MECHANIZEDPRESERVICE EXAMINATION OF SELECTED … · The examination of the St. Lucie Plant, Unit 2, reactor vessel commenced on January 28, 1982. The planning. activities associated

SOUTHWEST RESEARCH INSTITUTEPost Office Drawer 28510 6220 Culebra Road

San Antonio, Texas 78284

MECHANIZEDPRESERVICE EXAMINATIONOF SELECTED COMPONENTS OF THE

ST. LUCIE PLANT, UNIT2

VOLUME I

FINALREPORTWITH APPENDICES

SwRI Project 6831

Prepared for

Florida Power and Light Company9250 W. Flagler StreetMiami, Florida 33174

July 1S82

Prepared by Approved by

Reviewed and pproved by:

T. CarrFPL — PNS aff

82111504'21110FPL — PNS Staff PDR ADQCK 05000389Section Supervisor i, 8 PDR

Wayne T. FlachDirectorDepartment of Engineering ServicesQuality Assurance Systems

and Engineering Division

'I ~

0

INTRODUCTION

LPLEMENTATION OF REGULATORY GUIDE 1.150"ULTRASONIC TESTING OF REACTOR VESSEL MELDS DURING

PRESERVICE AND INSERVICE EXAMINATIONS"

INTRODUCTION

I

Implementation of Regulatory Guide 1.150,"Ultrasonic Testing of Reactor. Vessel Welds During

Preservice and Inservice Examinations"

.1. Introduction

The reactor vessel examinations performed at St. Lucie Plant, Unit 2,were performed in accordance with,the 1977 Edition of Section XI withAddenda through Summer 1978 (77S78) and Regulatory Guide 1.150 to theextent practicable. This Introduction is intended to summarize the impact ofRegulatory G'uide 1.150 and the methods by which Southwest Research Institute(SwRI) implemented its requirements.

The examination of the St. Lucie Plant, Unit 2, reactor vessel commencedon January 28, 1982. The planning. activities associated with these examina-tions were based upon the requirements as set forth in the Regulatory Guideand prior implementation at Florida Power and Light's (FPL) Turkey Point Plant,Unit 3. Due to the nature of the Regulatory Guide, several areas required fur-„ther clarification in order to assure that its intended requirements could beimplemented. As a consequence, this provided the basis'or the comments in-cluded in Section 3. of this Introduction relative to the St. Lucie Plant,Unit 2.

2. Im lementation of Re ulator Guide.1.150 As A lied to St. LuciePlant, Unit 2

The following is a transcript of .Regulatory Guide 1.150 with SwRI com-ments inserted. These comments represent, SwRI's position i.n addressing theintent of the Regulatory'Guide as the Institute has interpreted the require-ments and, in some cases,'ur proposed method of'erforming examinations incompliance with the Regulatory Guide. These comments'are made relative tothe Regulatory Position portion of'the Regulatory Guide only, as SwRI under-stands that this is the portion to which the NRC will audit for compliance.

C. REGULATORY POSITION

Ultrasonic examination of reactor vessel welds should be performedaccording to the requirements of Section XI of'he ASME BGPV Code,as referenced in the Safety Analysis Report (SAR) and its amend-ments, supplemented by the following:

G-2

INSTRUMENT PERFORMANCE 'CHECKS

The checks described in paragraphs 1.2 through 1.5 shouldbe made for any UT system used for the recording andsizing of reflectors in accordance with regulatory posi-tion 6 and for reflectors that exceed the Code-allowablecriteria.

Frequency of Checks

As a minimum, these checks should be verified within 1 daybefore and within 1 day after examining all the welds thatneed to be examined in a reactor pressure vessel duringone outage. Pulse shape and noise suppression controlsshould remain at the same setting during examination andcalibration.

1.2 Screen Height Linearity

Screen height linearity of the ultrasonic instrumentshould be determined according to the mandatoryAppendix I to Article 4, Section V of the ASME Code,within the time limits specified in regulatory posi-tion 1.1.

1.3 Amplitude Control Linearity

Amplitude control linearity should be determinedaccording to the mandatory Appendix II of Article 4,Section V of the ASME Code, 1977 edition, withinthe time limits specified in regulatory position 1.1.

1.4 Frequency-Amplitude Curve

A photographic record of the frequency-amplitudecurve should be obtained. This record should beavailable for comparison at the inspection sitefor the next two successive inspections of thesame volume. The reflector used in generatingthe frequency-amplitude curves as well as theelectronic system (i.e., the basic ultrasonicinstrument, gating, form of gated signal, andspectrum analysis equipment) and how it is usedto capture the frequency-amplitude informationshould be documented.

SwRI believes that it is inappropriate to photographically document afrequency-amplitude curve of a sample situation. The frequency spectrumanalysis of,a waveform provides only a record of the relative frequenciesin a signal produced from a particular situation. Also,'he equipmentneeded to provide the frequency spectrum analysis is relatively delicatelaboratory-type equipment which is not amenable to field use.

is in use, whichever is less) or each time anycomponent (e.g., transducer, cable, connector,pulser, or receiver) in the examination systemis changed.

SwRI agrees with the intent of the above requirement, and it has longbeen our standard operating practice to conduct calibration verificationchecks .more frequently than required by the Regulatory Guide. During theexaminations at St. Lucie 2, it was SwRI practice to completely check cali"bration of the mechanized ultrasonic instruments (FTS MK II) a maximum ofevery 12 hours and the manual ultrasonic instruments (FTS MK I) a maximumof every 4 hours. During mechanized examinations, this check coincidedwith the shift change so that operators from both shifts had an oppor-tunity to observe the calibration and repeat their own calibration tech-niques. This procedure has proved to be a significant aid in maintainingconsistent instrument sensitivity while minimizing the effect of differentoperators during long examinations.

Additionally, in accordance with the procedures used at St. Lucie 2, if acalibration could not be verified to within the plus or minus 2 dB toler-ance, all examinations since the last qualified calibration were'erformedover. Under these circumstances, it was unwise to extend mechanizedcalibration checks for a period greater than 12 hours. It was also SwRIpractice to check all points on the DAC curve during each calibration veri-fication. When a mechanized examination did not last for 12 hours, thecalibration was performed and verified at the end of each particular exami-nation setup. SwRI also complied with the requirement that calibration beverified each time that there was a change in any component of, the exami-nation system, i.e., transducer, cable, instrument pulser, etc.

Where possible, the same calibration block shouldbe used for successive inservice examinations ofthe same RPV. The calibration side drilled holesin the basic calibration block and the block sur-faces should be protected so that their characteris-tics do not change during storage. These side holesor the block surface should not be modifed in anyway (e.g., by polishing) between successive exam-inations. If the block surface or the calibrationreflector holes have been polished by any chemicalor mechanical means, this fact should be recorded.

SwRI agrees with the intent of the above requirement. All cali-bration blocks used during the St. Lucie 2 RPV examination are theproperty of FPL and are subject to these requirements.

Establishment of a correction factor was not necessary, asall data utilized for Code sizing and analysis of unidentified reflectorswas obtained in the same direction as used during calibration. Mhen per-forming examinations for the purposes of detecting reflectors orientatedtransverse to the weld, scanning was performed in a circumferential mode(perpendicular to the orientation of transverse indications ) In thiscase, calibration and examination were performed in the same direction.

c. For mechanized scanning, signals should notbe maximized during the establishment of theDAC curve.

This statement is ambiguous by implying that signalsshould not be maximized during the calibration. Such a practice is simplyinconsistent with normal, reasonable operating procedures. It is SwRI'sinterpretation that the intent of this requirement was to maintain thedirection of the sound beam to be essentially perpendicular to the cali-bration block's side-drilled hole. SwRI standard practice precludesskewing of the search unit toward the intersection of the side-drilledhole and the side of the block.

d. One of the following alternative guidelinesshould be followed for establishing the DAC

curve:

The DAC curve should be establishedusing a moving transducer mounted onthe mechanism that will be used forexamination of the component.

(2) Correction factors between dynamic andstatic response should be establishedusing full-scale mockups.

The above statement is essentially the mechanism SwRI used in order topreclude some of the other requirements. SwRI conducted a comparison ofthe response between dynamic and static conditions on a full-scale mockup.Iri this comparison, a calibration block was used that accurately repre-sented the full section of a reactor pressure vessel wall. It was shownthat a correction factor was inappropriate and that the results wereconsidered to be consistent. Therefore, a correction factor of "1" wasused and calibrations were performed statically. Scanning of the weldswas performed in a direction parallel to the weld, except when taking flawsizing data.

(3) Correction factors should be establishedusing models and taking scaling factorsinto consideration (assumed scaling rela-tionship should'e verified).

G-7

0

Code, 1980 edition, a correctionfactor should be used to adjust theDAC level to compensate for the largerreflector holes. Also, if the reactorpressure vessel has been previouslyexamined by using a conventional block,a ratio between the DAC curves obtainedfrom the two blocks should be noted(for reference) with the significantindications data.

3 ~ NEAR-SURFACE EXA"fINATIONAND SURFACE

RESOLUTION

The capability to effectively detect defectsnear the front and back surfaces of theactual component should be estimated. Theresults should be reported with the report ofabnormal degradation of reactor pressureboundary in accordance with the recommendationof regulatory position 2 '(3) of RegulatoryGuide 1.16. In determining this capability,the effect of the following factors shouldalso be considered:

a ~ If an electronic gate is used, the timeof start and stop of the control pointsof the electronic gate should be relatedto the'olume of material near eachsurface that is not being examined-

b. The decay time, in terms of metal pathdistance, of the initial pulse and of thepulse reflections at the front and backsurface should be considered.

C ~ The disturbance created by the clad-weld-metal interface with the parent metal atthe front or the back surface should berelated to the volume of material near theinterface that is not being examined.

d ~ The disturbance created by front and backmetal surface roughness should be relatedto the volume of material near each surfacethat is not being examined.

G-9

'

veld/parent-metal interface unless it can bedemonstrated that unfavorably oriented planarflaws can be detected by the UT techniquebeing used. Otherwise, use of alternativevolumetric NDE techniques, as permitted bythe ASME Code, should be considered. Alter-native NDE techniques may be considered toinclude high-intensity radiography or tandem-probe ultrasonic examination of the weld-metalinterface.

The .requirement to examine the weld/parent metal interface with'sound beam that essentially intersects the fusion zone at +15 degrees

was an impossibility for the majority of the vessel circumferential welds.Due to the weld orientation as depicted in the vessel drawings and thegeometry of the vessel shell, exception was taken to this requirementsVessel welds that were geometrically accessible were examined in accor-dance with the requirements. These areas were the vessel-to-flange andnozzle-to-shell welds. The vessel-to-flange weld was examined from theseal surface with sound beams essentially directed perpendicular to theweld. For nozzle-to-shell welds,„ the requirement was fulfilled byperforming examinations from the nozzle bore.

The use of alternate volumetric NDE techniques was considered;however, under the circumstances involved, alternate techniques wereimpractical and essentially impossible due to accessibility and geometricconditions.

Furthermore, SwRI's experience has shown that the standard 45-and 60-degree search unit angles as required by the ASME Code are verysuccessful in detecting flaws within the weld area.

6. SIZING

Indications from geometric sources need not be recorded-

6.1 Traveling Indications

Indications that travel on the horizontal baselineof the scope for a distance greater than indica-tions from the calibration holes (at 20 percentDAC amplitude) should be recorded. Indicationsthat travel should be recorded and sized at"

'20 percent DAC. Where the indication is sizedat 20 percent DAC, this size may be corrected bysubtracting for the beam width in the through-thickness direction obtained from the calibra-tion hole (between 20 percent DAC points) thatis at a depth similar to the flaw depth. If theindication exceeds 50 percent DAC, the size shouldbe recorded by measuring the distance between

This paragraph reduced the amplitude level to which data wererecorded from 20 to 10 percent. SwRI complied with this requirement in asfar as practicable with the exception of those areas where the signal-to-noise level prevented identification of low amplitude signals. SwRIcontends that the 10 percent of DAC data is of debatable value indetermining flaw size.

7. REPORTING OF RESULTS

Records obtained while following the recommendationsof regulatory positions 1, 2, 3, 5, and 6y alongwith discussions and explanations, if any, shouldbe kept available at the site for examination bytPe NRC staff. If the size of an indication, asdetermined in regulatory positions 6.1 or 6.2,equals or exceeds the allowable limits of Section XIof the ASHE Code, the indications should be reportedas abnormal degradation of reactor pressure boundaryin accordance with the recommendation of regulatoryposition 2.a(3) of Regulatory Guide 1.16.

Along with the report of ultrasonic examination testresults, the following information should also beincluded:

a. The best estimate of the error band in sizingthe flaws and the basis for this estimateshould be given.

When discussed with the NRC, it was noted that this statementis intended to assure that the examination agency would provide its bestestimate of the true size of detected flaws.

b. The best estimates of the portion of thevolume required to be examined by the ASlKCode that has not been effectively examinedsuch as volumes of material near each sur-face because of near-field or other effects,volumes near interfaces between claddingand parent metal, volumes shadowed by laminarmaterial defects, volumes shadowed by partgeometry, volumes inaccessible to the trans-ducer, volumes affected by electronic gating,and volumes near the surface opposite thetransducer.

Examination areas that received limited examination coverageare discussed in detail in Appendix F of this report. As previouslycited, there were no limitations associated with the required examinationvolume as a result of inadequate near-surface resolution except in thoseareas identified as having physical or geometrical restrictions.

G-13

1'ata Ac uisition S stem (See Fi re 3)/

Sonic FTS MK II ultrasonic instruments were used for mechanizedexaminations. Recording of the mechanized data was accomplished by usingthe SwRI Data Acquisition System (DAS), which simultaneously recorded testdata from three separate ultrasonic search units. Gating and positioningcircuits were incorporated into the system to provide reflector locationand amplitude information. The SwRI DAS is a portable, compact, modularsystem designed for rapid and accurate recording and/or processing ofultrasonic test information obtained during mechanized examinations.

Information obtained from UT examinations was processed by theSwRI DAS in the following manner. Signal information from each of the UTinstruments was displayed on the appropriate CRT for each instrument.Amplitude and time analog information was channeled through electronicgates and examined according to preselected levels. For the signals whichexceeded these levels, calibrated voltages were generated relative to thegate positions and lengths for each instrument. The time analog and ampli-tude analog voltages corresponded to the first triggering signal encoun-tered along the sound beam and the signal with the largest amplitude,respectively. These data were combined with location information andtransmitted to a six-channel strip-chart recorder and the analog taperecorder.

This system produced the following types of examination records:

VideotapeStrip chartAnalog tape

As a requirement of every examination, the TV videotape record-ing provided- a continuous record of all information displayed on the CRTunit and the analog-to-digital display. Thus, it furnished an exactrecord of the information which can be used as a more interpretative toolfor the other record forms, and it also provides a redundant backup exami-nation record.

The six-channeled strip-chart recording provided a "hard copy"of test data for the gated regions of each of the three UT instruments.Search unit module position was also recorded, providing exact correlationwith other data records.

Analog tape recording of test data allows the largest degree offreedom for the SwRI DAS. It may be used in place of or in addition tothe strip chart recorder.

