUANTITY] DESCRIPTION RINSE AT 50 GPM ATR DRIED|AND REMARKS CAPPED BAGGED
80°C g 60 GPM AT 90°C

 

 

 

 

 

 

L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MSRE CLEANING AND INSPECTION FORM NO. 1

CLEANING FLUIDS CHECKED FOR CONTAMINANTS
PER CLEANING PROCEDURE

INSPECTOR
g

Appendix E

Control of Material After Delivery to Building 7503
51

~

INTRA-LABORATORY CORRESPONDENCE
Osk Ridge National Laboratory

October 17, 1962

MSR-62-89

To: W. B. McDonald
From: B. H. Webster

Subject: Control of Material After Delivery to Building 7503

Purgose:

This procedure covers the methods for receiving, storing, issuing, and record
keeping for all materials to be used at Building 7503 in the construction and
maintenance of the MSRE. (See attached chart).

B & LT

B. H. Webster

BRW: jc

Attachment

Distribution

MSRP Director's Office H. G. MacPherson
S. E. Beall W. B. McDonald
E. S. Bettis H. F. McDuffie
F. F. Blankenship C. K. McGlothlan
C. E. Childress R. L. Moore

A. J. Cook L. P. Pugh

D. E. Ferguson D. Scott

C. D. Greenway (3) I. Spiewak

W. R. Grimes A. Taboada

T. R. Housley (3) J. W. Teague

J. P. Jarvis (5) J. R. Tallackson
R. B. Lindauer B. H. Webster (3)
W. B. McDonald -2- October 17, 1962

General: Preliminary arrangements have been made with the Stores department
to set up a store in the compressor building just west of T503. X-10 Stores
will furnish a storekeeper to issue materials, keep records, and maintain
inventory during the construction period and possibly during the operation
and maintenance of the MSRE.

Shelves and bins for materials will be furnished by the stores department.

Final arrangements should be made with stores approximately 60 days prior to
the completion date of the contract work in order that the store will be
ready when the ORNL forces are ready to start work in the building.

A. Materials to be Stored

1. Miscellaneous Non-critical Supplies

(a) protective clothing

(b) decontamination equipment and materials
(¢c) small tools

(d) insulation, etc.

2. Critical Materials

Critical materials include all pipe, valves, gages, tubing, and
fittings of any type or material and all INOR and SS material of
any shape or description.

3. BSemi-critical Materials

(a) heaters
(b) electrical disconnects
(e¢) M.I. cable, etc.

B. Receipt of Material
1. All c¢ritical material must be approved by Inspection Engineering.

2. A copy of the materials history must accompany the material to be
stored; this record will show:

Type of Material

Heat No.

IR No.

Cleaning Record

Test Records, etc. (Whatever records may be applicable
to the material in question).

3, Critical materials will not be accepted unless the above mentioned
conditions are met.

4. Non-critical materials may be placed in the store at the discretion of
the storekeeper and project materials control representative.
23

W. B. McDonald -3 Octcber 17, 1962

5.

Semi-critical materials will have been inspected and accepted at the
vendor's and may be stored as they are received providing records are
presented with the material or equipment.

Rules for Issuing Materials

L.

L.

Critical and semi-critical materials will be issued only on the
signature of cne of the following: J. T. Beall, L. P. Pugh, ¥. T.
Anderson, H. J. Klemski, J. P. Jarvis, W. D. Todd, J. W. Teague,
C. K. McGlothlan; B. E. Webster,; R. S. Jackson, P. Leinart.

Materials listed as critical will not be available to project personnel
(including E and M people)} from any source other than the 7503 Store.
Preliminary discussions with the X-10 Stores Supervisor indicate

that limitsations can be placed on the type of material that can be
bought on any given work order number from the regular X-10 Stores.

Respcnsibility will be assigned to one person to see that unused
criftical materiszl is sent to Inspection Engineering for rechecking
or returned to Stores.

Nen-critical meterials may be bought at X-10 Stores; however, an
attempt will be made to store as many items as possible in the 7503
Stcres. These items wili bte issued in the normal manner.

Records

Receiving reports, inspection reports, cleaning records, etc., will be
turned cver to a project materials control representative after material
is sccepted by Stores.

Speciai forms* will be provided for issuing critical and semi-critical
material. These forms will te made out in duplicate, one copy tc te
retained by the stcrekeeper as an assist in maintaining the proper
inventory,; and one copy turned over to the project materials control
represertative t¢ he kept cn file along with receiving reports,
inspection repcrts, etc.

=

e sturekeeper will maintain a pre-determined inventory of non-
ritical materials by whatever method is normally used by the stores
department. .

o3

*  See Attacted Form - UCN-38L0
 

MSRE BILL OF MATERIAL |°ATE

WORK ORDER MUMBER SKETCH NUMBER 7 TworxK B Y [E&!WWORKORSEENUMBER

e o

 

—_ |

JCB DESCRIPTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM NO. QUANTITY ! STOCK NO. i INSP, REQUEST NO. DESCRIPTION
|
—_— —k——— e — = = = —
i |
-
! f |
!
|
- ) i
e L S
—— P OV (S - —
! |
== - i —_ e T e L- I — T T T T o e e e T
T - T - T T/ T “Tsiengo BY - o -
UCN-3849)

{3 19-62)

 
D5

ORNL-DWG 70— 6933

 

 

 

 

 

 

 

 

 

 

CRITICAL MATERIAL SEMI-CRITICAL NON-CRITICAL
OUTSIDE VENDORS OUTSIDE VENDOR VENDORS
AND INSPECTION BY AND
AREA STORES INSP ENG AREA STORES
Y
INSP ENG
RESPONSIBLE FOR

 

 

INSP TEST, 1D
CLEANING, ETC

 

 

 

Y

7503 STORES —
RECEIVING, ISSUING

 

 

 

 

 

 

 

 

 

 

 

 

RECORD KEEPING | M
j 1
MATERIAL
=]  USAGE |
BLDG 7505

 

 

 

 

LEFTOVER MATERIAL
ROUTING DEPENDS ON
CONDITION OF MATERIAL

 

 

 

 

 

 

!

