Issue Date: 06/20/83 - 1 - 55050

NRC INSPECTION MANUAL DQASIP

INSPECTION PROCEDURE 55050

NUCLEAR WELDING GENERAL INSPECTION PROCEDURE

PROGRAM APPLICABILITY: 2512, 2515, 2730

55050-01 INSPECTION OBJECTIVES

01.01 To determine whether the licensee's welding specification

and procedures meet applicable ASME Code, regulatory, and contract

requirements.

01.02 To determine through direct observation whether welding

activities are performed in accordance with the ASME Code and SAR

Commitments.

01.03 To review a sample of records to determine whether they

are prepared, evaluated and maintained in accordance with the ASME

Code, applicable commitments and/or requirements.

01.04 To determine that welding specifications, procedures,

production equipment and established licensee quality control

systems are adequate for the production of sound welds.

Inspection Schedule

Inspection Must Be Started Must Be Completed

1st inspection: After work is

5% complete

Before work is

15% complete

Subsequent inspections: Periodically until startup of the plant.

The schedule listed above applies to inspection of nuclear

construction site and other long-term inspection efforts. For

short-duration projects and vendor inspections a different schedule

may be more practical.

55050-02 INSPECTION REQUIREMENTS

The inspection requirements contained in this section may be

fulfilled during a single inspection or several inspections

depending upon type and scope of inspected welding activity. For
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short duration projects and vendor inspections, the completion of

all requirements listed below may not be practical.
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02.01 Base Material and Filler Metal Compatibility for Welding

a. Verify that base metal and welding filler material combinations are as those listed in Table 1 of this procedure.

b. Evaluate base material/filler metal combinations other than

those listed in Table 1 to determine the suitability of

application.

c. Perform the following verifications related to control and

handling of welding materials:

1. Verify that the contractor/licensee has established

procedures and instructions for purchasing, receiving,

storing, disbursing, and handling of welding materials

including welding electrodes, filler material, consumable

inserts, fluxes, and gases.

2. Review sufficient sampling of welding material purchasing

and receiving records to verify that these operations are

conducted in accordance with approved procedures or

instructions.

3. Verify that welding material storage procedures, contain

requirement for environmental (moisture) control, specify

appropriate holding and baking temperatures and

out-of-oven exposure time for each class of materials,

and that actual practice follows these requirements.

4. Verify that there are effective procedures for limiting

electrode moisture pickup and maintaining identification

after the welding materials are issued to the welder and

that these procedures are strictly enforced.

5. If the contractor/licensee uses a single system for

welding material control, verify that this system is

conservative and meets the requirements for the most

restrictive application and personnel involved are

knowledgeable of the system, including material

designations.

6. Verify that welding materials are clearly identified at

all times in accordance with approved procedures and that

identification of acceptable material is retained

throughout storage handling and use until the material is

actually consumed in the process.

7. Verify that the method for disbursement of welding

materials is effective and controlled in accordance with

approved procedures and the unused welding materials are

scrapped or recycled in accordance with special

provisions which include maintaining identification and

rebaking of coated electrodes when applicable.

8. Verify by examination of representative records or direct

observation that ASME Code required tests are performed

on each lot of covered, flux cored or bare electrodes,
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rod, or wire, for each heat of consumable inserts and for

each combination or bare electrodes and dry blend of flux

mix to be used for welding.

02.02 Welding Procedures

a. Verify that the contractor/licensee has established adequate

procedures or instructions for preparation, qualification

approval/certification, distribution and revision of welding

procedure specifications (WPS).

b. Select two welding procedures (WPS) from each welding process

or combination of processes used for ASME welding applications

and verify conformance with procedures referenced in a,above.

c. Verify that the WPSs(b above) define all essential variables,

supplementary essential variables and nonessential variables

in accordance with the applicable editions of Section III and

IX of the ASME Code.

d. Verify that each of the above procedures has been qualified

in accordance with Section III and IX of the ASME Code and

that the supporting procedure qualification records (PQRs) are

on file.

e. Review PQRs for the above procedures and verify that each PQR

lists the essential variables for the specific welding process

or processes covered and that the values or ranges of these

variables are consistent with those permitted by the WPS and

are within the limits of Section IX of the ASME Code.

f. Verify that all mechanical tests required by Section III and

IX of the ASME Code (including notch toughness when

applicable) have been completed and are properly documented

in the PQR.

g. Verify that the PQR has been certified by the

contractor/licensee and that the mechanical test results meet

or exceed the minimum ASME Code requirements.