2. Reactor Vessel Examination Device (Fi re 4)

The Reactor Vessel Examination Device, fabricated by Prograaunedand Remote Systems, Inc. with technical input from SwRI, was adapted tothe St. Lucie Plant, Unit 2, RPV by the use of tripod legs speciallydesigned and built for that purpose. The examination positioning

FIGURE 4. REACTOR VESSEL E)U&1INATION DEVICE IN POSITIONDURING THE ST. LUCIE 2 RPV E~fINATION

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ePAGE . 1

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'T~ LUCIE PLAHTi UNIT 2

SUHHARY OF THE PRESERVICF EXAHINATIONPAGE

REACTOR PRESSURE VESSEL (FIGURES REFERENCED BELOW)

(CONTD)

ASHE ASWESECT XI SEC1 XI WELD NUHBER AND/OR EXAM,ITEN HO CATGY EXAHIHATIOH AREA IDENTIFICATION HETHOD

LONGITUDINAL SHELLi HELDS (SEE FIGURE A"4)

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ST ~ LUCIE PLANTi UNIT 2SUHHARY OF THE PRESERVICE EXAHINATION

REACTOR PRESSURE VESSEL (FIGURKS REFERENCED BELOM)

(CONTD)

PAGE 5

ASHESECT XIITEH NO

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MELO NUHBER AND/OREXAHINATION AREA IDENTIFICATION

HERIDIONAL HEAD MELDS (SEE FIGURE A 3)

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REACTOR PRESSURE VESSEL (FIGURES REFERENCED BELOH)

(CONTO)

PAGE

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HELD NUHBER AND/OREXAHINATION AREA IDENTIFICATION

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(CONTD)

PAGE 9

ASHE ASHESECT XI SECT XI1TEH NO CATGY

MELD NUHBER AND/OREXAHIttATION AREA IDENTIFICATION

NOZZLE VESSEL HELOS (SEE FIGURE A-2)

N I 00 N G T

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-0ST ~ LUCIE PLANTt UNIT 2

SUHHARY OF THE PRESERVICE EXAHINATION

RLACTOR PRESSURE VESSEL (FIGURES REFERENCED BELOW)

(CONTO)

PAGE ll

ASHE ASHESECT XI SECT XIITEN NO CATGY

HELD NUHBER ANO/OREXAHINATION AREA IDENTIFICATION

NOZZLE INTEGRAL EXTENSIONS (FIGURE A"2)

EXAH~

HETHOD

N I 0ONGT

SHRI SUHHARY R S E HPROCEDURE SHEET E I 0 E

NO ~ /REV ~ NUMBER C G H R REHARKS

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*a*BASIC CALIBRATION BLOCK***IR CSCL 66 SLC

83 100 8-D ON-IE-8OUTLET NOZZLE AT 180 OEG ~

60T 700i6/10 003700 X

***BASIC CALIBRATION BLOCK*i*IR-CSCL 66 SLC

NOZZLE INSIDE RADIUS SECTIONS (SEE FIGURE A 2)

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83 ~ 100 B-D ON-IR-8OUTLET NOZZLE AT 180 DEG ~

UT90 . 700 5/9 003800 X

UT90 700 5/9 003900 X

~*~BASIC CALIBRATION BLOCKi**IR"CSCL"66"SLC

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**DIBASIC CALIBRATION BLOCK*w*IR-CSCL 66"SLC

APPENDIX A

CLASS 1 WELD IDENTIFICATION FIGURES(Reactor Pressure Vessel)

APPENDIX A

CLASS 1 WELD IDENTIFICATION FIGURES(Reactor Pressure Vessel)

Table of"Contents

Fi ure No. Title ~Pa e

A-1 Reactor Pressure Vessel Outline and WeldIdentification

A-1

A-2 Reactor Pressure Vessel Nozzle Outline and A-2Weld Identification

A-3 Reactor Pressure Vessel Upper Shell andLower Head Outline and Weld Identification

A-3

A-4 Reactor Pressure Vessel Middle and LowerShells Outline and Weld Identification

A-4

A-5 Reactor Pressure Vessel and Associated Butt A-5Welds

REACTOR PRESSURE VESSEL OUTLINE AND WELD IDENTIFICATION

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MATINS~SURFACE

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ORE BRANTI~ ROT LU

INLET

IOAMENT

FIGURE A- I

REACTOR PRESSURE VESSEL UPPER SHELL AND LOWER HEAD OUTLINE

AND WELD IDENTIFICATION

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101-122A 0.

UT TAROET

101-154 A30o

201-141

Oo330o

101.154

FIG UR E A -S

REACTOR PRESSURE VESSEL AND ASSOCIATED BUTT WELDS

RC 201-128A RC- 201-1288

RC-112-6 AC-121-6

RC- 401-128A

I904

RC- 401 1288

RC 114 I R 0-125-I

00 180—

~ NOHTH27 04

AC-II5-6/

RC- 201 1280

RC-124-6

AC 201 1280* SHOP WELD No.

PP NOT USE SUBASSEMBLY

FIGURE A-5

APPENDIX B

MODULE CONFIGURATION SKETCHES

APPENDIX B

MODULE CONFIGURATION SKETCHES

Table of Contents

Drawin No.

A-SK 683

A-SK 678

SK 783

SK 781

SK 684

SK 760

SK 868

SK 872

SK 799

A-SK 710

SK 870

Title

Wall Scrubber Module Configuration Nos. 1 and 2

Wall Scrubber Module Configuration Nos. 3 and 4

Transverse Wall Scrubber Configuration Nos. 5 and 6

Transverse Wall Scrubber Configuration Nos. 7 and 8

Inlet/Outlet Nozzle Butt Weld Shoe Away from VesselC/L 6 CWT Configuration No. 9

Inlet/Outlet Nozzle Butt Weld Shoe Toward VesselC/L & CCWT Configuration No. 10

Inlet Nozzle, I.D. Inspection Configuration No. 11

Nozzle/Shell Outlet Configuration No ~ 12

Computer Controlled Module Nozzle"to-ShellConfiguration Nos. 17 and 18

Vessel Plange Configuration No. 19

Outlet and Inlet Nozzle Used with ConfigurationNos. 11 and 12

~Pa e

B-1

B-2

B-3

B-4

B-5

B-7

B-8

B-9

B-10

B-11

CONF IOUflATION tIO. 2 COIIFIOUAATION NO. I

60 0 I0

Tof'F VESSEL

o J

„DlflECTION OF ANOLE DEALl—OO

WELD

45

4O0 DIIIECTIOtl OF AIIOLE SEAM

0I o

l

80

WALL SCflUBDEA

MODULE

A-SK 683

BEAM QIRKCTIQN C W

SwRI ROTATOR at

CQNF36UR ATION NO. 5

CTS.

TQP OFVKSSKL

—ii 1.5 60

OF WEt 0

C ONFl GVRATI QN NO. 6

J.

6Q

BEAi4 QIRE CTIQN CCW

SwRI ROTATOR at ta'4 I a ~

TPANSVPRSK 'NALL SCRUBc" R

SX 783

B-3

l;L

INCIDENCE I'OINT

882—

INCIDENCE POINT

GWT llAHSVEIISE

Q VESSEL

PIVOT POINT

INLET/OUTLET NOZZLE OUTl WELD SIIOE

AWAY FIIOhl VESSEL 4 Il CWT

CONF lbunATION Ho. gSk- 684

I

e

0

VesselCenterline

I —RI

2

INC IDENCEPOINT

5.9

Inlet Nozzle I.D. InspectionConfiguration No. 11

SK 868S T. LUG I E 2

B»7

45H02ZLE

TDC

Iz 7

eoQOOUt e POSITION AT0 CT3 OH 220 COHTRQLLKR,

I1 I

II

CQHFIGURATIOH H-. 17

BEAM OIR CTIQH C C %

SC*H OIRE~iOH C 'W

NOZZLETDC

I—I.2

//

II

)~

I

I

60

XOOULK POSITION AT0 CTS OH 220 C~H i ROt.'~

CQHRQURATIOH .I-. 18

9EA M OIR ECTIOH C'H

SCAN OIRKC< IOH C7f

5 iC 799

B-9

LO N G I TU D IN AL

I5

3.2

VESSELCENTERLINE

OUTLET 8 INLET NOZ ZLEUSED WITH CONFIGURATION NOS. 11 AND 12

SK 870ST. LUG IE 2

APPENDIX C

SwRI Nuclear Projects Operating Procedures.

Administrative in nature; therefore, not

included as part of the Technical Report.

APPENDIX D

SOUTHWEST RESEARCH INSTITUTENONDESTRUCTIVE TESTING PROCEDURES

APPENDIX DC

SOUTHWEST RESEARCH INSTITUTENONDESTRUCTIVE TESTING PROCEDURES

Table of Contents

Procedure/Rev. No.

SwRI-NDT-600-15/46Dev. 2

SwRI-NDT-700-5/9

SwRI-NDT-700-6/10

Title

Manual Ultrasonic Examination of PressureVessel Welds

Mechanized Ultrasonic Examination of VesselComponents, Vessel Welds, and Piping Welds

Mechanized Ultrasonic Examination ofFerritic Vessels Greater than 2.0 Inches inThickness

SwRI-NDT-800-78/0Devs. 2 and 3

SwRI-NDT-900-7/3

Mechanized Ultrasonic Examination ofSt. Lucie RPV Nozzle-to-Piping Butt Welds

Visual Examination of Nuclear Reactors

1I

P ROCEDURE DEVIAT)ON

SI TE t

St. Lucie Unit2'EVIATIONl40. PAGE "

I DATE REQUESTED I

2OP 9

)Peb. 25, 1982

PROCEDURE / REVISION HO.

600-15/46SECT IOk: PAGE

.0,6.0,8.0 *OP 33

I. lit Hs I H s«ith this ssvlof ton

etc. )

S Fos' List socs sosclf Ic stse st csnlooneli I f0 oe s soistne4 In occord onc sstot ~ ~ so inInotton F or sod, coinoonont 14entlfl cotlon, Ilns idsntlf lection, «oi4 identtflcotlen,

CiiIJ

Cl

Manual examination of reactor pressure vessel welds to be conducted during the1982 PSI shall be affected by this deviation.

*Pages 2, 9, 23, 32

~dVu 10 II I r th t II w 0 b I I h ~ 4 / hi ~ Ifolio«s l uss scoot «ordlno srooossd, scdltlonol shoots iney hs use4 If sscssscry )i

fr sin es

Change 2.1 to read as follows:

The following documents, as applicable, form a part of this'procedure.

ASME Boiler and Pressure Vessel Code, Section XI, 1977 Edition, withAddenda through Summer 1978, "Rules for Inservice Inspection of NuclearPower Plant Components."

(2) ASME Boiler and Pressure Vessel Code, Section V, 1977 Edition with Addenaathrough Summer 1978, "Nondestructive Examination."

,(3) SwRI Nuclear Quality Assurance Program Ywnual (NEPH).

(4) NRC Regulatory Guide 1.150 entitled, "Ultrasonic Testing of ReactorVessel kvelds During Preservice and Inservice Examinations."

6.1.3 I7aveform Photos

Photographs shall be taken of the RP waveform of a reflector and of theunloaded initial pulse. This shall be performed during initial andfinal calibration and upon change of ultrasonic instrument, search unit,search unit cable, or use of another calibration block.

W CVltd'aC4

Lttv

0dI

JI!s. tFIc ytois i !tucson oneness is necsssery ond «not it is ntenoe4 to occoinotish I use C44tttonot snouts ifnecessary ) ~

These changes are necessary to reflect the code requirements for the St. LucieUnit 2 PSI, to comply with the requirements of NRC Reg. Guide 1.150 and to providethe examiner with new forms which are more compatible with the Reg. Guide require-ments.

s«nt vonii ft

DEVIATION: {Continued)

Deviation 2«RI NDT-600-15/46Page 3 of 9

(4) Check the CBZ sweep iateasity for enough brightnessfax a good photograph. Vith the CRT camera, obtain aPolaroid picture oi the KF waveform. Label the pictureas to ultrasonic instrument serial number,,os~~oscopecontrol settings, i.e., VOLTS/DXV, TZK/DIV and DELE'iHE,delay ~ position coatrol.

Change 8.0 eo z'ead as follows:

8.0 RECORDS AND SIZING CRZ3.:.RZA

80TE

It is recoga"red that not all ule asonic reflectors iad" cateflaws, since certain meeallurgical discontinuities aad geo-me~c conditions may produce iadicati'oas that are noerelevant. Inc'uded ia this category are plate segregatesin the heat-af ec ed roue, cLad iaterface aad backs»re"lectioas. Plate segz'egaees in the heat»affected tonemay become reflective azter fabrication; these may,

appear's

spot or ~~ e iadicatioas when ezra~~ ed using stra"ghe-beam long ending. wave techniques. These indications shallnot be considered a repor aole cond"eioa.

8.1 Recordia Criteria

Ultrasonic reflectors producing a response 20K or g eaterof the reference 1evel shall be recorded. Ultrasoa"c plaaarsurface reflectors obeained at 100K or g eater oi the responsefrom s~e notch shall be recox'ded.

Ult asoaic reflectors detected at 20X or greater of the,reiereace level aad planar sur=ace reilectoxs MOX orgreater oi ehe response f=om the square notch aad not re-solved as geome~ by the ezax~er shaLL remi e additionaldata to be recorded.

Iadicatioas noe resolved as geome~ shaLL be recorded tothe 1QX ~~ts along the length aad Wdth of the indication.

DEVIATION: (Cant»wued)I

Deviation 2SwRI M)T-600-15/46Page 5 of 9

8.3 ~Revortin

Ktzasanic reflectors 20X or greater of the referencelevel and planar surxace reflectoxs 100X or g eater oxthe response fxam the square notch investigated and foundto be other than geometrical in nature shall be reportedto the customer for evaluation.

Zf the sMe ox the indication, as deteraxLned in accaxdancewith Paragx'aph 8.2, eauals or exceeds the allowable limitsof Sect»an XZ of the fLPaH 3oiler and Pressux'e Vessel Code,the indications shall be reported.

The following s~~ also be reported:

(1) The best estimate of the erxar band in si ing theflaws and the basis for this estimate should begLven o

(2) The best estimate ox the port»on of the volumerequired to be ezaMed by the A&K Bailer and.Pzessu=e Vessel Cade that has not been effectivelyexamined, such as:

(a) Volumes of material near each suxfzce due tonear-field or othe ezfects.

(b) Volumes near interfaces between clad~» andpaxent material.

(c) Volumes shadowed by 3.aminar defects.

(d) Volumes shadawed by par" geometry.

(e) Volumes inaccessible to the search unit.

(z) Volumes affected by electronic gat»~g.

(g) Volumes near the sux=ace opposite fram thesea-ch un» t.

Change the second paragraph of 10.0 to read as follows:

Documents generated in'ccordance with this procedure shall be storedand retained as a portion of,the e~mination report. The examinationreport shall be stored by the iMnager of the Support and AdministrationSection, Quality Assurance Systems and Engineering Division, in theData Storage Facility for the period specified by the contxactual agxee-ment with the customer.

S IR l PRESSURE VESSEL EXAMlNATION RECORDPnOJECT No.

SYSTEM COMPOIIEtlT

SITE

LltlE SUDASSEMOLY

0 E:DA- ot- n

IDENTIFICATION

T El 2 In.c ocKEXAM STAIITEDEQM ENDEDip LOCATION

SIIEET tlo.

Wp LOCATION

EXAMINEn

EXAMINEn

SNT LEVEL

SNT LEVEL

pnocEounE

No.

nEv.

OEV.

CALIDnaTlotSIIEET (S) ANGLE

USED

SCAtltlln0DO

o EXAMltlATION SUDFACE SUNFACE TEMP.

INSIDEQ OUTSIDEQ OF

WELD LENOTI WELD TYPE

IND No. MAX o/o OF OAC SEancll UNIT At(OLE SEAncll UtllT LOCATION

LMEAsltnEMEIITs

loo/ DAC 20o/ DAC Soo DAC IOO% Oac W MAX 100/o DAC 5O% Oac 20 / OAC Io / DAC

nEMANKs

WI h'IP Wtl MP Wl MP Wl MP Wl hIP W2 MP MP W2 MP

IO%LI

20% LI

50% L I

l00%LI

L MAX

00% L2

50%L2

2O%I.2

I0%L2

L POS

L POS

nEYIEwED DY

SWhl Fohll NO. NOIh IF-IOO lit I-4II

EVELSNT L DATEPAGE OF

M III'o

COO A4Q M V

OlM

Qrt

o~HOI P~a~

C3I

~,

I

u

4

SN R I PRESSURE VESSEL INDICATION RECORD —CONTINUATION SHEETPROJECT tl0. SIZE DATEI DAY-MOH - YA Z E: 24 life Cj OCKkA S IIZKD

EXAM ENDED

SIIEET HO.

SYSZEM COMPONEtlT LINE SUBASSEMBLY IDE T F C TION CONTINUED FROM SIIEET

EXAtAIIIEII SHZ I.EVEL EXAMINEII SHT LEVEL CONTltlUED ON SIIEET

IHD HO. MAX % OF DAC SEAACII UNIT ANGLE SEAIICII UtlIT LOCATION

LMEASUAEMEHZS

I0% DAC 20 j DAC 50% DAC IOO /o DAC W MAX 100 jo DAC 50% DAC 20% DAC too/o DAC

AEMAIIKS

WI MP Wl Vll MP WI MP VI MP Wl MP W2 MP VI2 MP W2 MP

L POS

L POS

L POS

L POS

L POS

L POS

L POS

L POS

L POS

L POS

L POS

IIEVIEWED DY

SWRI SORM llO. HD'fR ll l07 II1 l Sl)

SHT LEVEL DATE

PAGE OF

I

J'

SOUTHWEST RESEARCH lNSTlTUTENUCLEAR PROJECTS

OPERATING PROCEDURE

SwRI-%)T-600-15Revision 46September 1981Page 1 of 33

TitleManual Ultrasonic Examination of Pressure Vessel. fields

EFFECTlVITYAND APPROVAL

Revision 4d oi this procedure became eiiective on >oi h i 9> . Other revisions oi the base documem maybe effective con"-urrentiy.

1

Approvals

Manager of CLA.

Date

s/i</r<

Date

v

ICog i nt Director

dEe . Pd~E

g(P

Date

f~~/r|ne following information may be used for convenience. mpletion of this portion is not mandatory.

Deviation No.