SALVAGE

Flow Chart: 7503-Material Control
57

Appendix F

ORNL Operator's Qualification Test Specification QTS-33
For Inert-Gas-Shielded Tungsten-Arc Welding
Of INOR-8 Alloy Pipe, Plate and Fittings tc Inconel Material
59

CORNL OPERATCR'S QUALIFICATION TEST SPECIFICATION QTS~33
FOR INERT-GAS-SHIELDED TUNGSTEN-ARC WEIDING
OF INOR-8 ALIOY PIPE, PLATE AND FITTINGS TO INCONEL MATERIAL
Revised Sept. 1, 1962

SCOPE:

This specification covers the qualification of operators for appioval to
inert-gas shielded tungsten-arc weld Inor-8 alloy pipe, plate and fittings
to Inconel material in accordance with Procedure Specification P.S.-33.

REFERENCES:

Procedure Specification P.S.=-33.

Procedure Specification Figure P.S.-33-A.

Operator's Qualification Test Specification Figure QIS-33-A.
Operator's Qualification Test Specification QTS-1.

Operator's Qualification Test Specification QTS-25.

ASTM B167 latest revision (Inconel Seamless Pipe and Tubing).
MET-RM-B167-T Specification for Ni-Cr-Mo-Allcy Seamless Pipe and Tube.
ASME Boiler and Pressure Vessel (ode Section IX.

PRICR QUALIFICATION REQUIREMENTS:

The operator shall meet the requirements of Qualification Test Specification
QTS~1 and QTS-25 prior to taking this test.

MATERTAL REQUIRED:

 

Unless prior approval for the use of alternates is obtained, test weldments
shall be made using MET-RM-B167-T Inor-8 alloy pipe or tubing end ASTM B167
Inconel pipe or tubing of the following description:

1. Three tests (Test A, B, and C) are required to cover the entire material
thickness range of P.S.~33. Test A qualifies a welder to weld materials
in the thickness range of 0.020" through 0.100". Test B gualifies s
welder to weld materiasls in the thickness range of 0.109" through 0.375".
Test C qualifies a welder to weld materials in the thickness range of
0.375" through 1.000",

2. Welders shall meet the requirements of Test B before taking Test A or
Test C.

TEST A:
l. For Butt welds

Inor-8 alloy tubing

1 piece 1" 0.D. x 0.065" wall, 3" long

1 piece 0.500" 0.D. x 0.045" wall, 3" long and

1 piece 0.500" 0.D. x 0.020" wall, 3" long are required.

Inconel tubing

1 piece 1" 0.D. x 0.065" wall, 3" long

1 pilece 0.500" 0.D. x 0.045" wall, 3" long and

1 piece 0.500" 0.D. x 0.020" wall, 3" long are required.

FEach piece shall be square cut and fitted as shown on Figure P.S.-33-4,
(Design for Welds in Tubing).
60

2. For Seddle welds

Inor-8 alloy tubing
1 piece 1" 0.D. x 0.065" wall, 3" long end
1 piece 0,500" 0.D. x 0.045" wall, 3" long are required.

Inconel tubing
1 piece 1" 0.D. x 0.065" wall, T" long &and
1 piece 0.500" 0.D. x O.045" wall, T" long sre required.

Eech plece shall be cut and fitted as shown on Figure P.S.~33-A, (Design for
Welds in Tubing).

TEST B:

 

l. For Groove welds

Two pleces of 3" diameter schedule 40 Inor-8 alloy pipe and two pieces of 3"
Jdiemeter schedule 40 Inconel pipe are required. Each piece shall be approzi-
mately 4" long and beveled and fitted as shown on Figure QTS-33-4, Test B.

2, For Fillet welds

Two pleces of 3" dlameter schedule 40 Inor-8 alloy pipe 4" long and one
Inconel backing ring 11" wide by " thick are required. All pieces of

pipe shall have both ends square cut end fitted as shown on Figure QIS-33-A4,
Test B.

TEST C:

 

1. For Groove welds
Two pieces of 8" diameter schedule 80 Inor-8 alloy pipe and two pteces of 8"
diameter schedule 80 Inconel pipe are required. Each piece shall be spproxi-
mately 4" long and beveled and fitted as shown on Figure QTS-33-A, Test C.

2. For Fillet welds
Two pleces of 8" diemeter schedule 80 Inor-8 alloy pipe 4" long and one
Inconel backing ring 13" wide by 3/8" thick are required. All pieces of pire
shall have both ends square cut and fitted in accordance with Figure QTS-33=4,
Test (¢

FILLER METAL:

The filler metal shall be Inconel 82-T International Nickel Company 2lloy or equal.

QrS-33

Page 2
61

TEST POSITIONS:

1.

2.

QTS~33

Pege 3

Butt welds

Position 2G - A butt weld shall be made between one piece of Inor-8 tubing and
one plece of Inconel tubing of the following sizes:

1" 0.D. 0.065" wall

%" 0.D. 0.045" wall

5" 0.D. 0.020" wall

The tubing will be placed with the axis in the vertical fixed position and the
weld in the horizontal pleane as shown on Figure P.S. 33-A.

Position 5G = A butt weld shall be mede with the same conditions and sizes as
in above except with the tube axis in the horizontal fixed position and the
weld in the vertical plane as shown on Figure P.S. 33«A.

Saddle welds

Two saddle welds shall be made, one joining one piece of Inor-8 tubing and
one piece of Inconel tubing 1" 0.D. x 0.065 wall and one joining one piece
Inor-8 tubing end one piece Inconel tubing 0.500" 0.D. x 0.045" wall as shown
on Figure P.,S. 33«A. These welds may be made in any convenient position.