h. Verify that in making procedure test plates for butt welds of

heavy section materials with 80,000 psi or higher tensile

strength, consideration has been given to the effect of

angular, lateral and end restraints of the weldment (ASME

Section III-NX-4320).

i. Verify that any changes or revisions of the WPS essential

variables are supported by requalification of the original WPS

or a new WPS.

j. Verify that any changes in the WPS nonessential variables are

properly identified and documented either as revisions to the

original or a new WPS.

k. Verify that, whenever applicable, the WPSs comply or meet the

intent of Regulatory Guides referenced in Section 03 of this

procedure.
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02.03 Welder Performance Qualification

a. Verify that the contractor/licensee has established procedures

for qualification of welders and welding operators in

accordance with Section III and IX of the ASME Code. These

procedures should include adequate provisions to preclude

falsification of welders and welding operators qualifications.

b. If practical, sample adequate number of welders taking the

qualification tests and confirm by positive identification

that the person welding the test weldment is indeed the person

being qualified.

c. Verify that the contractor/licensee has a workable system for

maintaining a continuous record of the qualification status

of all welders and welding operators and that this system is

effectively utilized and accurate.

d. Verify by review of the qualification status records that

welders and welding operators performing production welding

have been and are currently qualified to weld under the

respective procedures.

02.04 Production Welding

a. Survey ongoing welding activities and select typical

in-process operations representing different welding

processes, procedures, and joint configurations for detailed

review. Perform the following verifications:

1. Verify that work is conducted in accordance with a

"traveler" or similar document which coordinates and

sequences all operations, references procedures or

instructions, establishes hold points, and provides for

production and QC signoffs. This document should be

available at the work station.

2. Verify that welding procedures, detailed drawings and

instructions if applicable, and weld data sheets are at

the work station or readily available.

3. Verify that the WPS assignment is in accordance with the

applicable ASME Code requirements. This is accomplished

by comparing the essential variables of the WPS with the

production weld.

4. Verify that welding technique and sequence requirements

are specified.

5. Verify that the base metals, welding filler materials,

fluxes, gases, and backing materials are of the specified

type and grade, have been properly inspected, tested, and

identified and are traceable to test reports or

certifications.

6. Verify that weld joint geometry is as specified and that

surfaces to be welded have been prepared, cleaned, and
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inspected in accordance with applicable procedures or

instructions.

7. Verify that parts to be welded are assembled and held in

place within specified gap and alignment tolerances and

verify that the alignment is within limits allowed by the

ASME Code.

8. Verify that temporary attachments such as bridging bars

or fit-up clips have been attached by qualified welders,

in accordance with qualified WPS.

9. Verify that gas purging, if specified, is used in

accordance with the applicable procedure and that

protection is provided to shield the welding operation

from adverse environmental conditions.

10. Verify that preheat, if specified, is in accordance with

applicable procedures requirements.

11. Verify that the technique of each welder is in accordance

with the welding procedure.

12. Verify that welding electrodes are used only in the

positions and with the electrical characteristics

specified in the welding procedure.

13. Verify that shielding gas flow and composition is as

specified in the WPS.

14. Verify that shielding gas flowmeters indicate the gas

type for which they are applicable and have appropriate

conversion factors if a different gas or gas mixture is

used for work under review.

15. Verify that welding equipment, including power cables and

gas lines, is in good condition and that ammeters and

voltmeters used for automatic welding have been

calibrated in accordance with applicable procedure

requirements.

16. Verify that interpass temperature is controlled in

accordance with specified requirements. The interpass

temperature for welding austenitic stainless steels and

high nickel alloys should not exceed 350 F.

17. Verify that interpass cleaning, grinding (especially

starts and stops) and peening are conducted in accordance

with applicable procedure.

18. Verify that backgouging, if applicable, is performed as

specified.

19. Verify that temporary attachments, arc strikes and weld

splatter are removed and inspected in accordance with

specified procedures.
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20. Verify that the process control system (travelers) have

provisions for weld repairs and that approved procedures

or instructions are available which describe or reference

acceptable methods of defect removal and weld repair.

21. Verify by direct observation and/or record review that

repairs are conducted in accordance with specified

procedures.

This verification should include:

(a) Review of weld repair consistent of mechanical

removal of surface defects with no rewelding.

(b) Review of repair involving metal removal by chipping,

grinding or machining followed by rewelding.

(c) Review of a repair involving metal removal by thermal

cutting or gouging followed by rewelding.

22. Verify that any repairs to the base metal are properly

documented in a special report as required by Section III

of the ASME Code (NB 4132). Verify that any repairs of

modifications to ASME Code-stamped components are

properly documented in a special report as required by

ASME Sections III and XI.