Date Effective

Procedure Section(s)Affected

Notes:

SwRI Form daAMOAW

I ~ ~ ~

II ~

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SOUTHWEST RESEARCH INSTITUTE

NUCLEAR PROJECTS OPERATING PROCEDUREtS-

SwRI-NDT-600-15Revision 46September 1981

Page 5 of 33

ScreenDistance Block T e

BlockDimension

5 Qrr SwRI Half-Round,AWS Type DCIIW

1.0"1.0"

0 rr

10 ~ 0" t 20 0" IIW 4.0"


BlockDimension

5.0" SwRI Half-Round,AWS Type DC

1.0" Radius1.0" and2.0" Radii


IIW

1.0"1. 0"

Qlr

4.0"

Radiusand.RadiiRadius

5.3

20.0", 40.0" IIW

Basic Calibration Block

4.0" Radius

Where the component material is clad, the basic calibrationblock shall be clad to the component clad nominal thickness of ~1/8 inch.Deposition of clad shall be by the automatic method used on the component.Whexe the automatic method is impxactical, deposition of clad shall be by 'themanual method used to cover the circumferential welds of the component.

Side-drilled basic calibration hole reflectors in accordancewith Figure T-434.1 of Article 4 of Section V of the ASIrE Boiler and PressureVessel Code shall be placed in a block manufactured from one of the following:(1) the component nozzle dropout; (2) the component prolongation,'r (3) mate-rial of the same specification, product form, and heat treatment as one of thematerials being joined. The basic calibration block thickness shall be .detex-mined by the average thickness of the weld. The requirements for basic cali-bration block curvature limits, heat treatment, surface condition, and scribelines shall be in accordance with Article 4 of Section V.

sw4I Form OA 3 2'

(0 SOUTHWEST RESEARCH INSTITUTE

SNUCLEAR PROJECTS OPERATING PROCEOURE

SwRI-NDT-600-15,Revision 46September 1981

Page 7 of 33

The exit point of the sound beam and the actual refracted beam

angle of shear-wave search units shall be determined on an IIW block. The exitpoint of the sound beam shall be marked on the search unit wedge.

Search unit wedges shall be fabricated to produce 45'2'nd60'2'efracted shear-waves as demonstrated on the IIW block. A search unitproducing 0'traight-beam longitudinal-waves shall also be used.

5.5

The nominal search unit frequency shall be 2.25 MHz.

Ultrasonic Instrument

. The examiner shall select an appropriate ultrasonic instru-ment from the following:

(1) Sonic PTS Mark I(2) Sonic PTS Mark II(3) Sonic UWA Mark'II

Each instrument shall be aligned and shall display an alignmentcalibration sticker as required by NQAP 10-1.

5.6 Couolant

(1) USP-grade glycerine or deionized water (with or withoutwetting agent) shall be used when performing ultrasoniccalibrations and examinations in accordance with thisprocedure.

(2) Couplant materials used for examinations shall be thesame as used for the calibration.

(3) Light oil or other compounds, which in the opinion of theLevel II examiner provide adequate ultrasonic coupling,may be used upon concurrence of the Project Managerresponsible for the examination.

(4) All couplants other than deionized water shall be certi-fied for sulfur content and total halogens in accordancewith ASTM D-129-64 and ASTM D-808-63. The residualamount of total sulfur or halogens shall not exceed 1% byweight. Deionized water, when used, shall be supplied bythe customer.

SwRI Fnrm OA-3 2 ~

t. SOUTHWEST RESEARCH INSTITUTE

q. $g NUCLEAR PROJECTS OPERATING PROCEDURElg

]


Page 9 of 33

6.1.2 Am litude Control Linearit

(1) Position a shear-wave search unit on a basic calibrationblock to obtain maximum amplitude from the 1/2T hole.

(2) Without moving the search unit and according to thefollowing table, set the indication to the requiredpercent of FSH and increase or decrease the dB asspecified. The signal shall be estimated and recorded tothe nearest 1% of FSH and shall fall within the limits ofthe following table:

IndicationSet at X ofFull Screen

dB ControlChan e*

IndicationLimits, % ofFull Screen

,e80X80X40X20X

-6 dB-12dB+6dB+12 dB

32 to 48%16 to 24%64 to 96X64 to 96%

*Minus denotes decrease in amplitude; plus denotesincrease.

6.2 Calibration

The complete ultrasonic examination system calibration shall beperformed prior to the examination.

NOTE

The "REJECT" control shall be maintained inthe "0" position during calibration andexamination.

The "FREQ MHz" control shall be turned to "2"when a 2.25 MHz search unit is used.

The centerline of the search unit shall be atleast 1-1/2 inch from the nearest side of theblock. (Rotation of the beam into the cornerformed by the hole and the side of the blockmay produce a higher amplitude at a longerbeam pass; this beam pass shall not be usedfor calibration.)

swRI FOrm OA 3 2

t-e, SOUTHWEST RESEARCH INSTITUTE

NUCLEAR PROJECTS OPERATING PROCEDURE$$ -


Page 11 of 33

(2) Position the 45'earch unit on the appropriate referenceblock and observe the radius echoes.

(3) Construct a linear screen as specified in Paragraph6.2.2.

(4) Record reference block data required on the appropriateSwRI Sonic Instrument Calibration Record.

Do not change the "MAT 'L CAL," "RANGE,"or 'DELAY" controls during the next stepor attempt to compensate for any slightdifference observed between the 45'nd60'creen distance calibrations.

(5) Position the 60'earch unit on the appropriate refer-ence block and observe the maximum amplitude and loca-tion of the first echo from the radius.

(6) Record reference block data required on the appropriateSwRI Sonic Instrument Calibration Record.

6.2.3 Strai ht-Beam Distance Am litude Correction for MaterialGreater than 2.0- to 12.0-Inches in Thickness

(1) Position straight-beam search unit on the basic calibra-tion block to obtain maximum response „from the calibra-tion hole with the highest amplitude from the following:

Hole

1/4T1/2T3/4T

lf

(2) Adjust gain controls to obtain the primary referenceresponse at 80% +5X of PSH and mark this amplitude on theinstrument screen.

NOTE

Ensure that instrument gain controls arenot changed once the primary referenceresponse has been established.

SwRI ForfTI Oa 3 2

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~ II ~

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~ II I ~ 'l ~ ~ ~ ~ II ~ ~

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~ SOUTHWEST RESEARCH INSTITUTE

NUCLEAR PROJECTS OPERATING PROCEDURE

I


Page 17 of 33

(4) Type, size, beam angle, and serial number of the ultra-sonic search unit

(5) Nominal search unit frequency

(6) Couplant (which shall be the same type as used in theactual examination)

(7) Signature and ultrasonic certification level of exam-iner conducting calibration

(8) Date calibrated

(9) Time of calibration and calibration verification

(10) Temperature of calibration block

(ll) Length and type of search unit cables

(12) Serial number of thermometer used.

7.0 EXAMINATION

7.1 Surface Condition

The contact surfaces must be free from weld spatter, rough-ness, or other conditions which interfere with free movement of the search unitor impair the transmission of ultrasound.

7.2 Reference Points for Ph sical Measurements

7.2. 1 Nozzle-to-Shell Welds

A concentric reference circle around each nozzle which encom-passes the scan area shall be marked on the shelf. This circle shall be refer-enced to the centerline of the respective nozzle by indicating its radius'helocation of the 0'zimuth of each nozzle shall be noted on the appropriateSwRI examination record. The 0', 90', 180', and 270'zimuth shall be markedalong the concentric reference circle for any nozzle weld examined. All azi-muth locations marked on the shell shall be numbered in a clockwise direc-tion as viewed from the vessel exterior. Each 30 degrees of azimuth shall bemarked around the reference circle for nozzle welds with a radius greater than4 inches. Each 15 degrees of azimuth shall be marked on nozzle welds with aradius greater than 12 inches . Nozzle welds with a radius greater than24 inches shall be marked along the reference circle each 5 degrees of azimuth.A concentric reference circle shall also be marked within 1/2 inch of the weld

SwRI Fnrm QA 3 2

SOUTHWEST RESEARCH INSTITUTEIg

NUCLEAR PROJECTS OPERATING PROCEDURE,y A3


Page 19 of 33

(2) Add 6 dB of gain by adjusting the fine gain control only.Observe the signal amplitude.

(3) Add 6 dB of gain by adjusting a combination of both fineand coarse gain controls. Observe the signal amplitude.

(4) Add 6 dB of gain by manipulating the 6 dB switch, ifpresent. Observe the signal amplitude.

(5) Choose the method above which yields a signal responseclosest to 80X FSH.

(6) The method chosen shall be used during the valid calibra"tion period for all scanning at 2 times the referencelevel sensitivity.

The examiner shall ensure that the signal response of themethod chosen is within ~2 dB of 100% FSH. Record this amplitude and method onthe SwRI Sonic Instrument Calibration Record.

Instrument gain settings for scanning shall be recorded on theappropriate SwRI examination record.

The search unit movement rate for scanning shall not exceed 6

inches per second.

7.5 Scannin Overla

Scanning overlap shall be a minimum of lOX of the search unitpiezoelectric element dimension perpendicular to the direction of scan. Scan-ning performed in a direction perpendicular to the weld shall extend asrequired to examine 1/2t of base material from the weld fusion line. Scanningperformed in a direction parallel to the weld shall extend a minimum distanceof 1/2t on each side of the weld, when possible. \

7.6 Lon itudinal and Circumferential Butt Welds in Vessels

Longitudinal and circumferential butt welds in ferritic pres-sure vessels greater than 2.0- to 12.0-inches nominal thickness shall beexamined.

Manual ultrasonic examination of pressure vessel welds andadjacent base material shall be performed from the inside or outside surface ofthe vessel.

SwRI Form 0 JL 3 2'


NUCLEAR PROJECTS OPERATlNG PROCEOURE.[s .

r~ A)

SvRI-NDT-600-1'evision

46September 1981

Page 21 of 33

7.6.4 Strai ht-Beam Examination of Melds

A straight-beam examination shall be applied when possible, tothe surface of the weld crown and 1/2t of base material on each side of theweld. Calibration for the straight-beam examination shall be in accordancewith Paragraphs 6.2.1 and 6.2.3.

7 ~ 6.5 An le-Beam Examination for Indications Per end'icular to theMeld

Angle-beam examination shall be conducted using a 45'2'nd60'2'hear"wave search unit. This examination shall be conducted by placingthe search unit on the weld with the sound beam directed into and parallel withthe veld to detect indications perpendicular to the weld. The length of theweld as specified in the applicable examination plan and 1/2t of base materialon each side of the weld shall then be scanned with the search unit sound beamdirected in this manner. The search unit shall then be turned 180'nd thescan repeated. Calibration for these examinations shall be in accordance with

'aragraphs6.2.2 and 6.2.4 (or '6.2.5).

7.7 Nozzle-to-Vessel But t Melds

Manual ultrasonic examination of nozzle"to-vessel butt welds inferritic vessels greater than 2.0- to 12.0-inches nominal thickness shall beperformed from the inside or outside surface of the vessel.

Base material ad)acent to the weld for a distance of 1/2t fromthe fusion line of the weld shall be examined.

I

7.7.1 Base Material Lamination Scan

A lamination scan using a straight-beam search unit shall beperformed before'he angle-beam examination. This examination shall cover asmuch as practical of the area through which the angle-beam is later to bepassed. Screen distance calibration for this examination shall be conducted inaccordance with Paragraph 6;2.1. Scanning sensitivity shall be as required tomaintain the first back reflection at an amplitude of 80X of PSH.

Intermediate echoes having an amplitude equal to or greaterthan the remaining back reflection shall be recorded. To record an inter-mediate indication, obtain a back reflection signal from an indication-freearea and ad5ust the instrument gain controls until this signal is at 80X ~5/ o:PSH; then record the intermediate indication when its amplitude is equal to theremaining back reflection- If total loss of back reflection accompanies theintermediate echo, the area of total loss of back reflection shali be recordedon the appropriate SwRI examination record.

swRr Fnrm QA 3 2'

S OUTHWEST RESEARCH INSTITUTE

NUCLEAR PROJECTS OPERATING PROCEOUREIS-

,, .I~P

SwRI-NDT-600-15'evision

46September 1981

Page 23 of 33

8.0 RECORDING CRITERIA.

Ultrasonic reflectors producing a response 50Z or greater of the refer-ence level and planar surface reflectors equal to or exceeding the responsefrom the square notch shall be recorded on the appropriate SwRI examinationrecord.

Indications shall be recorded utilizing the techniques outlined in theapplicable revision of SwRI Nuclear Projects Operating Procedure IX-PE-118.

Indications producing a response 50Z or greater of the reference leveland planar surface reflectors equal to or exceeding the response from thesquare notch shall be investigated by a Level II or a Level III examiner to theextent necessary to determine the shape, identity, and location of thereflector.

Indications 50Z or greater of the reference level and planar surfacereflectors equal to or exceeding the response from the square notch investi-gated and found to be other than geometrical in nature shall be reported to thecustomer for evaluation.

When an examination is performed from the unclad side of a clad vesseland the calibration is as specified in Paragraph 6.2.5, indications observedpast the 4/8 vee-path shall not be recorded.

Scanning limitations shall be recorded-

9.0 EVALUATION

Evaluation of reportable indications shall be the responsibility of thecustomer, or the customer's representative, and shall be conducted in accordance with the ASME Boiler and Pressure Vessel Code, Section XI, IWA-3000. Theapplicable year and Addenda of the Code shall be as specified in Paragraph2.1(1) of this procedure.

10.0 RECORDS

The customer shall receive copies of documents „generated in accordancewith this procedure in the examination report.

The onsite control of examination records generated in the field shall bein accordance with SwRI Nuclear Projects Operating Procedure X-PE-3.01-1.

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SMRI-NDT-600-1SRevision 46September 1981Page 27 of 33

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Sw.R.I. SONIC INSTRUMENT. CALIBRATION RECORD FOR ATTENUATION/LAMINATIONEXAMINATIONPROJECT tlo.:

EXAMItlER: { SIGNATUAE )

EXAhlltIEA: (OPEAATOA )

SITE:

SNT LEVEL

SNT LEVEL

pnoGEDunEHo.

AEV.

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DATE' DAY"MOtl."YR.) TIME: (24 IIA CLOCK) SIIEET No.:

SEAAGII UNITS

0 (L S ) 0 (ATT)OAAtlD SEAtAL I{UMBER

AEFEAEtlCE OLK. tto.:

CALIOAATION VEAIFICATIOII

TIME

INITIALS

SI7 E

t Ohltt{ALFREO. {hlllz)

ItlSTAUMEtlT SETTINGS

REJECT:

TIME

INITIALS

10 SCAEEtl DIVISIONS E ItlCltES Of hlETAL

hlODE 'OtlGITUDIHAL

AEhlAAKS:

FREQUENCY:

DELAY:

MATL. CAL:

flAIIGE

DAMPING:

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BASIC CALIBRATIONBLOCK No.

I ST ECIIO dO LINES OF AIIPLIZUDE

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FONQ NO. 5WAI Il 54 I llfV, 4 45 llI

SOUTHWEST R ES EAR CH INSTITUTENUCLEAR PROJECTS

OPERATING PROCEDURE

SwRI-NDT-700-5Revision 9December 1981

Page 1 of 23

TitleMECHANIZED ULTRASONIC EXAMINATION OP VESSEL COMPONENTS, VESSEL WELDS,

AND PIPING WELDS

EFFECTlVITY AND APPROVAL

Revision~ oi this nrocedure became attentive on'

. Other revisions oi tha base document mayJan. 04,1982

be effective concurrently.

SA

Approvals

Date

IQ~ 8(

Date

~ized~,

Technical Review

Mvmps

(Pf/7

Date«n

~/~~

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The following information may be used for convenience. mpletioh of this portion is not mandatory.r u

Deviation No.

Date Effective

Procedure Sec:ion(slAffected

Notes:

swRI Focm oA-40A.0

SOUTHWEST RES EARCH INSTITUTE SwRI-NDT-700-5Revision 9December 1981

NUCLEAR PROJECTS OPERATlNG PROCEDURE Page 3 of 23

calibration block to be either "t," no more than 25Xless than "t," or closer in thickness to the produc-tion material than the 3/4-inch alternate thicknessallowed by Article 5 for production material thick-nesses up to and including 1 inch. This exceptionwill assure a more accurate calibration than theArticle 5 basic calibration block design allowed byCode.

(b) Subsubparagraph T-535.1 (d) of Article 5 states thattransfer (attenuation compensation) be accomplishedbetween the production material and basic calibrationblock and a correction made for the difference. Noattempt shall be made by the examiner to compensatefor observed difference in "the acoustic propertiesbetween the basic calibration block and the produc-tion material, as referenced in 7.1.

(3) ASME Boiler and Pressure Vessel Code, Section IX, 1977Edition with Addenda through Summer 1978 "Welding andBrazing Qualifications"

(4) SwRI Nuclear Quality Assurance .Program Manual (NQAPM)

3.0 RESPONSIBILITY

(1) The Director of the Department of Engineering Services within theQuality Assurance Systems and Engineering. Division shall beresponsible for the preparation, review, control, and approval ofthis procedure.

(2) The Project Manager shall be responsible for the implementation ofthis procedure in accordance with the NQAPM specified in theapplicable SwRI Project Plan.

(3)

(4)

The examiner shall be responsible or implementing the require-ments of this procedure.