Groove welds

Position 2G - A groove weld shall be made between one piece of Inor-8 alloy
pipe and one piece of Inconel pipe placed with the axis in the vertical
rosition and the welding groove in a horizontel plene as shown on Figure
QTS<33~A. After welding, the pipe shall be stamped with nuwbers 1, 2, 3, and
L, clockwise and approximately 90° apart and the proper identification of the
operator and position.

Position 5G -~ A groove weld shall be made between one piece of Inor-8 alloy
pipe and one piece of Inconel pipe phlaced with the axis in the horizontal
position and the welding groove in the vertical plane as shown on QIS=33-A.
Before welding, the pipe shall be stamped with numbers 1, 2, 3, and 4, clock-
wise starting with number 1, h5° clockwise from the top when arranged for
welding and the proper identification of the operator and position.

Fillet welds

A full fillet shall be maede Jjoining the Inor-8 alloy pipe and the Inconel
backing ring as shown on Figure QTS-33-A, Part A. This Joint shall be welded
with the axis of the pipe in the horlzontal fixed position and the weld in a
vertical plane,

A full fillet shall be made on the other side of the joint, Joining the Inor-8
alloy pipe and the Inconel backing ring as shown on Figure QTS-33-A, Part B.
This joint shall be welded with the axis of the pipe in a vertical fixed
position and the welding plene horizontal (overhead).
02

Meke the close-in passes as shown on Figure QI'S~33-A, using any convenient

welding position. The pipe shall then be stemped with the numbers 1, 2, 3,
end 4 at 90° intervals around the weldment and the proper identification of
the operator and test.

WELDING REQUIREMENTS:

 

1. The welding operator shall be required to follow procedure specification P.S.«33
in making the welds and shall not be allowed to rotate or turn the pipe or tube
during welding, except saddle welds and elose-in passes.

2. An inspector shsll be present at all times while the qualification test is in
progress. The inspector may refuse acceptance of & test weldment if the operator
does not comply with the standard procedure in all respects,

NON~DESTRUCTIVE INSPECTION OF WEILDMENTS:

 

QTs-33

Page L4

1. Visual Inspection:

 

The finished weldments shall be inspected for deviation from the procedure
specification and for the points listed below:

The appearance of the completed welds shall indicate that the welds
were made in a workmanlike manner,

The outer surface of the weld bead reinforcement shall not be less than
flush or greater then 25% of the joint thickness and in no case shall it
exceed 3/32", There shell be no undercut, overlap, or lack of fusion,

The Groove snd Butt welds = There shall be complete, uniform penetration.
Penetration shell be at least flush with the inside surface, nelther shall it
protrude beyond the inside surface more than 20% of the joint thickness and
in no case shall it exceed 3/32”. Weldments having pin holes in the root will
not be accepted.

2. Liculd Penetrant Insvection:

 

The weld shall be liquld penetrant inspected after completion of the root
prass and after completion of the weld.

3. Radiographic Inspection:

 

The completed weldment shall be radiographed and meet the requirements &s
stated below:

Techniques as speciflied in UW 51 of the ASME Code for Unfired Pressure
Vessels shall be used,

For Test A, there sheall be no evidence of porosity, oxide or tungsten
inclusions, cracks, pin holes or lack of fusion. Any of the aforementioned
defects shall be cause for rejection.
63

Tor Test B, the welds shall show no cracks or lack of fusion. Porosity
or slag inclusions shall not be greater in size than "fine" as defined
in the ASME Porosity Standards for plate +" to %" thickness nor shall
there be more than one in any one linear inch of weéid.

For Test C, the welds shall show no cracks or lack of fusion. Porosity
or sleg inclusions shall not be greater in size than "medium" as defined
in the ASME Porosity Standsrds for plate 4" to 11" thickness nor shall
there be more than one in any one linear inch of weld.

DESTRUCTIVE INSPECTION OF WEIDMENTS:

1.

2.

3.

'

For Test A the 2G and 5G weldments shall be cut longitudinally to provide a
minimm of four sections each for metallographic exemination.

The saddle welds shall be cut to provide & minimum of four sections each for
metallogrephic examination. Two sections shall be of the throet and two shall
be of the toe of the jJoint.

For Tests B and C the weldments shall be machine cut and specimens removed in
accordance with paragraph Q-24, Figure Q-13.2 (a2), Section IX, ASME Boiler

and Pressure Vessel (Code, The specimens shall be stemped with the proper
identification number of the operator, position and specimen number. Additional
specimen cutting is required in paragraph L.

 

Two weld specimens approximetely %" wide shall be removed as welded from the
weldment from positions epproximetely 180° epert and these shall be stamped
with the proper identification number of the weldment, position end opersator.
The welds shaell be prepared for metallogrephic evaluetion of the trensverse
section and examined in the polished and etched condition for evidence of flaws.

Weld reinforcement on the specimens, root penetration or backing ring shall be
removed flush with the surface of the specimens by machining, filing or grinding
and it will not be permissible to remove undercutting or other defects below the
surface of the base metal.

Neither will it be permissible to remove any base metal from the under side of
the specimen in order to conceel any evidence of lack of penetration or fusion
at the root of the weld. The edges of all weld specimens shall be rounded by
removel of the burr with a file.

Each specimen shall be given a gulded bend test in accordence with pareagreaph
Q-8 (b), Sectilon IX, ASME Boiler and Pressure Vessel Code.

RESULTS REQUIRED:

For Test A, the metallographic examination shall show no evidence of cracking,
incomplete fusion; povosity or inclusions. ‘

Groove weld specimens:

QTS-33

Page 5

l. For Test B the convex surface of the bend specimens shall be free of all

cracks or other open defects.,
Fillet

1.

3.

RETESTS :

6k

The convex surface of the weld shall show complete penetration with no
evidence of lack of fusion at the root of the weld.