23. Identify all welders and welding operators observed

during inspection of joint fitup, welding and weld repair

for qualification review per 02.03 above.

24. Verify, if applicable, that no peening has been done on

the root and surface layer of the weld or base metal at

the edges of the weld.

25. Verify that the contractor/licensee has a periodic

preventive maintenance program for welding equipment used

for welding safetyrelated materials.

02.05 Preheat and Post Weld Heat Treatment

a. Verify that approved procedures are available for weld joint

preheating when required by a welding procedure specification.

These procedures should specify acceptable preheating methods

and provide requirements for monitoring and recording preheat

temperature before, during and, if specified, after welding

until post weld stress relief.

b. Sample sufficient number of in-process components to verify

that preheat control procedures are being followed in

production welding.

c. Verify that the preheat used in production welding is within

the limits specified by the welding procedure.

d. Verify that approved procedures are available for the conduct

of postweld heat treatment and that the fabricator has a
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system capable of meeting the heating and cooling rates, metal

temperature, temperature uniformity and control limits

specified in Section III of the ASME Code. The procedures

should cover furnace as well as local heating if both methods

are used in production.

e. If furnace heating is used, verify that furnace atmosphere is

controlled as specified in approved procedure.

f. Review a sufficient sampling of PWHT operations (in-process

and records) to assure that the following items are satisfied.

1. Verify that components are instrumented to provide

time-temperature recordings for the duration of the

entire heat treatment cycle (both furnace and local HT).

2. Verify that sufficient thermocouples are used to measure

the anticipated hottest and coldest temperatures of the

weld during holding at temperature and to measure

temperature variation within any 15-foot interval of weld

length during heating or cooling. This variation must

not exceed 250F.

3. Verify that the PWHT temperature and holding time is

specified, is adhered to and is consistent with ASME Code

(NX-4600) requirements based on the material type and

wall thickness.

4. Verify that the maximum initial furnace temperature,

heatup and cool-down rates are specified, are adhered to

and are consistent with the ASME Code (NX-4600)

requirements.

g. Verify that procedures are available for conduct of

intermediate or "non-code" stress relief of in-process

components if such treatments are used in component

fabrication.

h. Verify that temperature control is exercised on in-process

components which are required to be maintained at pre-heat or

other specified temperature for extended time periods while

awaiting further processing.

i. Verify that measures are taken to avoid sensitization of

austenitic stainless steel and high-nickel alloys during

stress relief treatments. This generally involves provisions

which preclude furnace stress-relieving of austenitic

stainless steel components or parts and limit their exposure

to sensitization temperature range (800-1500 F).

j. Examine cumulative stress-relief records for typical component

welds and verify that the total time at temperature does not

exceed that permitted by Section III of the ASME Code based

on the welding procedure qualification records.

02.06 Examination of Welds
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a. Select welds produced by different welding processes,

procedures, and combination of procedures, and verify by

visual examination that the following characteristics conform

to the applicable ASME Code and fabricators welding procedure

requirements:

1. Weld surface finish and appearance. Include inside

diameter of pipe welds when accessible.

2. Transitions between components of different diameters and

wall thickness.

3. Weld reinforcement.

4. Shape and size of fillet and socket welds.

5. Joint configurations of permanent attachments and

structural supports to clad components.

6. Removal of temporary attachments, arc strikes and weld

spatter.

7. Finish-grinding or machining of weld surface - verify

absence of wall thinning.

8. Absence of surface defects including cracks, laps, lack

of penetration, lack of fusion, porosity, slag, oxide

film and undercut exceeding prescribed limits.

b. Verify that approved procedures are available for the

nondestructive examination of the weld when required by the

ASME Code and/or contact requirements.

c. Verify that the fabricator's nondestructive procedures meet

the ASME Code and/or contract requirements. To accomplish

this, select the applicable nondestructive examination method

and inspect per IE Procedures 57050, 57060, 57070, 57080 or

57090 as required.

55050-03 INSPECTION GUIDANCE

General Guidance. The IE inspector performing the inspection under

this procedure should be thoroughly familiar with the requirements

contained in Sections III and IX of the ASME Code. The knowledge

of welding and techniques, their applications, limitations and

evaluations, is essential for this inspection. The intent of this

procedure is to achieve an in-depth review of the overall welding

activities taking place at the construction site. It is intended

that early in the construction phase of the plant a cognizant IE

inspector will perform this inspection in order to advise the

regional management about potentially troublesome areas and identify

any significant deficiencies which need correction.