I

The Manager of the Support and Administration Section of theQuality Assurance Systems and Engineering Division shall beresponsible for storage of records generated in accordance withthis procedure.

swRI Form QA3-2

SOUTHWEST RESEARCH INSTITUTESwRI-NDT-700-5Revision 9December 1981

NUCLEAR PROJECTS OPERATING PROCEOURE Page 5 of 23

5.0 PERSONNEL AND E UIPHENT

5.1 Personnel Certification

Personnel performing examinations in accordance with thisprocedure shall be certified in accordance with-SwRI NQAP ll-l, "SpecialProcess Control.",

5.2 Reference Block

Reference blocks to be used for screen distance calibration andverification shall be as follows:

(1) SwRI Half-Round (Sketch 1)

(2) AWS Type DC (Sketch 2)

(3) IIW (Sketch 3)

The reference block shall be of the same basic material as theproduction material; i.e., carbon steel or stainless steel.

5.2.1 Reference Block Selection

calibration:Reference blocks shall be used as follows for screen distance

ScreenDistance

1.0", 2

''.5",

5.0"l 10.0"

Block Tyne

SwRI Half-RoundAWS Type DC

IIW

SwRI Half-RoundAWS Type DC

IIW

BlockDimension

] plf

P 5" or 1 0"pll

pllpll

] plf

20.0" IIW 4 plf

SwRI Farm OA 3-2„




Page 7 of 23

A flat basic calibration block or block of essentially the samecurvature as the part to be examined shall be used for examinations on contactsurface curvatures greater than 20 inches in diameters

For contact surfaces 20 inches or less in diameter, a singlecurved basic calibration block may be used to establish sensitivity calibrationfor examinations conducted on contact surfaces in the range of curvature from0.9 to 1.5 times the basic calibration block

diameter.'.4

Search Units

The size of search units shall be selected according to thefollowing table: ~

(1) An le Beam

Nominal ProductionMaterial Thickness Nominal Search Unit Size

0.4" to 1.0"0.4" to 2.0"0.75" to 4.0"2.0" to 7.0"5.0" to 12.0"

1/4" x 1/4", 1/4" Round3/8" x 3/8", 3/8" Round1/2" x 1/2", 1/2" Round1/2" x 1", 3/4" Round1" x 1", 1" Round, 1-1/8" Round

Nominal ProductionMaterial Thickness Nominal Search Unit Size

0.4"1.0"2.0"3 0I~

5.0"

to 2.0"to 3.0"to 4.0"to 7.0"to 12.0"

1/4" Round3/8" Round1/2" Round3/4" or 1" Round1" Round or 1-1/8" Round

The exit point of the sound beam and the 'actual refracted beamangle of shear-wave search units shall be determined on an IIV block. The exitpoint shall be marked on the search unit wedge.

Search unit wedges shall be fabricated to ensure that the properangle of refracted snear- or longitudinal-waves are produced in accordance withthe appropriate SwRI Scan Plan.

SwRI Farm QA 3-2




Page 9 of 23

(3) Light oil or other compounds which, in the opinion of theLevel II examiner, provide adequate ultrasonic coupling maybe used upon concurrence of the Project Manager respon-sible for the examination.

(4) All couplants other than deionized water shall be certifiedfor sulfur content and total halogens in accordance withASTM D-129-64 and ASTM D-808-63. The residual amount oftotal sulfur or halogens shall not exceed 1X by weight.Deionized water, when used, shall be supplied by thecustomer.

5.7 Thermometer

Quicktemp thermometer Model 5X-666, calibrated and certified inaccordance with SwRI Nuclear Pro)ects Operating Procedure XII-PM-104 shall beused as required to measure basic calibration block and component surfacetemperature.

6+0 CALIBRATION METHOD

Calibration details such as vee-path positions and sweep distance shallbe described in the applicable SwRI Scan Plan.

The complete ultrasonic examination system calibration shall be per-formed prior to the examination.

NOTES

The "REJECT" control shall be maintained in the "0" position during'calibration and examination.

The nominal piping production material thickness shall be used to deter-mine the correct calibration block and search units for the examinationof piping components which may be thicker than the nominal pipe size andwelded to the pipe. The Level II examiner shall ensure that completecoverage of the thicker piping component is obtained. Additional cali- ~

bration vee-path positions and larger screen sizes may be required toassure this coverage. The additional calibration vee-path positions andlarger screen size shall be used for the examination from the thickercomponent and the nominal pipe side of the weld.

The "PREQ MHz" control shall be turned to "1" when a 1.5 MHz search unitis used and to "2" with a 2.25 MHz search unit.

SwRI Form QA 3.2




Page 11 of 23

(4) With the larger indication at 100X, record and the positionof the smaller indication, estimated to the nearest 1X ofFSH.

(5) Successively set the larger indication from 100X to 20X ofFSH in 10X increments (or 2 dB steps if a fine control isnot available) ~ Observe and record the smaller indication,estimated to the nearest 1X of FSH, at each setting. Thereading must be 50X of the larger amplitude within 5X ofFSH.

6.1.2 Amnlitude Control Linearit

EXCEPTION

Am amplitude control linearity check is not required if anelectronic DAC is utilized and/or the gain controls are notto be manipulated.

(1) Position a shear~ave search unit on an SwRI Half-Roundreference block to obtain maximum amplitude from theradius.

(2) Without moving the search unit and according to thefollowing table, set the indication to the required percentof the FSH and increase or decrease the dB as specified.The signal shall be estimated and recorded to the nearest1X of FSH and shall fall within the limits of the followingtable:

IndicationSet at X ofFull Screen

dB ControlChan e*

IndicationLimits, X ofFull Screen

80X80X40X20X

-6 dB-12dB+6dB+12dB

32 to 48X16 to 24X64 to 96X64 to 96X

*Hinus denotes decrease in amplitude; plus denotesincrease.

6.2 Strai ht-Beam Distance Calibration

Distance calibration for circumferential welds and longitudinalwelds shall be constructed by observing the back reflections from an applicablereference block and adjusting the "KKTrL CAL," "DELAY," and "RANGE" controls

swRI Form QA 3-2

SOUTHWEST RESEARCH INSTlTUTESwRI-NDT-700-5Revision 9December 1981


Position the search unit to obtain maximum response from thebasic calibration hole at 1/2T. Adjust this amplitude to the primary referencelevel at 50% ~5% of full screen height (PSH) and mark the amplitude on thescreen. A straight horizontal line shall then be drawn on the instrumentscreen at the amplitude of the primary level. The line shall extend a distanceequal to the nominal thickness of the production material. All indicationsrecorded shall be referenced as a percentage of this line for signal amplitude.

6.5 Electronic Distance Amnlitude Correction

Electronic DAC is used to set reflector responses from a cali-bration block equal in amplitude regardless of the distance of the reflectorfrom the search unit.

6.5.1 An le Beam and Strai ht Beam for Welds

Electronic DAC curves shall oe constructed by utilizing theresponses from the basic calibration hole(s). The initial point on the DAC

curve is established by manipulating the search unit to obtain maximum responsefrom the nearest suitable position. The instrument gain is then adjusted sothat this response is 50% ~5% PSH. This is the primary reference response andshall be marked on the instrument screen. The search unit shall be placedsimilarly at other required positions. Using the electronic DAC controls,adjust remaining responses to the primary reference level and mark theiramplitudes on the screen. These points shall be joined by a straight hori-zontal line, not to extend more than 1/8 vee-path or 1/4T beyond the lastqualified calibration point.

6.5.2 Multinle-Point Zone Calibration

Maximum response from the nearest suitable reflector shall beobtained by manipulating the search unit. Adjust the instrument gain to setresponse at 50X ='5% PSH. This is the primary reference response and shall bemarked on the instrument screen. The search unit shall be placed to obtainmaximum response from the other required reflectors. Using the electronic DAC

controls, adjust their maximum responses to the primary reference level andmark their amplitudes on the screen. These points shall be joined by astraight horizontal line, not to extend more than 20% of the wall thickness toeither side of the calibrated zone.

6.5.3 Sin le-Point Zone Calibration for Inner Radius Without UsinElectronic Distance Am litude Correction

Examination of the inner radius from the inside surface shall beconducted without using the electronic DAC controls. Two search units shall be

SwRI Form QA 3-2

0




Page 15 of 23

(3) The last calibration verification at the end of a shiftshall be conducted during the interface period and inconjunction with the oncoming crew. The two crew leadersshall verify the calibration together as a handoff. Bothcrew leaders'nitials should appear on the calibrationsheet for verification conducted in this manner.

NOTES

The mechanized positioning equipment calibration shall beverified in conjunction with the instrument calibrationverification or at least every 12 hours during the exami-nation. Device counts per increment shall be verified tocoincide with counts per increment as specified in the ScanPlan examination tables'he "0" position and linearity ofthe X and Y readout shall be veriried in accordance withthe appropriate Operating Guide.

Ultrasonic instrument functional checks shall be conductedevery 4 hours during scanning to determine if any apparentfunctional changes have occurred in the instrument. H'nyreflector from the function block has moved on the sweepline more than 5X of full screen width or changed in ampli-tude more than 20X or 2 dB, the instrument calibrationshall be verified on the appropriate reference and basiccalibration blocks.

6 6.2 Calibration Chan es

(1) Perform the following if any point on the DAC curve hasdecreased more than 20X or 2 dB in amplitude, any point onthe DAC has moved on the sweep line more than 5X of fullscreen width or more than 10/ of the sweep divisionreading, whichever is less:

(a) Void all examinations referring to the calibration inquestion and performed after the last valid calibra-tion verification.

(b) Conduct a new calibration.

(c) Reexamine the areas for which examinations have beenvoided.

SwRI Farm OA3.2

SOUTHV/EST R ES EAR CH INSTITUTE


SwRX-NDT-700-5Revision 9December 1981

Page 17 of 23


(6) Couplant (which shall be the same as used in the actualexamination)

(7) Signature and ultrasonic certification level of examinermaking calibration

(8) Date calibrated

(9) Time of calibration and calibration verification'I

7.0 EXAMINATION

7.1 Examination Areas

The following are specific areas on which mechanized ultrasonicexamination of pressure vessel welds, piping welds, adjacent base material, andcomponents from the inner or outer surface of pressure vessels shall beperformed:

(1) Piping welds and adjacent base material in a thicknessrange of greater than 0.4 inch and up to 5.0 inches

(2) Vessel welds and adjacent base material in a thicknessrange of greater than 0.4 inch and up to 2.0 inches

(3) Nonwelded vessel'omponents (i.e., nozzle inner radius, andintegral extensions)'n a thickness range of greater than0.4 inch and up to 12.0 inches

Attempts to determine differences in the acoustic propertiesbetween the basic "calibration block and the production material which wouldresult in an instrument gain change are not permitted.

F 1.1 Vessel Welds

Examinations shall be performed on components in their completedcondition. Examination of vessel welds shall include the weld and base mate-rial for 1/2t from the fusion line of the weld. The required 1/2t examinationarea on base material thicknesses that differ on each side of the weld shall bedetermined by the nominal thickness of the base material on the side or theweld from which the examination is to be performed. The 1/2t to be examinedshall be measured from the outside sur ace fusion 1'ine at the weld

crown.'he

examination of vessel welds and adjacent base material shallbe conducted with a 45'2'nd a 60'2'earch unit . The 45'2'nd the

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-700-5Revision 9December 1981

NUCLEAR PROJECTS OPERATlNG PROCEDURE Page 19 of 23

coverage for piping welds shall be adequate to examine the required portion ofthe weld and base material for 1/4 inch, as measured from the fusion line oneach side of the weld. Scanning coverage for nonwelded components shall bespecified in the applicable SwRI Scan Plan.

Examination techniques including search unit angles, contactsurface and examination coverage will be described in the detailed SwRI ScanPlan for the particular examination. The SwRI Scan Plan shall be approved bythe Director of the Department of Engineering Services.

sensitivity.Scanning shall be performed at the primary reference level

The search unit movement rate for scanning shall not.exceed 6inches per second.

Before the angle-beam examination of welds, a lamination scanusing straight-beam shall be performed, covering as much as practical of thearea through which the angle beam is later to be passed. Screen distance cali-bration for this examination shall be conducted in accordance with Paragraph6.2 of this procedure. Scanning sensitivity shall be as required to maintainback reflection at an amplitude of between 50X and 90% of FSH.

This lamination scan is performed by noting whether back echoesare lost or intermediate echoes are observed in any of the areas to be examinedwith an angle-beam search unit. Intermediate echoes having an amplitude equalto or greater than 50% of the initial back reflection shall be recorded. Torecord an intermediate indication, obtain a back reflection signal from anindication-free area and adjust the instrument gain control until this signalis at 75% ='5% of FSH. Record the intermediate indication when its amplitude isequal to 50X of the initial back reflection and accompanied by a 50X loss ofback reflection. If total loss of back reflection accompanies the intermediateecho, the area of total loss of back reflection shall be recorded.

7.4 Postexamination Cleanin

Arrangements shall .be made with the„customer for postexaminationremoval of couplant materials.

8.0 RECORDING CRITERIA-

Ultrasonic reflectors producing a response greater than 50% of the refer-ence level shall be recorded. Indications found to be greater than 50% of thereference level and not readily attributable to geometry by the examiner, whenscanning in the X direction (length of indication), shall require scans in the

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SwRI-NDT-700-5Revision 9December 1981Page 23 of 23

IIW REI-"REICE ELOCK

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SO UTHWEST R ES EAR C H I NSTITUTENUCLEAR PROJECTS

OPERATING PROCEDURE


Page 1 of 27

MECHANIZED ULTRASONIC EXAMINATION OF FERRITIC VESSELS GREATER

THAN 2.0 INCHES IN THICKNESS

EFFECTIVITYAND APPROVAL

Revision >0 ot this qrocedure became eifective on ~hh ~ ~ . Other revisions of the base document maybe effective concurrently.

Approvals

Wrinan By r; .inert -:„~(„I

Manager of Q.A

Date

Date

Technical Review Datev

/ Ifnjr

v

Date

I Ji'hefollowing information may be used tor convenience. Completion of this portion is not mandato~.

Deviation No.

Date Effective

Procedure Section(slAffec:ed

Notes:

swRI Fare QA-'0A-0

CR"' NUCLEAR PROJECTS OPERATING PROCEDURE


Page 3 of 27

3.0 RESPONSIBILITY

(1) The Director of the Department of Engineering Services, QualityAssurance Systems and Engineering Division, shall be responsiblefor the preparation, review, approval, and control of thisprocedure.

(2) The Project Manager shall be responsible for the implementation ofthis procedure in accordance with the NQAPM specified in theapplicable SwRI Project Plan.

(3) The examiner shall be responsible for implementing the requirementsof this procedure.

(4) The Manager of the Support and Administration Section of theQuality Assurance Systems and Engineering Division shall beresponsible for storage of reco'rds generated in accordance withthis procedure.

4.0 CODE AND PROCEDURE RE UIREMENTS

The requirements listed below shall be applied when performing mecha-nized ultrasonic examinations in accordance with this procedure.

Re uirements Section

(1) Weld types and configurations to beexamined, including thickness dimensi,onsand product form

7.0

(2) The examination surface(s)

(3) Surface condition

(4) Couplant

(5) Technique used

7.0

7.0

5.0

2.0

(6) Angles and mode of wave propagation inthe material

5.0'I

(7) .Type and size of search unit 5.0

swRI Farm QA 3.2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-700-6Revision ~ 10December 1981

MW

R'-I'UCLEARPROJECTS OPERATING PROCEDURE Page 5 of 27

5.2.1 Reference Block Selection

calibration:Reference blocks shall be used as follows for screen distance


BlockDimension

5.0" SwRI Half-RoundAWS Type DCIIW

1.0"1.0"1.0"

10.0", 20.0" IIW 4.0"

(2) An le-Beam

ScreenDistance Block Tv e

BlockDimension

5 0 11 SwRI Half-RoundAWS Type DC

'.0" Radius1.0" and 2.0"Radii

5.3

10.0"

20.0", 40.0"

Basic Calibration Block

SwRI Half-Round,AWS Type DC

IIW

IIW Block

1.0" Radius1.0" and2.0" Radii4.0" Radius

4.0" Radius

If examinations are to be conducted on a clad component, thebasic calibration block shall be clad to the nominal thickness of the componentcladding 21/8 inch. Deposition of clad shell be by the automatic method usedon the inside of the component. Where the automatic method is impractical,deposition of clad shall be by the manual method used to cover the circum-ferential welds of the component .

SwRI Form QA3-2


NUCLEAR PROJECTS OPERATING PROCEDURE Page 7 of 27

Avera e Weld Thickness Nominal Search Unit Size

2.0" to 4.0" 1/2" x 1/2", 1/2" Round2 '" to 7.0"5.0" to 12.0" 1" x 1", 1" Round, 1-1/8" Round

The exit point of the sound beam and the actual refracted beam

angle of shear-wave search units shall be determined on an IIW block. The exitpoint of the sound beam shall be marked on the search unit wedge.