The metallographic examinations shall show no evidence of cracking or in-
complete fusion. Gas pockets or inclusions shall not exceed one per specimen
and none shall exceed 1/32" in its greatest dimensionm.

For Test C the convex surface of the bend specimens shal) be free of cracks
or other open defects exceeding 1/32" in sny direction. The number of open
defects shall not exceed 1 in any one specimen. Cracks occurring at corners
of specimens during testirg shall not be considered unless it is indicated
that the origination was from a welding defect.

The metallographic examination shall show no evidence of cracking or in-
complete fusion. §as pockets or inclusions shall not exceed 1 per trans-
verse section and shall not exceed 1/32" in its grestest dimension.

weld specimens;

For Test B the convex surface of the bend specimens may show a maximum of
cne crack or other open defect per specimen and it shall not be greater than
1/32" in its grestest dimension.

The metallogrsphic examination shall show no evidence of cracking or incomplete
fusion., Gas pockets or inciusions shall not exceed one per transverse section
and shall not exceed 1/32" in its greatest dimemsion.

For Test C the convex surface of the bend specimens shall be free of cracks
or other open defects greater than 1/32" in its grestest dimension. The
total number of defects shall not exceed 2 in any one specimen.

The metallographic exsminaticn shall show no evidence of cracking or incom-
plete fusion. Gas pockets or inclusions shall not exceed 1 per transverse
section and shall not exceed 1/32" in its greatest dimension.

In case a welding operator fails to meet the requirements as stated, a retest msy
allowed under the following conditions:

1.

An immediate retest mey be made which shall conslst of two welds of each type
and test pnsition that has been failed, a1l of which shall meet the reguire-
ments specified for such welds; or;

A complete retest may be made at the end of & minimum period of one week
providing there is evidence that the operator has had further training and/or
practice,

ASSIGNMENT OF CQODE UPON PASSING QUALIFICATION TEST:

Welding operstors passing the ahove test whtll be gualified and his operator's card
so marked for welding by the imert-gas-shielded tungsten-arc process as specified
~nder Procedure Specification P.S.~-33.

QTS-33

Pege 6
65

RECORD QOF TEST:

A record shell be kept of all pertlnent test data with results thereof for each
operator meeting these requirements. This record shall be originasted by the in-
spector.

Tested specimens shall be identified end made avallsble for examination by interested
parties until all febrication requiring the use of this specification has been com-
pleted and the system has been accepted.

 

 

I Yo

G.M, Slaughtet] Metallurgist
Metals & Ceramics Division

QTS-33
Pege 7 9/1/62
FIG. QTS-33-A
TEST B
DETAILS FOR GROOVE AND FILLET TEST WELDMENT

  
 

|OO°

INCONEL INOR-8
||| ‘
6 MAX,
_l__
I6

T MAX 3

"MAX. ;

 

 

 

 

 

 

6}
_LII;MAX
POSITION 5G
POSITION 2G (PIPE AXIS HORIZOTAL FIXED)
(PIPE AXIS VERTICAL FIXED)

 

 

5
ft—— = = " "
CLOSE-IN WELDS\ 8 2 SCH 80 PIPE, 3 LONG
(6 PASSES)

NEaNR AANE
Ve ST
lsngCH 40 PIPE—/

(BACKING RING) | i

 

o
o
A
/]

 

 

v

 

 

 

 

 

 

rol—,
r

./ AXIS VERTICAL
WELD COMPLETELY

AROUND THIS SIDE

(PASSES 1,2,83)

WELD AROUND
THIS SIDE

- (PASSES 4,5,86)
£ s
HORIZONTAL

 

PART "A" '
{ PIPE AXIS HORIZONTAL FIXED)

PART "B"
(PIPE AXIS VERTICAL FIXED)
o7

FIG. QTS-33-A
TEST C

DETAILS FOR GROOVE AND FILLET TESYT WELDMENTS

ey

 

 

 

 

 

 

'
l

 

 

 

POSITION 26 POSITION S6
(Pipe oxis vertical fixed) (Pipe axis horizontal fimd)
TR
Close-in uelfit\%-—— fi" /—I'Sch 80 pips 4" long
{ INOR - 8 ’ ; INOR-8
’ ‘

 

 

 

 

 

 

 

W INCONEL
L] ]

Weid completely
around this side

(Posses 1,2,3,4.5.6)

|

Axis vertical

  
  

Weld around
this side
T t'_ (Posses?,8.9,
Axis 10,1l and 12)
horizontel
PART "A"
—_— W 80
{Pipe axis horizontal fixed) PART '8

( Pipe eoxis verticol fixed)
DATE. 9-|-62
69

Appendix G

Welding, Brazing, and Weld Inspection of INOR-8 Components
71

Appendix G

WELDING, BRAZING, AND WELD INSPECTION OF INOR-8 CCMPONENTS

Component drawings will have details for machining weld preparations

on parts, weld symbols for each weld, and other general welding informa-

tion. This symbol will indicate the type of weld, serial number of weld,

and inspection schedule,

Welding shall be performed only by welders gualified by Mechanical

Inspection to applicable specifications on drawings (ES-23, PS-25, PS-26,

WS=~1, WS-2) and inspected by the Mechanical Inspection group to Speci-
fication MET-WR-200, MET-NDT-L4, MET-NDT-5, and MET-NDT-6.
Each drawing with welding will be stamped with the following in-

spection schedule prior to issuing the request for fabrication:

Inspection Schedule
(as per Met-WR-200)

 

 

 

Inspection Method A B C D E F
Visual X X X X X X
Partial penetrant X X X
Complete penetrant X X

Radiograrh X X

Ultrasonic X X
73

Appendix H

Materials Which Have Been Analyzed for Use on INCR-8 and
Stainless Steel for the Molten-Salt Reactor Experiment
X.822

 

DATE:

SUBJECT:

TO:

FROM:

>

QAK RIDGE NATIONAL LABORATORY

 

Operated by For Internal Use Only
UNION CARBIDE NUCLEAR COMPANY
Division of Union Carbide Corporation 0 R N l

= CENTRAL FILES NUMBER

Post Office Box X
Oak Ridge, Tennessee

63-10-87

 

 

 

October 25, 1963 COPY NO. L

Materials Which Have Been Analyzed for Use on INOR-8 and Stainless
Steel for the Mclten-Salt Reactor Experiment

Distribution

B. H. Webster -

ABSTRACT

During the fabrication and installation of the MSRE a number of
commercial products were analyzed to determine what would be accept-
able as cleaning agents, lubricants, insulation, threading and tapping
compounds, etc., on INOR-8 and stainless steel materials. All of these
commercial items were analyzed for sulphur, since we have found sulphur
to be extremely harmful to INOR-8. It may be noted that mest items were
analyzed for low-melting metals and alloys which are also harmful to
INOR~8 under certain condtions. This listing is submitted with the

hope that it will be beneficial to other groups in the Laboratory.

NOTICE

This document contains information of o preliminary nature
ond wos prepored primarily for internal use at the Oaok Ridge
National Laboratery. It is subject to revision or correction
and therefore does not represent a final report. The information
is not to be abstracted, reprinted or otherwise given public
dissemination without the approval of the ORNL patent branch,
L egol and Information Control Department.
Materials Which Have Been Analyzed for Use on INOR-8 and Stainless Steel

 

 

S Al Ag cl He Pb
Ttem ppm ppm pPpm ppm ppm ppm

"Whiz" Gasket Maker Type # 500 55 15 T1 1.5 45

"Permatex" - Form-A-Gasket #3 50 2h0 17 39 0.6 87

Tape, Cloth, "Hampton" Type #3 4100 13,430 660 2980 10

Tape, Plastic, Elec. "JM" No. 166 1400 630 00 270,000 10 1500

Tape, Glass, Elec. "Scotch" #27 50 40, 490 580 340

Tape, Masking, "Scotch” #202 2800 180 30 710 10

Tape, Teflon 50 300 10 10 10

Thread Compound, "Fel-Pro C5A" 6500 640 70 20 10 10 to 100

Pipe Joint Comp., "Key Tite" 550 3070 830 1050 10 <hoo

Sealing Glaze, "Duroc" 140 33, 200 1640 15, 400 1 1 x 10l+ to 1 x
107

ILeak Check, "Sherlock" 870 5 9 L8 1.1

"Reliance" Tallowaid 410 410 300 10 10 100

"Tap-Magic" Tapping Comp. 20, 500 2 8 262 L 210

"Kel-F" Grease, 3-M Co. 7000 2640 3h0 226,000 10 18

Pipe Fitting Comp. "Grinneil” 36,900 ol 12 306 0.8 T2

Polyethelene Plastic Film 50 100 60 20 10

"Carey-Temp'", Tnsulation Cement 4500 27, 900 900 13,200 110 1000 to 10,000

"Gulfite" Cutting Oil 200 1k 6 2 .1 18

"Tech Pen" Ink 6900

9.
 

 

S Al Ag cl Hg Pb
ITtem ppm ppm ppm ppm ppm ppm

Blotting Paper 220 1870 450 290 10

Asbestos Paper 400 2870 1300 780 10

Asbestos Cloth 390 800 900 2470 10 <Loo

Vacuum Grease, "Dow Corning" 3200 34,900 900 1010 110 <h

Apiezon 170 370 10 100 10 <4

Hydraulic 0il (Code HB) <50

Neo-ILube, Thread Lubricant <50

Zip=-Strip Iabel Tape 11,000

Gulfspin 35 Drum No. 1 2600 20 10 40 .3 <0.2

Shell Tellus #72 (BL) 600 20 20 50 <.01 17

Nebula #1 Grease (UK) 600 400 2 <10 <.1 17

Shell Tellus #69 (KB) TOO 20 T T <.01 ~0 .3

Shell Hydrax #33 (BG) 200 10 L .9 <.01 <0.2

Shell Macoma #73 (CC) 5L00 20 3 3 <.01 10,000

Corborundum "Fiberfrax" Type XSW <160

Cloth, Insulating, Reinforcing, 130

Permaglas Mesh Co.
Compound, Waterproofing Mastic, 200
No. 30-36 Sealfas Mastic

Insulation, Carey "Hi-Temp" 210

Carey Insulation Cement (1900°F) 360 10~100% (Reported Alog)

FiberFrax Paper <200

 

Ll
79

Appendix T

Helium Leak Test Procedure

 
81

HELIUM LEAK TEST PROCEDURE

 

 

ITEM UNDER TEST WORK REQUEST NUMBER

 

 

 

 

1. SET UP EQUIPMENT AS SHOWN PER MSRE-SK-216, ESTABLISH HELIUM ATMOSPHERE IN PLASTIC ENCLOSURE, HAVE
LEAK DETECTOR IN OPERATION AND ROUGHING PUMP IN OPERATION, VALVES C, D, E, F, AND J CLOSED, VALVES
A, B, AND H OPEN.

WHEN LEAK DETECTOR IS READY FOR TEST ACCORDING TO INSTRUCTIONS ON MACHINE, NOTE TIME ’
READ GAUGES. (IN READING LEAK RATE METER INDICATE BY AT OR AB AFTER THE READING WHETHER THE TOP
OR BOTTOM SCALE WAS READ.)