Periodic assessments of the welding activities performed by a

cognizant IE inspector will be required throughout the construction

phase of the plant. This procedure should be used also in cases
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when the regional management have reasons to believe that the

welding performed on the site does not meet established practices

and standards; e.g., serious allegations related to welding, and

discovery of significant welding problems which will lead to

degradation of hardware etc.

This inspection of the nuclear welding activities performed on the

site as outlined in this procedure can be described as a four-phase

progressive review: First, prior to performing an inspection the

inspector familiarizes himself with the requirements pertaining to

the particular site scheduled for inspection. Second, the

licensee's procedures and practices are reviewed. Third, the work

is observed to determine that the work is accomplished in accordance

with these procedures and practices. Finally, records are reviewed

to verify that they are complete, accurate and retrievable. It is

estimated that at least three weeks of actual site inspection will

be needed to perform the required in-depth review of items b through

d below. The complete inspection of welding activities at the site

can be accomplished during a single inspection or by the completion

of each phase of the procedure during several inspections.

Additional guidance concerning each phase of inspection is provided

below:

a. Preparation for Inspection. Prior to performing an inspection

in accordance with the requirements of this procedure, the IE

Inspector should review the following:

1. NRC requirements.

2. Licensees' commitments relative to applicable Codes and

standards; e.g., which Addenda of the ASME Code applies

to this site.

3. NSSS vendor specification pertaining to welding.

4. NSSS/AE vendor interface requirements relevant to balance

of plant.

5. Applicable portions of the SAR.

6. Licensees' programs and procedures pertaining to the

subject.

7. Applicable portions of the QA Manual.

8. Licensees' commitments relative to welding and associated

activities.

b. Review of Welding Specification and Procedures. The inspector

should perform the following reviews:

1. Identify contractors or fabricators performing welding at

the site.

2. Identify which welding processes are used at the site and

perform a review of all welding procedures used in
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production welding in accordance with the applicable

paragraphs of Section 02 of this procedure.

3. Determine whether the welding procedures being used meet

all of the ASME Code and additional contract requirements

(if any). Establish whether the use of these procedures

will result in the production of sound welds suitable for

the intended application.

c. Work Observations. The IE inspector should select for work

observation a sample of welds composed of a combination of

systems and welding contractors associated with the work. The

selected welds should also represent a good cross section of

the production activities in terms of welding processes used

(SMA, TIG, etc.) and materials to be welded (stainless steel,

carbon steel, etc.). Considerations such as physical

location, difficulties to weld and limited accessibility

should be also incorporated in the sample selection. The

total number of sampled welds selected for observation should

be at least thirty (30) but need not be greater than sixty

(60), since statistically a greater sample size will not

significantly increase the confidence interval of the sampled

production welding. However, it is very important that the

inspected sample is representative of all ongoing production

welding.

d. Record Review. The IE inspector should review all of the

relevant documentation related to a sample of at least thirty

(30) randomly selected welds for each ASME subsection (e.g.,

NB, NC, ND, etc. For subsection NG, "core support

structures", the sample size can be reduced at the discretion

of the inspector). Same considerations as those stated in c

above are applicable. It is preferable that the welds

identified for record review are not the same welds identified

for work observation. However, certain circumstances may

necessitate the use of some of the welds sampled in c above

(e.g., contractor/licensee has completed only three welds to

date and all three welds need to be included in the sample to

provide meaningful statistical representation).

The sampled weld records must be inspected in accordance with

the applicable paragraphs of Section 02 of this procedure.

55050-04 REFERENCES

10 CFR 50, Appendix B, Criterion IX

ASME Boiler and Pressure Vessel Code Section III and IX

Safety Analysis Report, Chapters 1, 3, 5, 6 and 17

Regulatory Guide 1.31, Control of Ferrite Content in Stainless Steel

Weld Metal.

Regulatory Guide 1.44, Control of the Use of Sensitized Stainless

Steel
55050 - 12 - Issue Date: 06/20/83

Regulatory Guide 1.50, Control of Preheat Temperature for Welding

of Low-Alloy Steel

Regulatory Guide 1.58, Qualification of Nuclear Power Plant

Inspection, Examination, and Testing Personnel

Regulatory Guide 1.71, Welder Qualification for Areas of Limited

Accessibility

Regulatory Guide 1.85, Materials Code Case Acceptability ASME

Section III Division 1

Regulatory Guide 1.88, Collection, Storage and Maintenance of

Nuclear Power Plant Quality Assurance Records

END
Issue Date: 06/20/83 T-1 55050 Table 1

TABLE 1

BASE MATERIAL AND FILLER METAL COMPATIBILITY

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