Search unit wedges shall be fabricated to produce 45'2'nd60'2'efracted shear-waves as demonstrated on the IIW block. A search unitproducing 0'traight-beam longitudinal-waves shall also be used.

Other angles may be used for examination of:

(a) flange welds, when the examination is conducted from theflange face,

(b) nozzles and nozzle welds, when the examination isconducted from the nozzle bore,

5.5

(c)'xamination of double taper junctures.

The nominal search unit frequency shall be 2.25 MHz.

Ultrasonic Instrument and Scannin Mechanisms

The examiner shall select an appropriate ultrasonic instrumentfrom the following:

(1) Sonic PTS Mark II(2) Sonic UWA Mark III(3) Branson Sonoray Series 600

Rota ing, revolving, or scanning mechanisms used when

performing mechanized ultrasonic examinations shall be described in the SwRI

Scan Plan.

SwRI Form QA 3.2

S-R~ NUCLEAR PROJECTS OPERATING PROCEDURE


Page 9 of 27

Linearity Verification Record and the sheet number referenced on the applicableSwRI Instrument Calibration Record. An angle-beam search unit and the )/2T and

3/4T holes in a basic calibration block shall be utilized to conduct theinstrument, linearity checks.

6.F 1 Amplitude Linearity

(1) Position an angle beam search unit on a basic calibra-tion block to obtain indications from the 1/2T and 3/4Tholes.

(2) Adjust the search unit position to give a 2-to-1 ratiobetween the two indications, with the larger indicationset at 80/ of full screen height (FSH) and the smallerindication set at 40% of FSH.

(3) Without moving the search unit, adjust the instrument sen-sitivity (gain) to set the larger indication'o '00% ofFSH.

(4) With the larger incication at 100/, record the positionof the smaller indication, estimated to the nearest 1% ofFSH.

(5) Successively set the larger indication from 100/ to 20%

of FSH in 10% increments (or 2 dB steps if a fine controlis not available); observe and record the smallerindication estimated to the nearest 1/ of FSH at eachsetting. The reading must be 50/ of the larger amplitudewithin 5% of FSH.

6.1.2 Amnlitude Control Linearit

EXCEPTION

An amplitude control linearity check is notrequired if an electronic DAC is utilizedand/or the gain controls are not to bemanipulated.

(1) Position an angle-beam search unit on an applicable basiccalibration block to obtain maximum amplitude from the1/2T hole.

(2) Without moving the search unit and according to thefollowing table, se" the indication to the required

swRI Farm QA 3.2

SOUTHWEST RESEARCH,INSTITUTESwRI-NDT-700-6Revision 10December 1981

SR"I I'"

NUCLEAR PROJECTS OPERATING PROCEDURE Page ll of 27

(3) Using the oscilloscope controls obtain a stable RF wave-form. Using the delayed sweep function of the oscillo-scope expand the desired RF waveform to a suitable formfor photographing.

(4)'heck the CRT sweep intensity for enough brightness for a

good photograph. With the CRT camera, obtain a Polaroidpicture of the RF waveform. Label the picture as to theUT instrument serial number, remote pulser channel, andoscilloscope control settings; i.e , VOLTS/DIV, TIME/DIV,and DELAY TDK, and delay time position control.

For the reflector RF waveform the following shall be performed:

(1) Preset control on Tektronix oscilloscope, capable ofdelayed sweep, or equivalent oscilloscope to measure anRF waveform of approximately 0.5 volts, peak to peak.

(2) Using a coaxial cable approximately four feet longconnect oscilloscope channel one to the RF output )ackprovided on the UT instrument.

(3) Using the oscilloscope controls obtain a stable RF

waveform. Using the delayed sweep function of theoscilloscope expand the desired RF waveform to a suitableform for photographing.

(4) Check the CRT sweep intensity for enough brightness for a

good photograph. With the CRT camera obtain a polaroidpicture of the RF waveform. Label the picture as to.UTinstrument serial number and oscilloscope controlset tings; i.e., VOLTS/DIV, TIM/DIV, DELAY TDE, anddelay time position control.

6.2 Calibration

Calibration details such as vee-path positions and sweep dis-tance shall be described in the applicable SwRI Scan Plan. 8

The complete ultrasonic examination system calibration shall be

performed prior to the examination.

swRI Form QA 3-2

SOUTHWEST RESEARCH INSTlTUTE


SwRZ-NDT-700-6Revision 10December 1981

Page 13 of 27

shall be constructed by observing the back reflections from an applicablereference block and adjusting the "MAT'L CAL," "DELAY," and "RANGE" controls ofthe instrument to obtain the required linear sound path distance displayedalong the screen baseline. The screen distance chosen shall be the shortestapplicable size to include at least 1/4t beyond the nominal production materialthickness.

Distance calibration for vessel-to-flange welds from the sealsurface and nozzle-to-shell welds from the inner bore shall be constructed byobserving the back reflections from an applicable reference block and adjustingthe "MAT'L CAL," "DELAY," and "RANGE" controls of the instrument to obtain therequired linear sound path distance displayed along the screen baseline'hescreen distance chosen shall be the shortest applicable size to include atleast 25% of the wall thickness beyond the anticipated examination distance.

6.2.2 An le-Beam Distance Calibration

Distance calibration for the examination of nozzle-to-shellwelds from the vessel surface, circumferential welds, and longitudinal weldsshall be constructed by observing the radius echoes from an applicable ref-erence block for the material and th'ckness involved and adjusting the "HAT'LCPJ„" "DELAY," and "RANGE" controls of the instrument to obtain the requiredlinear sound path distance displayed along the screen baseline. The screendis ance chosen shall be the shortest applicable size to include at least 1/8vee-path beyond the examination range ~

Distance calibration for nozzle-to-shell welds from the innerbore shall be constructed by observing radius echoes from an applicable ref-erence block fo- the material and thickness involved and adjusting the "MTrLCAL," "DELAY," and "RANGE" controls of the instrument to obtain the requiredlinear sound path distance displayed along the screen baseline. .The screendistance chosen shall be the shortest applicable si e to include at least 25%

of the wall thickness beyond the anticipated examination distance.

The search unit wedge shall be removed prior to the preliminarydistance calibration for examinations in which angle-beam longitudinal-wavesearch units are used. Observing the back reflections from an applicablereference block, adjust the "FATrL CAL," "DELAY," and "RANGE" control of theinstrument to obtain the required linear sound path distance displayed alongthe screen baseline.

Remount and couple the search unit wedge to the search unitafter the preliminary distance calibration of the angle-beam longitudinal wavesearch unit. Position the search unit on the basic calibration block andobtain the maximum response from a reflector. Physically measure the metalpath distance to this reflector and adjust the signal to the appropriate

SwRI Form QA 3.2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-700-6Revision 10December 198]


(2)

(3)

The search unit shall be placed similarly at the otherrequired vee-path positions. Using the electronic DAC

controls adjust their responses to the primary referenceresponse and mark their amplitude on the screen-

Join these points with a straight horizontal line.

(4) With the instrument gain set at the primary referencelevel, position the search unit to obtain maximum ampli-tude from the square notch on the opposite surface. Harkthe signal amplitude with an "X." The indication fromthe square notch must be considered when evaluatingreflectors at the opposite surface.

6.3.2.2 Distance Amnlitude Correction from the Unclad Side

(1) Electronic DAC curves shall be constructed by utili ingthe 1/8, 2/8, and 3/8 vee"path responses from the basiccalibration holes at 1/4T, 1/2T, and 3/4T. The initialpoint on the DAC curve is established by manipulating thesearch unit to obtain maximum response from the 1/8 vee-path position. The instrument gain shall be adjusted toset this response at or between 40% to 80% PSH. This isthe primary reference response and 'shall be marked on theinstrument screen.

(2) The search unit shall be placed similarly at the othe".required vee-path positions. Using the electronic DAC

controls adjust the responses to the primary referenceresponse and mark their amplitude on the screen.

(3 ) Join these points with a straight horizontal line, thelength of which shall extend 1/4T beyond the lastqualified calibration point ~

(4) With the instrument gain set at the primary referencelevel, position the search unit to obtain maximumamplitude from the square notch on the opposite surface.Hark the signal amplitude with an "X." The indicationfrom the square notch must be considered when evaluatingreflectors at the opposite surface.

6.3.3 Hultinle-Point Zone Calibration

Haximum response from the nearest suitable reflector shall be

obtained by manipulating the search unit. Adjust the instrument gain so thisresponse is set at 40% to 80% FSH. This is the primary reference response and

SwRI Form QA 3.2

SOUTHWEST RESEARCH lNSTITUTE



Page 17 of 27

(5) Position the search unit to obtain maximum amplitude fromthe 1/4T hole. Move the search unit toward the holeuntil the indication equals the 50% DAC linc'easureand record the distance from the incident point of thesearch unit to the scribe line above the 1/4T hole (Wl) ~

(6) Hove the search unit away from the hole until the indica-tion equals the 50% DAC line. Measure and record thedistance from the incident point of the search unit tothe 1/4T scribe line (W2).

(7) Repeat steps (5) and (6), recording the measurements forthe 1/2T'nd 3/4T holes.

(8) Plot these points on a 1:1 or 2:1 scale drawing of thebasic calibration block thickness or on the graph on theback of the SwRI Beam Spread Record. "W's" are plottedusing the horizontal scale of the graph, placing thepoints at the appropriate depth (1/4T, 1/2T, or 3/4T).

(9) Draw a separate line to eacn of the Wmax points from theincident point of the search unit.

(10) The angle to each of the points shall be measured using aprotractor. The beam angle shall be established by deter-mining the average of the three Wmax angles measured.This angle shall be recorded on the SwRI Beam SpreadRecord and considered'during resolution of indications ~

(ll) Connect the three Wl points extending the line to thesearch unit drawn at the top of the graph. Repeat thisoperation for the W2 points ~ If the three Wl or W2

points do not form a straight line, a line representingthe average of the three points shall be drawn andextended until they cross (the three points must beprojected along the same beam path on the block drawingto complete this task) ~

(12) Measure the angle between the Wl line and W2 line. Thisis the angle of beam spread.

6.6 Calibration Verification

6.6.1 Freauenc of Instrument Calibration Verification

Sweep range calibration shall be verified on the appropriatereference block; and DAC curve calibration, if applicable, shall be verified onthe basic calibration block:

swRI Form QA 3.2

SOUTHWEST RESEARCH lNSTlTUTEMW


SwRE-NOT-700-6Revision 10December 1981

Page 19 of 27

6.6.2 Calibration Chan es

(1) Perform the following if any'point has moved on the sweep,line more than 5X of full screen width, or more than 10X

of the sweep division reading, whichever is less, or -anypoint on the DAC curve has decreased by 20% or 2 dB inamplitude:

(a) Void all examinations referring to the calibrationin question and performed after the last validcalibration verification.

(b) Perform and record a new calibration.

(c) Reexamine the areas for which examinations havebeen voided.

(2) Perform the following if any point on the DAC curve hasincreased by 20% or 2 dB in amplitude:

(a) Correct the calibration.

(b) Reexamine any indications recorded since the lastvalid calibration verification.

(c) Enter proper values on a new SwRI ExaminationRecord.

6.6.3

recalibration:

Recalibration

Substitution of any of the following, shall be cause for

(1) Search unit (wedge, module, or transducer)

(2) Couplant

(3) Ultrasonic instrument

(4) Examination personnel (substitution of examination person-nel shall be defined as any substitution of the Level Tlor Level ZIi crew leader during a shift)

(5) Cable type or length

(6) Change in type of power source; e.g., a change from alter-nating to direct current

SwRI Form QA3.2

SOUTHWEST RESEARCH INSTITUTESwRI-K)T-700-6Revision 10December 1981

n wrra

RIl.1


(3) This procedure is applicable to ultrasonic examinationsof components greater than 2.0 inches and up to 12.0 inchesin thickness.

Examinations shall be performed on components in theircompleted condition. Veld examinations shall include the weld and basematerial for 1/2t from the fusion line on each side of the weld. The 1/2t tobe examined shall be measured from the fusion line at the weld crown.

7.2

The transfer method shall not be used.

Surface Condition

The contact surfaces shall be free from weld spatter, rough-ness, or other conditions whicn interfere with free movement of the search unitor impair the trandmission of

ultrasound'.3

~Scannrn

Scanning overlap shall be a minimum of 10% of the search unitpiezoelectric element dimension perpendicular to the direction of scan. Scan-ning coverage for welded components shall be adequate to examine the weld and1/2t of base material from the fusion line of the weld.

Examination techniques including search unit angles, contactsurface, and examination coverage will be described in the detailed SwRI ScanPlan for the particular examination ~ The SwRI Scan Plan will be approved bythe Director of the Department of Engineering Services.

sensitivity.Scanning shall be performed at the primary reference level

The search unit movement rate for scanning shall not exceed6 inches per second.

Before the angle-beam examination, a lamination scan usinglongitudinal- -ave shall be performed, covering as much as practical of the areathrough which the angle beam is later to be passed'creen distance calibra-tion for this examination shall be conducted in accordance with Paragraph 6.2.1of this procedure. Scanning sensitivity shall be as required to maintain thefirst back reflection at a minimum amplitude of 80% of PSH.

This lamination scan is performed by noting whether back echoesare lost or intermediate echoes are observed in any of the areas to be examineewith an angle-beam search unit . Intermediate echoes having an amplitude equalto or greater than the remaining back reflection shall be recorded. To recordan intermediate indication, obtain a back reflection signal from an indication-free area, adjust the instrument gain control until this signal is at 80% of

swhl Form QA 3.2ll

SOUTHWEST RESEARCH INSTlTUTE~<L@ic NUCLEAR PROJECTS OPERATlNG PROCEDURE

I

'wRI-M)T"700-6Revision 10December 1981

Page 23 of 27

one-half degree). The recorded information shall include the indication travellength (metal path) and the transducer position for 10%, 20%, 50%,'nd 100X DAC

and the maximum amplitude of the signal.

~ Volumes of material not examined and the reason for thescanning limitation shall be recorded.

8.2 Investi ation and Sizin

Ultrasonic reflectors producing a response 20% or greater ofthe reference level and planar surface rerlectors 100X or greater of theresponse from the square notch shall be investigated by a Level II or aLevel III examiner to the extent necessary to determine the shape, identity,and location of the reflector.

8.2.1 Travelin Indications

Indications that travel on the horizontal baseline of theinstrument screen for a distance greater than indications from the calibrationholes (at 20X amplitude) shall be sized. Indications that travel shall berecorded and sized at 20X DAC. %hen the indication is sized at 20% DAC, thissize may be corrected by subtracting the beam width in the through-thicknessdirection ootained from the calibration hole (between 20X DAC points) that isat a depth at or near the flaw depth. If the indication exceeds 50X DAC, thesize shall be recorded by measuring the distance between 50% DAC levels withoutusing the beam-width correction. The determined size shall be the larger ofthe two.

8.2.2 Nontravelin Indications

Nontraveling indications above 20% DAC that continue for ascanning distance of more than 1 inch, plus the beam spread between 20% DAC

points shall be sized. The size of these flaws should be determined by measur-ing the distance oeween points at 50X DAC and between points at 20X DAC wherethe beam-width correction is made only for the 20% DAC size. The recorded sizeof the flaw is the larger of the two determinations .

8.3 ~Reaort|n

Ultrasonic reflectors 20X or greater of the reference level andplanar surface reflectors 100% or greater of the response from the square notchwhich are investigated and found to be other than geometrical in nature shallbe reported to the customer for evaluation.

If the size of an indication, as determined in accordance withParagraph 8.2, equals or exceeds the allowable'imits of Section ZI or the AS';E

Boiler and Pressure Vessel Code, the indications shall be reported.

swRI Form QA 3.2

~ I I~ g

~ ~ ~

I ~ ~ t ~

~ ~ ~


IIW REFt=R|=iMCE BLOCK

~ i ~ ~ iC'0Z CA

-WPIZ

TYP= 'P

60'0'

,OSI~V I ti 'iS 9I I I I II

YQT|=:Dii.R P~W AP.. &D'M6t CCKS WiTH P~QHTLY iver="PITO~W~ICN6 CR 0@i~ ~i=RATZN SLQT rMiii~~~ F ""SAM~~.

SKETCH 3

P ROCEDURK OEVlAT]0N

SITE:,,

St. Lucie, Unit 2

r"RONDURE / REVISION NO.

800-78/0OEYIATION NO.