 

MICRONS LEAK RATE RANGE

 

PROCEDURE TIME MICRONS LEAK RATE RANGE

 

    
 

2. OPEN VALVE C

 

 

WHEN LEAK DETECTOR STABILIZES,
" NOTE:

)

 

4, CLOSE VALVE C

 

 

WHEN LEAK DETECTOR STABILIZES,
" NOTE:

OPEN VALVE D, CLOSE VALVE H,
" OPEN VALVE J

WHEN LLEAK DETECTOR STABILIZES,
" NOTE:

w

 

   

 

~d

 

8. BEGIN 30 MINUTE TEST PERIOD

 

9 AT END OF EACH TEST PERIOD,
"NOTE:

 

—

0. OPEN VALVE F, CLOSE VALVE J

 

 

WHEN LEAK DETECTOR STABILIZES,
Y NOTE:

 

 

12. CLOSE VALVE F, OPEN VALVE J

 

 

WHEN LEAK DETECTOR STABILIZES,
"NOTE:

 

 

14, CLOSE VALVE D

 

 

WHEN LEAK DETECTOR STABILIZES,
“NOTE:

 

16. OPEN VALVE C

  

 

17. WHEN LEAK DETECTOR STABILIZES,
NOTE:

 

 

 

 

 

UCN-5113
(3 10-63)
 

 

PLASTIC

   
   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

    

 

 

 

 

 

 

 

ENCLOSURE
CALIBRATED
coLD TRAP STANDARD
LEAK
THROTTLE .- .
vALIE "B” : N\ WALVE G QO
FORE PUMP | .y \ L]
VALVE "4 " \ ! I : .
- D ITEM }
FORE PUM \ | i ; H
T \ValvoI ,fK N 4 E
- : L
G VALVE "D" VALVE "H" |
| 4 U
He. LED X vALVE'E"
CABINET. w M
| VALVE C
ROUGHING PLINP _fi“’
BUILT IN STD. LEAK !
T
% CHELIUM LEAK TEST SE£7-UFP
™ MSRE EQUIPMENT
W
X
1
)
S~
&

k- B,

 

 

a3
83

Appendix J

Fixtures and Components During Assembly
 

 

 

 

0

 

 

»

L2

 

 

»

PHOTO 62892

 

cg
87

Appendix K

Check List — Reagctor Cell Salt System
Fuel Salt Piping, lines 200 & 201 from HX to wall, Flow & ievel Instruments,

89

CHECK LIST
REACTOR CELL SALT SYSTEM

Includes: Reactor Vessel, Heat Exchanger, Fuel Pump Bowl,

Bearing Housing & Rotary Element, Pump Motor,

Space Coolers, Thermal Shield, Pump Support,

Heat Exchanger Supports, Pipe Supportis.

Pipe & Component Heaters to Disconnect, T. C. Components to Disconnect,

And Salt Piping

 

I&C

P&E

RD

 

A - Components

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

l. Reactor Vessel ‘ :
{a) Fabricate per Drawing - Material meets Specs. | : %
(b) Cleaned Inside é
(c) Check for Al outside - cleaned
(d) Ieak Tested - Recorded é_
(e) Welds Inspected - Accepted E
(f) Fitted to Jig - Recorded - Photographed
(g) Installed per Drawing - Using Remote Tooling %
(h) Deviations noted on Drawings and Drawings ;

returned to Design :

(1) Photographed

2. Heat Exchanger
(a) Fabricated per Drawing - Material Meets Specs.
(b) Cleaned Inside
(¢) Check for Al outside - cleaned 1
(d) Ieak Tested - Recorded
(e) Welds Inspected - Accepted
(£) Fitted to Jig - Recorded - Photographed
(g) 1Installed per Drawing - Using Remote Tooling !
(h) Deviations noted on Drawings and Drawings §

 

 

 

 

 

 

 

 

 

returned to Design

 

(1)

Photographed

 

 
90

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHECK LIST REACTOR CELL SALT SYSTEM
I&C P& E RD
3. Pump Bowl
% (a) Fabricated per Drawing - Material Meets Specs.
(b) Cleaned Inside é
(¢) Check for Al outside - cleaned
(d) Ieak Tested - Recorded % g
: (e) Welds Inspected - Accepted g
% (f) Fitted to Jig - Recorded - Photographed % i
% (g) TInstalled per Drawing - Using Remote Tooling g %
§ (h) Deviations noted on Drawings and Drawings % %
§ returned to Design : 3
? (i) Photographed é
4. Bearing Housing - Rotary Element ’
(a) Fabricated per Drawing - Material Meets Specs.
(b) Cleaned Tnside _ . L
(c) Check for Al outside - cleaned T
(d) Ieak Tested - Recorded -
(e) Welds Inspected ~ Accepted _ % 1
(£) TFitted to Jig - Recorded - Photographed j T I
f 3 -
(g) Installed per Drawing - Using Remote Tooling i ? i_ |
(h) Deviations noted on Drawings and Drawings : % é
returned to Design 5
ii) Photographed ;
% 5. Pump Motor . -
1 (2) Run in along with Rotary Element L
(b) Cnecked Blectrically i
(4) Installed per Dravisg - Wit Remote Tools =

 

 

 

(£)

Deviations noted on Drawings and Drawings
returned to Design

 
e

CHECK LIST

91

REACTOR CELL SALT SYSTEM

 

I&C ! P&E RD

¥
?
:

 

6.

Thermal Shield

 

7.

 

 

 

bR L e e G e

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(a) Fabricated & Tested per Drawing ;
(b) Welds inspected - Accepted §
(¢c) Tnstalled per Drawing ?
(d) Pressure Tested

(e} Ieak Tested

(f) Filled with Balls - Weight recorded

(g) Removable Sections checked for fit

(h) Removed & re-installed remotely

opace Coolers

(a) Meets Specifications

(b) Welds Inspected - Accepted

(c) Installed per Drawing

(d) Ieak Tested

(e) Fitted to Jig - Jig labeled

(f) Installed per Drawing - Using Remote Tools

 

 

B - Component and Pipe Supports

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1. Space Cooler Supports

(a) Fabricated & Installed per Drawing

(b) Material meets Specifications %

(c) TInstalled & Removed Remotely !

(d) Bolts checked for proper torgue
é (e) Deviations noted on Drawings and Drawings ;
§ returned to Design ;
% 2. Heat Exchanger Supports ;
é (a) Fabricated & Installed per Drawing ' %
g b) Checked for Proper Ioading before heat up ; §
? (c) Checked for Proper Iosding after heat up § §
; (d) Material meets Specifications g i
; (g) Deviation noted on Drawings and returned |

to Design

 
92

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHECK LIST REACTOR CELL SALT SYSTEM
. T&CIP&E RD [
3. Pump Supports | |
(a) Fabricated per Drawing —
(b) 1Installed per Drawing _i %
ipl Modified per Drawing :
(d) Checked for proper loading {(cold)
(e) Checked for proper loading after heat up
(f) Deviations noted on Drawings and Drawings
returned to Design
4. Reactor Supports
igl_ support Rods ete. fabricated per Drawing
{b) Material meets specifications
{c) Checked for proper loading on each rod _
(d) Deviations noted on Drawings and Drawings ,
returaed to Design !
5. Pipe Supports
igl_ Fabricated per Drawing
(b) Installed & aligned per Drawing ;
(c) Proper loading (cold) %
{a) Proper loading after heat up é
(e) Deviations noted on Drawings and Drawings %
returned to Design } f

IC - Salt Piping

'

| (a)
| (1)
()
(a)
(e)
(£)

1. Lines 100, 101, 102, 103, F. V. 103, & F F

Materials meet specifications
Fabricated per Drawing
Installed per Drawing
Welding Inspected, Approved
Pipe Cleaned

Pipe checked for Al outside - cleaned

 

e st e e et i e 8
93

 

 

 

 

 

 

CHECK LIST REACTOR CELL SALT SYSTEM
T &C P&E RD

g (g) Ieak Tested

g (h) Deviations noted on Drawings and Drawings

: returned to Design

g 2. ILines 200, 201,

s e s o

 

 

 

 

 

 

 

 

 

 

(a) Materials meet specifications |
(b) Fabricated per Drawing %
(¢) Tnstalled per Drawing §
(d) Welding Inspected, Approved _
(e) Pipe Cleaned
(f) Pipe checked for Al outside - cleaned Ai
(g) ILeak Tested ;
(h) Deviations noted on Drawings and Drawings g

'D - Heaters

ll

returned to Design :

 

2‘

 

 

 

 

 

 

 

 

 

 

 

Pipe Heaters and Heater Bases
(a) Fabricated per Drawing, checked dimensionally
(b) Heaters Checked
(¢) Bases installed per Drawing
(d) Heater Assemblies checked per Drawing
Identified
(e) Heaters Installed, Checked for Alignment ;
(f) Disconnects attached per Drawing - Checked 2
(¢) Photographed ;
Fuel Pump Furnace
(a) Fabricated and Installed per Drawing.

Welded per Specifications

 

 

Insulation meets Specifications.
Installed per Drawing

 

(c)

Heaters fabricated. Installed per Drawing

 

(a)

Heaters megged -~ Checked for interference
with pipe, etc.

 

 

 

 

 

 
ok

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHECK LIST REACTOR CELI SALT SYSTEM
- - I&C| P&E IRD
(e) Total Assembly checked for alignment, hangers
checked for proper loading. : o
(f) Disconnects attached per Drawing - Checked f 4
{g) Photos of Assembly ;
(n) Deviations noted on Drawing and Drawings :
_ returned to Design
3. Reactor Heaters e L
(a) TFabricated and Installed per Drawing
Welded per Specifications . .
(b) Insulation meets Specifications
Installed per Drawing B
(c) Heaters fabricated. Installed per Drawing )
(d) Heaters megged - Checked for interference
with pipe, etc. o e
(e) Total Assembly checked for alignment, hangers
checked for proper loading. L L
(f) Disconnects attached per Drawing ~ Checked .
{g)_Photos of Assembly _ I
(n) Deviations noted on Drawing and Drawings _
____returned to Design e i - -
f
L. Power Cable to Space Coolers L
| |
(2) M I Cable megged, Approved o B e
: E
{b) Ends sealed, epproved. o e
(c}) M I Cable z*tached to J B or disconnect inside ‘ ;
cell - Atuach-1 ho J B outside Cell L , -
(d) Cable identifisd inside & outside Cell ; §
{e) Brazing inspected, approved o ____"_L
(£) Bualkhead s~z s installed, checked - L |

 

 

(g) J B or Disconnects located ver Drawing

(%) Photographed - Inside Cell

(1) Deviz*ions noted on Drawings and Drawings
returned to Design

S . —_ o ————

 

e e e
CHECK: LIST

95

REACTOR CELL SALT SYSTEM

 

<

I &

P & E |RD

 

5.

Power Cable to Pump Motor

 

(a)

M T Cable megged, Approved

 

(b)

Inds sealed, Approved

 

 

(c)

MT Cable attached to J B or disconnect inside
cell - Attached to J B outside Cell

 

(@)

Cable identified inside & outside Cell

 

 

 

{e) Brazing inspected, approved _
{(f) Bulkhesad seals installed, checked L
{g) J B or Disconnects located per Drawing

 

(h)

Photographed - Inside Cell

 

(1)

Deviations noted on Drawings and Drawings
returned to Design

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6. Heater Leads - Outside J B to disconnects
(a) M I Cable megged, Approved
(b) Fnds sealed, Approved
(¢} MI Cable attached to J B or disconnect inside
cell - Attached to J B outside Cell
(d) Cable identified inside & outside Cell
(e) Brazing inspected, Approved
(f) Bulkhead seals installed, checked
(g¢) J B or Disconnects located per drawing
(h) Photographed - Inside Cell L
(i) Deviations noted on Drawings and Drawings
returned to Degsign v
E. TInstrumentation .
1. Thermocouples J B outside Cell to J B inside Cell

 