2 !

lsAGE)

OATK REQU~I

1 OF 2 I 3 Februarv 1982

SEOTION t

6.011i12 OF 23

w

ct

~ 1tIIII I she 1 evr YvIIh Isis cculefIQI l stet ~ ~ 1onlleetlcn~ tc. I

Ust tech Ieoeiflc true uf cstesonon t te tc ~ se&lnc4 Ih tccetccnc ~)or104 ~ cotneoncet lcentlflcctleo ~ line i4ontlficctlon ~ vol4 i4entitlceticn

~

Hechanized ultrasonic examinations of RPV noz le-to-piping butt weldsto be performed during tne 1982 PSI at St. Lucie, Unit 2 shall be affectedby this deviation.

w

cf e

hj

'L ~OVM lO II i 1 lt l 3 1 I t* 1M ~ / t ~ \ C «I ~ ffstlcvs l uso theet corclhc tresescc I uccltiunel shoots oey 3 ~ usce lf neccssery )I

This deviation supercedes Deviation No. 1

6.0 Change 6.3.2.1 to read as follows:

6.3.2.1 Distance Amplitude Correction from the Clad Side or on NoncladBlocks - 45'nd 60'first half-vee)

I

(1) Electronic DAC curves shall be constructed by utilizing the1/8, 2/8, 3/8, and 5/8 vee-path responses from the basiccalibration holes at 1/4T, 1/2T, and 3/4T. The initialpoint on the DAC curve is established by manipulating thesearch unit to obtain maximum response from the 1/8 vee-path position. The instrument gain shall be adjusted toset this response at or between 40Z to 80Z PSH. This is theprimary reference response and shall be marked on the instru-ment screen.

w (2) The search unit .shall be placed similarly at the other requiredvee-path=positions. Using the electronic DAC controls, adjusttheir responses to the primary reference response and marktheir amplitude on the screen.

(3) Join these points with a straight horizontal line.

rucoI

tctI

0J

(cont'd on page 2)3. sue. Irtc yIQII ~ huoson cnenIt ~ Is ncceucoty cne unct It c ntcneoo te scceeolisn I us ~ tccittcnct Incols I t

neccssery )I

This change is necessary to change the calibration parameters to allow forexamination from the inside surface.

1 V n I Ieh Il ~ 't ~ 3

PROCEDURE DEVIATION

Sl TEc

St. Lucie, Unit 2

PROCEDURE / REVISlOH HO.

800-78/0DEVIATION NO. PAGE DATE REQUITED c

1 OF 6 )farch 30. 1982

SECTlON t PAGE

** OF 23i sttN i

e|lb ISI~ coslof tenetc. )

ipp L,l~ t serb specific oroe or colsponon t lo bo ~ soealned ln record coo ~

stet ~ ~ somtnet>on porlo4 ~ conponont l4ontlllection, line Idontltlcctlon, veld Identltlcotlon,

O

ccOIO4IC

O

Manual ultrasonic examinations of RPV nozzle-to-piping butt welds to be performedduring the 1982 PSI at St. Lucie, Unit 2 shall be affected by this deviation.

IZ

cc

*1.0, 2.0, 5.0, 6.0, 7.0, 8.0** Pages 2, 6, 10, 11, 12, 15, 16, 17, 18 and 19

s~VI4TIOK II I K Ia Ih I Ih I a hh K I I Ih I h ~ / II I I I I I Itcllev ~ I s ~ o ~ sect oordlnC pro poso4 ~ o44ltlooel shoots Dey bo oso ~ lf nocossory )a

Change 1.0 to read as follows:

This procedure provides the technical information and detailed steps required toensure a complete and accurate mechanized or manual ultrasonic examination of RPV

ferritic nozzle-to-piping butt welds in accordance with the applicable ASME Boilerand Pressure Vessel Code.

laaas

satIO

Change the first paragraoh of 2.0 to read as followsl

Mechanized and manual ultrasonic examinations shall be performed using shear-waveangle-beam and longitudinal-wave angle- and straight-beam, contact, pulse-echotechniques.

Add 2.2 to read as follows:

2.2 A licable Calibration and Examination Records

lal0sacc

sslaaI

lalIO

SwRI NDTR Form No.

17-1917-2517-3617-1817-1717-37

Add paragraph (4) to 5.5 to read as follows:

(4) Sonic FTS Mark T

Revision Date

7-10-807-10-809-22-767-31-75

12-10-792-18-80

ahc

snloOcc

JU$ TtptchTtott > Rocson chonco Is necessary cn4 vhct It ls 'ntondod tc cccocspllsh ( ooo eddltloncl shoots Itnecessary )a

These changes are necessary to allow manual ultrasonic examinations to be performedwith this procedure.

s'v nl feb st rc o s

'SwRI NDT-800-78/0Deviation No. 3March 30, 1982Page 3 of 6

(4) Join the calibration points with a smooth curved lineextended .to caver the examinations range but not morethan 1/4T beyond the last qualified calibration point.

6.3.2 An le-Beam Distance Am litude Correction from the Clad Sideor on Nonclad Blocks

6.3.2.1 First Half Vee (45'nd 60'.)

(1) Position the 45' 2'earch unit on the basiccalibration block to obtain maximum responsefrom the calibration vee-path position with thehighest amplitude from the following:

Hole 45'ee-Path Position

1/4T1/2T3/4T

1/82/83/8$ 5/8

(2) Adjust the gain controls to obtain the primaryreference response at 80X + 5% of FSH and markthis amplitude on the screen. The gain controlshall not be adjusted once the primary referencehas been established.

(3) Position the 45' 2'earch unit to obtain max-imum response from the three other vee-pathpositions and mark each amplitude on the instru-ment screen.

(4) Join the calibration points with a smooth curvedline to establish the distance amplitude correc-tion (DAC) durve.

(5) With the instrument gain set at the primary referencelevel, position the search unit (45' 2') for max-imum amplitude from the square notch on the oppositesurface. Mark the signal amplitude with an "X". TheMdication from the square notch must be consideredwhen evaluating reflectors at the opposite surface.

(6) Repeat steps (1) through (5) using a 60' 2''searchunit.

SwRI NDT-800-78/0Deviation No. 3March 30, 1982Page 5 of 6

(3) Position the 45' 2'earch unit to obtain maximumresponse from the two other vee-path positions andmark each on the instrument screen.

(4) Position the 45' 2'earch unit on the clad sideof the block. Determine the dB difference between the3/8 and 5/8 vee-path. Mark the location of the 5/8 vee-path on the baseline of the instrument.

r

(5) Position the appropriate search unit on the unclad sideof the block. Adjust the instrument gain controls tothe primary reference level established in step (2) andobtain the maximum response from the 3/8 vee-path.

(6) Decrease the signal from the 3/8 vee-path by the dBdifference determined in step (4). Mark the amplitudeof this signal at the predetermined location of the 5/8vee-path determined in step (4). Join the marks on theinstrument screen to construct the DAC curve.

(7) With the instrument gain set at the primary referencelevel, position the appropriate search unit to obtainmaximum amplitude from the square notch on the oppositesurface. Mark the signal amplitude with an "X". Theindication from the square notch must be considered whenevaluating reflectors at the opposite surface.

(8) Repeat steps (1) through (7) using a 60' 2'earch unit.

Change 6.6.1 (4) to read as follows:

(4) At least every 4 hours during the examination

Delete the last two paragraphs and note of 6.6.1.

Change 6.6.3 (4) to read as follows:

(4) Examination personnel

Change the first paragraph of 7.1 to read as follows:

Mechanized or manual ultrasonic examination of nozzle-to-piping buttwelds and adjacent base material from the inner or outer surface shall beperformed.

~~

SOUTHWEST RESEARCH INSTITUTENUCLEAR PROJECTS

OP ERATING P ROC ED U R E

SvRI-NDT-800-78Revision 0December 1981Page 1 of 23

Title

MECHANIZED ULTRASONIC EXAMINATION OF ST. LUCIE RPV NOZZLE-TO-PIPINGBUTT WELDS

EFFECTIVITYAND APPROVAL

Revision~ oi this procedure became effe ive on Jhn ~ 5 1982, Other revisions of the base document maybe effective concurrently.

Approvals

yyritten 8y

Manager of Q.A.

Date Technical Review

Date

l(&Pi 1 KJllZ

DateC mrI g~

pC/

Date

The following information may be used for convenience. Completion of this portion is not mandatory.

Deviation No.

Date Effec:ive

Procedure Action(s}Affec:M

Notes:

swRI Form cA~OAN

SOUTHWEST RESEARCH INSTITUTESwRX-NDT-800-78Revision 0December 1981


(2) The Project Manager shall be responsible for the implementation ofthis procedure in accordance with the NQAPM specified in theapplicable SwRX Project Plan.

(3) The examiner shall be responsible for implementing the requirementsof this procedure.

(4) The Manager of the Support and Administration Section of theQuality Assurance Systems and Engineering Division shall beresponsible for storage of records generated in accordance withthis procedure.

4.0 CODE AND PROCEDURE RE UXREMENTS

The requirements listed below shall be applied when performing mecha-nized ultrasonic examinations in accordance with this procedure.

Reauirements Section

(1) Weld types and configurations to beexamined, including thickness dimensionsand product form

7.0

(2) The examination surface(s)

(3) Surface condition

(4) , Couplant

(5) Technique used

7.0

7.0

5.0

2.0

(6) Angles and mode of wave propagation inthe material

5.0

(7) Type and size of search unit

(8) Examination frequency

(9) Search unit wedges, shoes, or saddles

(10) Ultrasonic instrument alignment

(11) Calibration method used

(12) Scanning

5.0

5.0

5.0

5.0

6.0

7.0

SwRI Form QA3.2

SOUTHVVEST RESEARCH INSTITUTE .SwRI-NDT-800-78Revision 0December 1981


(2) An le-Beam

ScreenDistance Block e

BlockDimension

5.0" SwRI Half-RoundAWS Type DC

1.0" Radius1.0" and 2.0"Radii


IIW

1.0" Radius1.0" and2.0" Radii4.0" Radius

20.0" IIW Block 4.0" Radius

5.3 Basic Calibration Block

If examinations are to be conducted on a clad component, thebasic calibration block shall be clad to the nominal thickness of the componentcladding 91/8 inch. . Deposition of clad shall be by the automatic method usedon the inside of the component. Where the automatic method is impractical,

'epositionof clad shall be by the manual method used to cover the circum-ferential velds of the component.

Side-drilled basic calibration hole reflectors, in accordancevith Figure T-434.1 of Article 4 of Section V of the ASlK Boiler and PressureVessel Code, shall be placed in a block manufactured from one of the following:(1) the component nozzle dropout; (2) the component prolongation; or (3) mate-rial of the same specification, product form, and heat treatment as one of thematerials being joined. The basic calibration block thickness shall be deter-mined from the average veld thickness. The requirements for basic calibrationblock curvature limits, heat treatment, surface condition, and scribe linesshall be in accordance with Article 4 of Section V.

Notches 2XT deep shall be machined in the basic calibrationblock surface, in accordance vith Article 4 of Section V.

A flat basic calibration block or block of essentially the same

curvature as the examination contact surface shall be used for the examinationof welds with a contact surface curvature greater than 20 inches in diameter.

A single curved basic calibration block may be used to estab-lish distance amplitude correction (DAC) curves fo" examinations on contact "

surfaces in the range of curvature from 0.9 to 1.5 times the basic calibrationblock diameter, when contact sur ace curvature is 20 inches in diameter orless.

SwRI Foram QA 3.2


RaI


Automatic defect alarm and recording equipment to be utilizedis specified in SwRI Nuclear Operating Procedures XII-PM-106, XII-PM-108, andXII-PM-129'ach instrument shall be aligned and shall display an alignmentcalibration sticker as required by NQAP 10-1.

5.6 ~Cou lant

(1) USP"grade glycerine or deionized water (with or withoutwetting agent) shall be used when performing ultrasoniccalibrations and examinations in accordance with thisprocedure.

(2) Couplant materials used for examinations shall be the'same as used for the calibration.

(3) Light oil or other compounds, which in the opinion of theLevel II examiner provide adequate ultrasonic coupling,may be used upon concurrence of the Project Managerresponsible for the examination.

(4) All couplants other than deionized water shall becertified for sulfur content and total halogens inaccordance with ASTM D-129-64 and ASTM D-808-63. Theresidual amount of total sulfur or halogens shall notexceed 1X by weight. Deionized water, when used, shallbe supplied by the customer.

5.7 Thermometer

Quicktemp thermometer Model 5X-666, calibrated and certified inaccordance with the applicable revision of SwRI Nuclear Projects OperatingProcedure XII-PM-104, shall be used as required, to measure calibration blockand component surface temperature.

6-0 CALIBRATION METHOD

6.1 Instrument Linearit

The ultrasonic instrument shall be verified for amplitude lin-earity and amplitude control 1'inearity in accordance with Paragraphs 6.1.1 and6.1.2. This verification shall be conducted at the beginning of each day inaccordance with the linearity requirements in Article 4 of Section V. For thepurpose of this procedure, a day shall be defined as a 24-hour period star"ingwith the A.M. shift. Data required shall be recorded on the SwRI Instrument

SwRI Form QA 3-2



specified. The signal shall be estimated and recorded tothe nearest 1X of FSH and fall within the limits of thefollowing table:

IndicationSet at X ofPull Screen

dB ControlIndi'cationLimits, X ofPull Screen

80X80X40X20X

-6 dB-12 dB

dB+12 dB

32 to 48X16 to 24X64 to 96X64 to 96X

+Minus denotes decrease in amplitude; plus denotesincrease .

6.2 Calibration

Calibration details such as vee-path positions and sweepdistance shall be described in the applicable SwRI Scan Plan.

The complete ultrasonic examination system calibration shall beperformed prior to the examination.

NOTES

The "REJECT" control shall be maintained in the "0"or "OPP" position during calibration and examination.

The "PREQ MHz" control shall be turned to "2"when a 2.25 MHz search unit is

used'he

instrument gain controls shall not be changedonce the primary reference response has beenestablished.

The temperature of the basic calibration block during calibra-tion and verifications shall be within 25'F of the component temperature. Porexaminations from the inside sur ace of vessels, water temperature inside thevessel may be used for component temperature. Under no circumstances shallexaminations be performed if the temperature of the basic calibration block isnot within 25'P of the component to be examined.

The temperature of the basic calibration block during theinitial calibration and the temperature during each verification shall berecorded on the applicable SwRI Instrument Calibration Record. The componenttemperature prior to performing the examination and upon completion of theexamination shall be recorded on the applicable SwRI Examination Record.

swRI Focm QA 3 2


NUCLEAR PROJECTS OPERATING PROCEOURE Page ll of 23

location on the screen baseline, using only the "DELAY" control ~ The screendistance chosen shall be the shortest applicable size to include at, least 25Xof the wall thickness beyond the anticipated examination distance ~ Thiscompletes the distance calibration.

6.3 Electronic Distance Am litude Correction

Electronic DAC is used to set responses from a calibrationreflector equal in amplitude xegardless of the distance of the reflector fromthe search unit.

6.3.1 Strai ht-Beam for Production Material Greater than 2.0 Inchesin Thickness

(1) Position the search unit for maximum response from thebasic calibration hole at 1/4T. Adjust the instrumentgain to obtain a signal amplitude at or between 40X to80X FSH. This is the primary reference response andshall be marked on the instrument screen.

(2) Position the search unit for maximum response xrom thebasic calibration hole at 1/2T. Using the electronic DAC

controls, adjust the signal amplitude to the primaryreference response and mark its amplitude on the screen.

(3) Repeat this operation for the 3/4T hole. Join thesepoints with a straight horizontal line the length ofwhich shall extend 1/4T beyond the last qualifiedcalibration point.

6.3.2 An le-Beam

6.3.2.1 Distance Amplitude Correction from the Clad Side or on NoncladBlocks

(1) Electxonic DAC curves shall be constructed by utilizingthe 1/8, 2/8, 3/8, and 5/8 vee-path responses from thebasic calibration holes at 1/4T, 1/2T, and 3/4T. Theinitial point on the DAC curve is established by manip-ulating the search unit to obtain maximum response fromthe 1/8 vee-path position. The instrument gain shall bead]usted to set this response at or between 40X to 80%FSH. This is the primary reference response and shall bemarked on the instrument screen.

(2) The search unit shall be placed similarly at the otherrequired vee-path positions. Using the electronic DAC

controls, adjust their responses to the primary referenceresponse and mark their amplitude on the screens

SwRI Form QA3-2

SOUTHWEST RESEARCH INSTjTUTESwRX-NDT-800-78Revision 0December 1981


6.4 Sin le-Point Zone Calibration Without Usin Electronic DistanceAm litude Correction

Maximum response from the applicable reflector shall beobtained by manipulating the search unit ~ Adjust the instrument gain to setthis signal to 80X &5X PSH. This is the primary reference response and shallbe marked on the instrument scr'een. The area to be examined shall extend nomore than 20X of the wall thickness to either side of the calibrated point.

6.5 Beam S read and Beam An le Determination

Angle-beam search units used for examinations shall be measuredfor beam spread and beam angle. These measurements shall be conducted accord-ing to the following steps for examinations calibrated in accordance withParagraph 6.3 or 6.4 as applicable.

NOTE

Beam spread and beam angle for zone calibrationsshall be determined by recording the distanceto the Wl 50Z DAC point, Wmax point, and W2 50XDAC point for each calibration reflector in amanner similar to that described below for vee"path calibrations.

(1) The instrument shall be calibrated as described in Para-graphs 6.2.2, 6.3, or 6.4 as applicable.