(a)

M I Cable megged, Approved

 

(b)
(c)

Ends sealed, Approved

M I Cable attached toc J B or disconnect inside

cell - Attached to J B ocutside Cell

| — e — ke e e LAy A A ¢ et o

 

(a)

Cable identified inside & outside Cell

 

e i |

 

 

et ekt < o e

 

 
96

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHECX LIST -8- REACTOR CELL SALT SYSTEM
? I&C P&E| RD ‘
l {e) Brazing inspected, Approved ? %
| (f) Bulkhead seals installed, checked L
% (g) J B or Disconnects located per Drawing ; é
(h) Photographed - Inside Cell i
(i) Deviations noted on Drawings and Drawlngs %
returned to Design : L
2. Thermocouples - J B inside cell to Contact Point o % |
(a) T. C. fabricated per drawing - ends sealed :_ghqgkedé_ §
:
(b) Pads welded on pive, etc., per Drawing % %
Inspected, Accepted ; Z !
{c) T. C. attached to pipe etc., & to disconnect per
specifications - Tnspected, Accepted % é
(&) m. ¢. Identified & J B Identified ; %
(e) Photographed % E
(f) Deviations noted & Drawings r=turned to Design % i :
: |

 

S T o

 
91

Appendix L

Fuel Drain Tank No, 2 in Jig
PHOTO 62722

 

 

 

 

)
&

 
  

 

   

 

 

 

 
101

Appendix M

Check Off lLiist for Main Blower Startup

 
103

CHECK OFF LIST
for
MATN BLOWER STARTUP

 

 

 

 

 

T&C P& E RD
1. Twbricate Motors
2. JTwbricate Blowers
3. Check Rotation of Motor
L., Check Operation of Backflow Dampers

 

5., Check Operation of Directional Vanes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6. Check Operation of Bypass Dampers
7. Open Bypass Damper
8. Check inside Radiator to see that all loose materials
are removed or tightened
Q. _Close Radiator Doors
10, Remove Stack Cover
11. Remove all loose materials from:
(2)_  Fan House
(b) Fan Housing
(c) Radiator duct upstream & downstreem of Radiator
(4) Stack
12. Close Backflow dampers on Blower No. 1
13. Close Entrance Doors
14. Start Blower No. 3, run ~ 60 seconds
15. Shut down Blower No, 3
16. Close backflow damper on Blower No. 3
17. Start Blower No 1, run ~ 60 seconds
18. Shut down Blower No., 1

 

 

 

 

 

NOTE : STEPS 1 THROUGH 13 MUST EE COMPLETED EEFORE STARTING STEP 1k

 

 
105

 

CRNL~-TM-2999
Internal Distribution

1. J. L. Anderson L3, M. T, Kelley

2. C. F. Baes L, H. G. Kern

3. S. E. Beall 45, A, I. Krakoviak

L, M. Bender L6, Kermit Taughon, AEC-O0OSR
5. E. S. Bettis Y7, M, I. Lundin

6. D. S. Billington 48. R. N. Lyon

7. R. Blumberg L9. R. E. MacFherson

8. A. L. Boch 50. C. L. Matthews, ARC-0SR
9. E. G. Bohlmann 51. H. B, McCoy

10. M. Booth, AEC, Washlngton 52. H. C. McCurdy

11. C. J. Borkowsk1 53+ C. K. McGlothlan

12. G. E. Boyd 54-55, T, W. McIntosh, AEC-Washington
13. R. B. Briggs 56. L. E. McNeese

1k, D. W. Cardwell 57. J. R. McWherter

15 W. H. Cook 58. A. J. Miller

D. F. Cope, AEC-ORO 59. K. L. Moore

18. . B. Cottrell 60. H., H. Nichol

19. J. L. Crowley 6l. E. L. Nicholson
20. F. L. Culler 62. A, M. Perry
21l. D. Elias, ARC-Washington 63. J. L. Redford
22, J. R. Engel 64, M. Richardson
23. D. E. Ferguson 65. D. R. Riley, AEC-Washington
2k, L. M. Ferris 66-68. M. W. Rosenthal
25. A, P. Fraas 69. H. M. Roth, AEC-ORO
26. J. K. Franzreb T0. A. W. Savolalnen
27. J. H. Frye TL. Dunlap Scott
28. C. H. Gabbard 72. H. E. Seagren
29. W. R. Grimes - G. M. Watson 73. M. Shaw, AEC-Washington
30. A, G. Grindell The M. J. Skinner

31« R. H. Guymon TS5« W. L. Smalley, AEC-ORO
32. P. A. Halpine, AEC-Washington 76. I. Spiewak
33. P. H. Harley 7. D. A, Sundberg
34, P. N. Haubenreich 78. R. E. Thoma
35. J. W. Hill, Jr. 79. D. B. Trauger

36. E. C. Hise 80-8L. B. H. Webster

37. H. W. Hoffman 85. A. M, Weinberg
38, A. Houtzeel 86. J. R. Weir
39. J. R. Hunter, AEC-Washington 87. M. E, Whatley
40. T. L. Hudson 88. J. C. White - A. S. Meyer
k1. W. H. Jordan 89. G. D. Whitman
42, P. R. Kasten 0. Gale Young
91-92.
93-9k.
95-97.
98,
99.
100.

lOl-
102.

103-117.
118,

106

ORNL-TM-2999

Tnternal Distribution

 

(continued)

Central Research Library (CRL)

Y-12 Document Reference Section (TRS)

Laboratory Records Department (IRD)

Laboratory Records Department, Record Copy (IRD-RC)
Nuclear Safety Information Center

ORNL Patent Office

External Distribution

J. Killion, Brown's Ferry Nuclear Flant
Decatur, Alabama
M. M. Price, Brown's Ferry Nuclear Plant
Decatur, Alabama
Division of Technical Information Extension (DTIE)
Laboratory and University Division (CORO)