(2) With the instrument at the primary reference level sensi-tivity, position the search unit to obtain maximum ampli-

~ tude from the 1/4T hole (Wmax). Measure and record thedistance from the incident point of the search unit tothe scribe line above the 1/4T hole ~

(3) Repeat step (2), recording the distance to the scribeline for both the 1/2T and 3/4T maximum

amplitudes'4)

Determine the location and mark a line on the screen torepresent the 50X DAC.

(5) Position the search unit to obtain maximum amplitude fromthe 1/4T

holey'ove

the search unit toward the holeuntil the indication equals the 50% DAC line. Measureand record the distance from the incident point of thesearch unit to the scribe line above the 1/4T hole (Wl) ~

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTEe

~,

R~ NUCLEAR PROJECTS OPERATING PROCEDURE

I


Page 15 of 23

(3) With any substitution utilizing the same type of powersource; e.g., a change from one direct current to anotherdirect current source

(4) At least every 12 hours during the examination

(5) At the finish of a series of examinations

(6) At any time when, in the opinion of the examiner, thereis doubt as to the validity of the calibration

When a group of examinations have been completed, the finalverification shall be initialed by the crew leader in charge.

The last calibration verification of each snift sh'all be con-ducted during the interface period and in conjunction with the oncoming crew.The two crew leaders shall verify the calibration together as a handoff. Bothcrew leaders'nitials should appear on the calibration sheet for verificationconducted in this manner.

NOTE

The mechanized positioning equipment calibration shall beverified in conjunction with the instrument calibrationverification or at least eve'ry 12 hours during the exami-nation. Device counts per increment shall be verified tocoincide with counts per increment as specified in theSwRI Scan Plan examination tables'he "0". position and

linearity of the X and Y readout shall be verified inaccordance with the appropriate SwRI Nuclear ProjectsOperating Guide.

Ultrasonic instrument functional checks shall be con-ducted every 4 hours of scanning time to determine if anyapparent functional changes have occurred in the instru-ment. If any reflector from the function block has moved

on the sweep line more than 5% of full screen width orchanged in amplitude more than 20% or 2 d3, the instru-ment calibration shall be verified on the appropriatereference and basic calibration blocks.

6.6.2 Calibration Chan es

(1) Perform the following if any point has moved on the sweep

line more than 5% of full screen width or if any point onthe DAC curve has decreased by 20% or 2 d3 in amplitude:

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTESwRI-NDT-800-78Revision 0December '1981

NUCLEAR P ROJ ECTS OP E RATING P RO CEO UR E Page 17 of 23

(1) Serial number of the basic calibration block

(2) Serial number of the reference block

(3) Type, serial number, and manufacturer of the ultrasonicinstrument

(4) Type, size, beam angle, and serial number of the ultra-sonic search unit


(6) Couplant (which shall be the same as used in the actualexamination)

(7) Signature and ultrasonic certification level of examinermaking calibration

(8) Date calibrated

(9) Time of calibration and calibration verification

(10) Temperature 'of basic calibration block

(11) Length and type of search unit cable

(12) Serial number of the thermometer.

7.0 EXAMINATION


Mechanized ultrasonic examination of nozzle-to~iping butt,welds and ad)acent base material from the inner or outer surface shall beperformed.

Examinations shall be performed on components in theircompleted condition. Weld examinations shall include the weld and basematerial for 1/2 inch from the fusion line on each side of the weld. The1/2 inch to be examined shall be measured from the fusion line at the weldcrown.

The transfer method shall not be used.

SwRI Form OA3 2

SOUTHWEST RESEARCH INSTlTUTESwRI-NDT-800-78Revision 0December 1981

Rlk


8 0 RECORDING CRITERIA

NOTE

It is recognized that not all ultrasonic reflectors indicateflaws, since certain metallurgical discontinuities and geometricconditions may produce indications that are not relevant. Includedin this category are plate segregates in the heat-affected zone,clad interface, and back~all reflections ~ Plate segregates in theheat-affected zone may become reflective after fabrication; thesemay appear as spot or line indications when examined using straight"beam longitudinal wave techniques. These indications shall not beconsidered reportable conditions.

Ultrasonic zeflectors producing a response 50X or greater of the refer-ence level shall be recorded. Ultrasonic planar surface reflectors obtained at100X or greater of the response from the square notch shall be recorded.

Ultrasonic reflectors detected at 50X or greater of the reference leveland planar surface reflectors 100X or greater of the response from the squarenotch if not resolved as geometry by the examiner, shall require scans to beconducted in the Y direction (width of indication) ~

Scans in the Y direction shall extend to the 20X limits of the rezlectoralong the X axis and to the 20X limits of the reflector along the Y axis.

Y scan increments shall be one-tenth inch (when incrementing with theSwRI rotator the increments shall be one-half degree) ~ All Y scans shall berun in the same direction, upon completion of which an I-scan shall be run atthe maximum amplitude location.

Ultrasonic reflectors producing a response 50X or greater of the refer-ence level and planar surface" reflectors 100X or greater of the response fromthe square notch shall be investigated by a Level II or a Level III examiner tothe extent necessary to determine the shape, identity, and location of thereflector.

Ultrasonic reflectors 50X or greater of the reference level and planarsurface reflectors 100X or greater of the response from the square notch,investigated and found to be other than geometrical in nature, shall be„

reported to the customer for evaluation.

Scanning limitations shall be recorded.

9.0 EVALUATION

Evaluation of indications shall be the responsibility of the customer,or the customer's representative, and shall be conducted in accordance with

SwRI Form OA 3.2

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SOUTHWEST RESEARCH INSTlTVTENUCLEAR PROJECTS

OPERATlNG PROCEDVRE

SwRI-NDT-900-7Revision 3March 1981

Page 1 of 9

VISUAL EXAMINATION OF NUCLEAR REACTORS

'FFECT1VITYAND APPROVAL

Revision 3 of this procedure became effectiv on ~ . Other revisions of the base document may

be effective concurrently.

SA

Approvals

Written By

M 3Manager of CLA.

Date

Date

l7gg/

ant Director/

/'ateWa./4'/9'&'at

it"fi

The following information may be used for convenience. mpletion of this portion is not mandatory.

Deviation No.

Date Effective

Procedure Section(s)Affected

Notes:

swnl arm QA~AN



SwRI-NDT-900-7Revision 3March 1981

Page 3 of 9

(2) The Project Manager shall be responsible for the implementation ofthis procedure in accordance with the NQAPM specified in theapplicable SwRI Prospect Plan.

(3) 'he examiner shall be responsible for implementing the require-ments of this procedure-

(4) The Manager of the Support and Administration Section of theQuality Assurance Systems and Engineering Division shall beresponsible for storage of records generated in accordance withth'is procedure.

4.0 CODE AND PROCEDURE REQUIREMENTS

The requirements listed below shall apply when performing visual exami-nations in accordance with this procedure.

Re uirements Section

(1) Personnel certification

(2) Examination area

(3) Surface condition and cleaning requirements

5.0

7.0

6.0

(4) Examination method 6-0

(5) Equipment 5.0

(6) Lighting requirements 6.0

(7) Resolution

5.0 PERSONNEL AND EQUIPMENT

6.0

Personnel performing examinations shall be certified in accordance withSwRI NQAP 11-2, "Procedure For Certifying Visual Examination Personnel."

The Visual Examination Acceptability Test Card shall be made from KodakNeutral Test Card No. R-27 or an equivalent, with an 18X neutral grey sidehaving a 1/32-inch~ide black line down the center.

SwRI Form OA 3 2



SwRI-NDT-900-7Revision 3Harch 1981

Page 5 of 9

Resolution shall be considered adequate when the combination ofaccess, lighting, and angles of vision, either unaided or corrected, canresolve a black line, 1/32-inch~ide, on an 18Z neutral grey card placed on thesurface to be examined or in a situation similar to the area to be visuallyexamined.

6.2 VT-2 Examinations

The examiner shall locate evidence of leakage from pressureretaining components, or abnormal leakage from components with or ~ithoutleakage collection systems as required during system pressure or functionaltests.

6-2.1 Noninsulated Com onents

The accessible external exposed surfaces of pressure retainingcomponents shall be examined for evidence of leakage.

Examination of the surrounding area, including the floor orequipment located underneath the component, shall be required for componentswith inaccessible external surfaces

6.2. 2 Insulated Components

Examinations may be conducted without the removal of insulation,by examining the accessible exposed surfaces and joints of the insulation.Vertical surfaces of insulation need to be examined only at the lowest eleva-tion where leakage may be detectable. Horizontal surfaces of insulation shallbe examined at each insulation joint.

Inaccessible piping and components shall require an examinationfor evidence of leakage on the surrounding area, including the floor areas andequipment surfaces located underneath the component, or other areas whereleakage may be channeled-

Discoloration or residue on surfaces examined shall be givenparticular attention to detect evidence of boric acid accumulations fromborated reactor coolant leakage.

swRI Form OA-3.2



S wRI-NDT-900-7Revision 3March 1981

Page 7 of 9

Pipe clamps and U-bolts shall be examined to ensure that they aresecurely attached to the pipe.

7.0 Examination

7.1 Surface Cleanin

Visual examinations which require c1ean surfaces or decontamina-tion for valid interpretation of results shall be preceded by appropriatecleaning processes.

Examinations may be required where the surface is painted or hasother types of coatings. This shall be permitted if it is determined that suchcoatings do not interfere with valid interpretation of results .


Components, parts and areas to be examined shall be as specifiedin the applicable SwRI Examination Plan. Remote visual examinations utilizingmechanized scanning devices shall be as specified in the applicable Scan Plan.Scanning parameters, if required, for the remote visual examination, shall beincluded in the applicable SwRI Scan Plan-

8 0 RECORDING CRITERIA

Indications shall be recorded in accordance with the techniques outlinedin IX-FE-116.

Visual abnormalities shall be recorded on the "SwRI Visual ExaminationRecord" and reported to the customer-

The completed "SwRI Visual Examination Record" shall contain, but not belimited to, the following information:

(1) Identification of the examined part and the extent of the examina-tion, including surface preparation, if required

(2) Method and techniques used in the examination

SwAI Form OA.3.2

S W R I VISUAL EXAMINATION RECORD

P RO JECT No. SITE DATE: (DAY- MON.- YR.) 4 IRCEXAM STARTEDEXAM ENDED

SHEET No.

EXAMINATIONAREA:(SYSTEM/COMP.) (LINE/SUBASSEMBLY) ( IDENTIFICATION ) Wo LOCATION WELD TYPE: ( —FLOW~ )

EXAMINER

EXAMINER

SNT LEVEL

SNT LEVEL

PROCEDURE

No.

REV.

DE V.

METHOD

DIRECT Q REMOTE QDESCRIBE: VISUAL AIDES

Lo LOCATION

WELD LENGTH

IND. No.LOCATION

LOCATION LOCATION STREAM

TYPEROUND OR

LINEAR

SIZE DIA.OR

LENGTHVT-IP

REMARKS

VT-2 Q VT-SQ VT-40 INI.

EXAMINATION AREA LIMITATION ( IF NONE~

SO STATE)

+ CA

to I%D

O M 5k~c) IV Q'C)OCOI

REVIEWED BY

swan ronu wo. ooro >r- as I oav. or- io-so)

SNT LEVEL DATE

PAGE

APPENDIX E

ULTRASONIC CALIBRATION BLOCK DRAWINGSAND CERTIPICATIONS

APPENDIX E

ULTRASONIC CALIBRATION BLOCK DRAWINGSAND CERTIFICATIONS

Table of Contents

Drawin No.

*UT-1

*UT-2

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Title

Upper Shell Block

Lower and Intermediate Shell Block

Bottom Head and Outlet Nozzle Safe EndBlock

~Pa e-

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5-CSCL-40-SLC

IR-CSCL-66-SLC

Inlet Nozzle Safe End Block

3-1/2" Thick Primary Piping BlockAssembly

Vessel Flange and Ligament Block

Inlet Nozzle Block

Outlet Nozzle Block

Block Standard

Inlet and Outlet Nozzle Inner Radius

E-4

E-5

E-6

E-8

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5CA LE 2/ITUPICAL 3 PLACES

SNIPE OI'&CE 04 RASE NEfALCUT TO RtCEIYE C(ADOW& 1$OP'fl&NAL,IUIRRI Allot OMITS

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IR-CSCL ('06- SLC

Ql MlllRIIL14(KIRI( (f Ns1 llssNIR UNs(ATIIN TRS(N MAYAll'E(.T AN@It R(AM CR SIRAICRT EtAM CAU&RATIONS.INIE flNMCASUS CLE rKAT Ns ZR3533 S RE (44 Rs.1&$ 0

QS STCEL SIIHP Ek Ns ARO IRAI Ils SARAN Ol NIRfA(E UN(CA(COSH CHARACTtR'5 3/I( IWNIMUM Ikl&HT

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QS ((AOOTIRIAT Pl N(OKAN(t IRIN 5«RT. PROCt0444 TIPS 540'4 Rll ~,

D(RUHR ANO RREAR SHARP EOCESI OSMENSNIHL ARC IH RICHES

NOTES'SO~lI os r rr r

ro ~ (,010~ 4 I/If(

~o

lftfEfls

RAM

SOVIHWEST RESEARCH INST(IUI~rsrl rosrrl ~ lllos rolrrirrrroor wN 'r r

I LINNER RADIUS

~ I orr r'll C D-n073 II8

'4I (NTNIC ETE SCIM\l(R CMR s0(4121 C

I I OLOCK C 3

LINDBERG/COOKHEAT TREATING

COMPANY CORPORATIONp.o. Oox paaao ~ Ttovrrort. T ax As yrot o ~ ltoranaaot

CERTIFICATION OF HEAT TREATMENT

SOUTHWEST RESEATKZ ZNSTZTUTP 0 DRAWER 28510

~ SAN ANTONZOr TEXAS 78284ATTN JZH SILVERS

wt »tttlvalivv oixr ne Txstt oltt»sto writolvoi ne Tollowvvo»txl lit»lie»ntwe xt rexf

DATE:

CERTIFICATION NO

OTHER ORDER NOS.:

NUMBER OF PARTS:

PART NUMBERS:

993 6 X 8 X 15 JOB 14141

DRAWN 12 0

rtlttttDED

STRESS ttSUStrED

SPM. ttQospCY

sar

Lssetsscstarcooss, 19~

We further rettily that heat treatment ite»crlbeil aT»ive i» true anil airrert anil that ti m

peratures and test resuhs were ohtaineil with ctanitar<l apprnveil mi thi»t».Suhscritwit amt sworn to beiore me this

~I521 Itsy illstmAT vteEATtsea cosepAsev

Notary Publicin anil inr the nunty of Marti ate iit Texa»

My Commission E'xpires 4PAms GAMBLEPLANT SUPERZNTENDENT

E-17

Biyhap machine. 5 Teel Ce. Inc.-1 3-

gUALITY CONTROL INSPECTION REPORT

Contract No.:

P/H - 0

Item

HSH

10

12

13

14

15

Acc Rej

16

17

18

19

20

21

22

23

24

25

26

27

2S

29

30

Acc Ref

31

32

33

35

36

37

39

40

41

42

44

45

Acc ReS

Tolerances on Dimensions(unless otherwise specified)

FractionsB 0.

Number and Types of Defects Found:

.X

.XX

.XXX

Number of Samples

Number ACCEPTEO

Number REJECTFD

nag. g~

Pt Be

LCQ

Corrective Action Taken:

LOT: ACCEPTEO

REJECTED ~Signed

DateI

E-19

Pebruary 8, 1982

MEMORANDUM

TO ~

PROM:

Pro)ect Pile 17-6787-721(St. Lucia Inner Radius Block)

Manager, Melding Research and Development

SUBJECT: Post Veld Heat Treatment of Inner Radius UT CalibrationBlock IR-CSCL-66-SLC, Draving No. ~073-118

The above block received a post veld heat treatment at 1150'P, -25'or a

period of 4-1/2 hours. This is a verification that the block received thepost veld heat treatment in accordance wiht Article IV, Section V, paragraphT-434.1.3 of the ASME Boiler and Pressure Vessel Code.

/ga

E-21

(MCTIOIV A.ASCALE Z/I

g NOM

TT

I'/OION RI/Z Ill(R.

.OEM'~SCALE Z/I

TYPICAL 3 PLACCSsee(pc of coot (p des% NCMLCUT TO P(KKIVC CIA(DINO 1$OPTIONAL ION(PI AMVC OMITS

I

I

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OIRKC;TION

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OIR E.C.T ION

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QV HIIIRNL TOR( IPII Cf ANV IAWNAR Pde(A(eSN VWOI HAYAlftl1 AN(IK d(AH OR eeIRAICPT d(AM VLIORATIONS,

. UICC (NAI SASOO CLC.VKAI Re. CIOSSS S a( ul ~ .IASO

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NOTES'

I

tSO

IR-(SCL -66-SLCHT. 218993

~e ~ el ~ 0 ew e ~ e

IR-C'5CL-(46 SLC

w e I,OI0~t I/I(g~ e SOUTNWCST ECStAKCN (NSIIIUI

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dna

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RAM

IINNER RADIUS

we ~ ~

""'I/ C 0 1073 II6

I (RTIAG EVE ALHASTIR CARR SO(A(Ply CP

I I DLOCK C 3

LINDB ERG/COOKHEAT TREATING

COMPANY CORPORATIONP,O. 0OX 14040 ~ KOL/STO//«TfXAS 75051 ~ Sta/4114401

CERTIFICATION OF HEAT TREATMENT

SOUTHWEST RESEMK2f ZNSTZTOT~P 0 DEQRER 28510

~ SIT ANTONZOr TEXAS '78284PZTH iTZM SZLVERS

wt «e«ts«ct«lv«n«LL ne LLL«5 ntsD«L«o wt«t 0«/ran ne «0«Lowi««o «e»f L«l«r««r««t

DATE:

CERTIFICATION NO rOTHER ORDER NOS.:

NUMBER OF PARTS:

PREHEAT

OUENCHED

PARTNUMBERS'93

6 X 8 X 15 JOB 14141

DRAWN 290

STRESS REVS/ED 'f

s«TERLAL

SPB:. NQ815IZ O «P C /5'9

HARDNESS TEST

nsseDnxs«4/coost.

19'otary

Puh(ie(n anil h«r the ounty of Harri ate ot Tcxa««

Ny Commission Eipires 4

We (urther rerti(y that heat trestmeot «le»er(he«I aT»«L«e i» true En«i «L«rrrrt anil that trmperature» and test results were ««h(a(ne«I with stander«l appnwe«1 m« th«««(s.

Suhserihrd an«««worn to br(ore me this

~2E «lay ii(.

~ ~

15

seKAT Ts»DATtKO COseNKT

E-17

Qi>hap machine O'eel Ca. Inc.-13-

EQUALITY COHTROL IHSPECTIOH REPORT

Contract Ho.:

P/H - d

0 ItemC(l,/

Acc Rej

16

17

18

19

20

21

22

23

24

25

26

Acc Ref

31

32

33

34

35

36

37

39

40

41

Acc Ref

12

14

15

Tolerances on Dimensions(unless othe ise specified)

..'.-,z

R O ~

27

28

29

30

. 42

43

Humber and Types of Defects Found:

.X

.XX

.XXX

Humber of Samples

Number ACCEPTED

Humber REJECTED

7

Po 8 ~

Lco

Corrective Action Taken:

LOT: ACCEPTED

REJECTED ~Signed

Date I

E-19

Pebruary 8, 1982

MEMORANDUM

TO:

FROM:

Pro)ect Pile 17-6787-721(Bc. L cla l ac Baddaa Black)

Manager, Welding Research and Developnent

SUBJECT: Post Weld Heat Treatnent of Inner Radius UT CalibrationBlock IR-CSCL-66-SLC, Drawing No. D-4073-118

The above block received a post weld heat treatment at 1150'F, -25'or a

period of 4-1/2 hours. This is a verification that the block received thepost weld heat treatttent in accordance wiht Article IV, Section V, paragraphT-434.1.3 of the ASME Boiler and Pressure Vessel Code.

/ga

E-21

APPENDIX E


APPENDIX E


Table of Contents

D rawin No.

*UT-1

*UT-2

*UT-4

Title

Upper Shell Block

Lower and Intermediate Shell BlockI

Bottom Head and Outlet Nozzle Safe EndBlock

~Pa e

E-1

E-2

E-3

*UT-5

*UT-6

*UT-8

*UT-9

*UT-10

5-CSCL-40-SLC

IR-CSCL-66-SLC

Inlet Nozzle Safe End Block

3-1/2" Thick Primary Piping BlockAssembly

Vessel Flange and Ligament Block

Inlet Nozzle Block

Outlet Nozzle Block

Block Standard

Inlet and Outlet Nozzle Inner Radius

E-4

E-6

E-7

E-8

E-9

E-15

*FPL Furnished Blocks (Certifications On Site)

SCRlOT LINC $ TVP GROOYC

~ASS 00 NOV USC ~ TTPDOTN SIOCS

1 -I

r-+-aI

II

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1 I

I/I III I I

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OG R ACT

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GROOVCTVLL RADIUS

P RALN 'CNDNOT t

Ql SICIL STAIOO Tlt IOCCONihG evelwIVV1111 + UN 1ViV CVAAACTCAS

~ 'I CNIIIATIOV110 UT IC001 VI M COO ICO%COACT Nl. T liltTellwLTOIATMINT T VR'L eelle

TAOCC TNICQNCSS NWCIGNC Ii)ll

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!

CrROOVCICCO tICP TVP

Sg

CAISTIND CLAD

Og

~ SCR10C VNC COCATCO ON $) N01.%$ ANO CDGC OCGROOVCS

fI ncr/~

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A 1 ACR TTP504110 0

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VVP AIL AAOVVD

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IT) 1

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HI tlat& ~ ~ tH ~ ~ ~ ~ I M1 ~

~ I

OCI'WCe C TIIT? ~ I~ 1 OOTCOUDUSIVel TNCINtCPViG

SOUIHWI55 OC Sf ATCN IN5IIIUIINii41 Rigel'AII ~ vteMIW taW

NiU ER SHLLL HLO(KUT I

n gl SI IVCir 0 i~ I » s

0- 683 I C'33

DRILL f. (.57$ 0) Dlh

TAP I-0 UNC t8x I MAX DffP

FULL RADIP5 fACH ENO TTP

SCRlbf LINf LOCATED ON f Or HolfS gEOCE Or CRODTES

.HIT

TTP T

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Rfr~AIL~II

LIIIE

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tf=m I

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tl '-*

AI

6 IT

b0770tf OFDEEPEST Htlf

3 AS MILT

87@ALTA

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DRILL g (.tSOO) DIAA 3 DEEP6 HOLES REF

»OQ

NOTES:I. DEMRR o BREAK SHARP EDCES WITH APPROX

Qg RADIUS DR CHAtfrfR2. THE CAITBRATION BLOCK MATERIAL SHALL bf CttfFLETELT

EXAtllNED WITH A STRAICHT BEAtl SEARCH UNIT. AREASWHICH CONTAIN LAMINAR INOICATIOH5 EXCEEDINC

THE'ftlhlNINCOAClf REFLfCIIOR AT THf INDICATIONtOSITIDN SNAII Of EXCIUDED Fhotf TNF Ofhtf PATH5NEEDED 70 AfhCN THf VARIOUS CALISRATION HOLES.

QZ57EEL STAMP THE FOLLOWINC INFORtfhTION WITH>nc IYIN RICH CHAIMCTERS:I

UT CAIIORAIION 010 VT tCOOf NO. tf-604;ICONTRACT NO. 7H72THERtlhL TREATMENT 2 HRSBLOCK 7HICHNE55 $'WEI6MT ICD w

HfAI'REATtffHTTIKE SHALL BE TWO HOURS

AT IISO'$ F OYER ANO ABOVE PRESENT HEATTAEATtlfHT. ROUCH CUT 70 5ltfT HEAT TAEATT ANDFINAL MACHIHf.ITHIS IS NOT A FAORICATION ORAWINC.REPRODUCED FOR SITE USE OHLT.

TKctf al »af N of»lee»l Nof»co N co»Teacf TKTI Nae»N~a» face»leaf»ao aac TK teotc af T et ooefeelcf Nfl lac» Nffffef~ aal »OKO »fit ~ ICT Ceca»cecf, aee a»aLL Nl N Ntat~Klo N cotffo, oa ell~ af Tac oaf» fN Tel eaeetacffK Nwl ct attuafel efT»eef tca»ff»»,

Lcl ~ c ~ oa oaf l c»e oN». a»e tell. TNO ~ o fae1.

~Ncaa»N ~ e»LI ~ o»efl ~~le»we ITIC~eacf feel 64+a»eccl +0 30tfell»

~ ttae Tl~

BwSh'h

~at»~I ella tae ~ »ael

OOOTO LIO'f»ac IOQL

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T.O.O. OOTII

SOUTHWEST RESEARCH INSTITUTEOflll!TTJTTffclffCC TfITI»T I»O ICCTOCCITIC CCTTTTOk

II» a»clef ~ ~IlalST LVCIE Z —BOTTOM HEAD (OUTLET NOZZLE SAFE END BLOCK

TOtf D.NNI II.II UT- ~»Clf I Of I

""'y< (o f Oal OE7OWCT

cflies

$$ REF

Rfrf FPL DWC E-THTt -Ifl-003PC ITC-310)

2 I I.IFT ETE

I I CAL BLOCK

STEEL STQISP THE FOILOWINC INFDRIIATIOkWITH I~ PHN MICH CHARACTERS

tIT ChtlbRATIPN STD UT-5COPf HD. PI- IIZOTCONTRACT NO. 7IO72THERIIAL TREATPIENT C Jrt ZHR5 IIINBLOCH THINNESS 3$WEICHT ID7 tbS

Cl APPINC .070 6hOOVf DEPTH

DRILL iIC (.IOTS) DIAL HOLES

.070 CROOVE DEPTH

Ib+TT

HOTESII. PEPORR E BRIAR SHARP EPCES MITH AFCROT

HZ RAPIDS OR CRANER.2. THf ChtlhRATIOH BLOCH ISATEAIAL SHALL bf

IOHPlfrllY EIAIIIHEP MTH A STRAICHI ¹IISEARCH DMT. AREA5 SIHJCH CONTAINLAIINAR IHPICAVIPNS ETCffPINC THERftIAININ6 BACH RfflfCTIPN AT TOEIHPIchrlO» F05ITIPN sbhtt bf txCLDPEDFROII THE BEAII PATHS HEEDED TO RfACHTHE YARIPIIS CALIBRATION HOlES ~

3. HEAT TREATIIEHT THSE )HALL BE TVP (2)HOURS IIIN AT IISD 25 F OVER iWD ABOVEPRESENT HEAT TREATPIENT

2 IT4 I

to ItIII

I

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DRILI. g (.57$ 0) DIA

TAII I-0 IINC-ZB2 I" IIAX DEEP

11

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3+f.

Fbtt RAPIDS EACH EHD~ rvr

5CAIBE LIHf LOCATEO ON $ OF HOLES gEOCE OF CROOVES

AEFt FFL DSPO 7/07 70 -002ISSY Nt. 755-ZII)

2 I EYE BOLT

I I CAL BLIIRac«IKR Kata ~ wff~~IIMaao + .OIO~slcfaaea 2 trSTseato + 0 30

~a«I «I~I acR

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telT «a«ttlsTS LIST

«IICOIL

SOUTHNEST RESEARCH INSTITUTE

tatltl ll«af K KKaeOl IIIIIKIlfCtaIIICT TKN RaeIKI~ao oc«I«II«aa aat Iat taatl ~ If ct IRIwtlfKKIK«M~«IKI Rt WKIMIIIICICOOIKKI aW O«aa IK K KtaO~eCII, ta Cat«o, Ol Kl~ lt Ial II«I tls Iat «aeetaCIIK oa~aat at attaaafel t«alef KIOI«ae.

Ltl ~ C1 W Oaf l Cea ~ IR Wa till«R os WsIISVISIONS

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TON D.CMCal ~ ~ ICTa Ct

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Ca1 lll41I~ 'IlailST LUCIE 23 4 THICK PRINRY PIPIIIC IILOCK hbSTUT- 6 ~IIClT I 4t I

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APPENDIX F

EXAMINATIONAREA LIMITATIONS FOR THEST. LUCIE PLANT, UNIT 2, REACTOR PRESSURE VESSEL

APPENDIX F

EXAMINATION AREA LIMITATIONS FOR THEST ~ LUCIE PLANT, UNIT 2, REACTOR PRESSURE VESSEL

l. Introduction

Limitations to examination coverage were experienced during themechanized PSI of the St. Lucie Plant, Unit 2, RPV and are genericallyidentified in the Examination Summary Table of this Final Report. Thepurpose of this appendix is to further define and quantify the examinationlimitations as specified in U.S. Nuclear, Regulatory Guide 1.150 and asrequested by FPL.

Two generic types of limitations were encountered most frequentlyduring the PSI of the St. Lucie Plant, Unit 2, RPV welds and components:

(1) Interference from search unit wedge-to-component near surfaceinterface noise, and

(2) Component geometric interference with the scanning equipmentand/or geometric shadowing of examination areas.

SwRI procedures implemented during the St. Lucie RPV exami-nations required full vee path calibration of the 45-degree shear wavescans to compensate for limitations encountered in the near surface andthose due to geometric shadowing. Additionally, manual scans were con-ducted from the outside surface of the RPV (where accessible) to comple-ment the inside surface examination coverage. Nevertheless, thoseexamination volumes which received other than 100 percent of the ASME

Code-required coverage are identified herein. Generally, interface noiseinhibited resolution capabilities at the. near surface for about 1/2 inchto 2 inches .of metal path for longitudinal wave examinations. It shouldbe noted that electronic gating did not result in any examination limita-tions since the entire instrument screen presentation was monitored duringthe examinations, video taped, and reviewed independently following theexaminations-

2. Descri tion of Limitations

The attached tables and figures detail the examination limitationsexperienced during the St. Lucie Unit 2 RPV PSI. Specifically, the tables "

quantify the limitations in terms of percent of Code-required examinationvolume which was not effectively covered. The accompanying figures graphi-cally depict the location and extent of the limitations with respect toweld metal and associated base material.

/2.1 RPV Lower Head Welds

No limitations were experienced during examination of the LowerHead Dollar Plate Weld 101-151.

shows the limitations to the shell side examination and depicts the cover-age obtained from the seal surface examination. Also shown is the taperedsurface where transverse examination was prohibited.

2.3 RPV Lon itudinal Shell Welds

The examinations of the Lower Shell Vertical Welds 101-142A, B,and C were limited due to near surface interface noise. Those volumesshadowed by the interface noise were effectively examined with the45-degree full vee path scans, except for a small area of interferencefrom the core barrel anti-rotation lugs in the case of Welds 101-142Band C. Figure 9 shows the limitation of the 45"degree vee path examina-tion. The examination of Weld 101-142C was also limited due to inter-ference of the surveillance capsules. This volume was effectivelyexamined by the 45-degree full vee path beam. The 0- and 60-degree beam

limitations are shown on Figure 10. Transverse examinations were not'imited by the lugs or capsules.

Examination of the Middle Shell Vertical Welds 101-124A, B,and C were limited by near surface interface noise in the case of'0- and60-degree beams, however the 45-degree full vee path scans obtained fullcoverage. The 60-degree examination of Weld 101-124C was further limitedby interference from the surveillance capsules as shown on Figure 10.

Examination of the Upper Shell Vertical Welds 101-122A and C

were limited by interference from the inlet nozzle inner radius blend andthe outlet nozzle integral extension as shown on Figure ll. The examina-tions were, however, complemented by the nozzle-to-shell weld examina-tions. Figure 12 shows 45-degree full vee path coverage of the volumesnot effectively examined by 0 and 60 degrees due to near surface interfacenoise.

2.4 Nozzle-to-Shell Weld Examinations

The inlet and outlet nozzle-to-shell welds were examined fromthe shell side and from the nozzle bore. The nozzle bore examinationswere limited due to near surface interface noise, however, surface waveexaminations were performed on the nozzle inner radius sections. Theshell side transverse examinations of the outlet nozzles„were limited dueto interference from the nozzle integral extensions. Limitations to theinlet nozzle examinations are shown on Figure 13 and limitations to theoutlet nozzle examinations are shown on Figure 14.

3. Conclusions

Limitations to effective coverage of ASME Code-required examinationvolumes were experienced during the St. Lucie Unit 2 RPV preservice exam-inations and are identified in the figures and table provided in thisappendix- The limitations were minimized 'to the maximum extent possible.Future equipment and technique development may further reduce limitationsto inservice examinations.

F-3

TABLE 1. RPV EXAMINATION LIMITATIONS (Cont'd)

Weld No.Exam~An le

Percent of VolumeNot Effectivel Examined

FigureNe.

101-142B

101-142C

101-124A

101-124B

101-124C

101-122A

pO

45'0'5'T

60'TCombined Coverage*

pO

45'p0

45'T60 T

Combined Coverage*

pO

45'0

45 T60'T

Combined Coverage*

pO ~

45'0'5'T

60'TCombined Coverage+

pO

45'0'5'T


pO

45'0'5'T


~ 245

120

120

246

120

120

240

120

120

240

120

120

240

121

120

191

180

170

999

N/AN/AN/A

N/A9

9 and 10N/AN/AN/A

N/AN/AN/AN/AN/AN/A

N/AN/AN/AN/AN/AN/A

N/AN/AN/A10N/AN/A

11 and 1211 and 12ll and 12

1212N/A

*Combined Coverage indicates the percent of Code~equired volume noteffectively covered by at least one calibrated beam.

F-5

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LIMITATIONS DUE TO LUGS

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ST. LUCIE UNIT 2VERTICAI WELDS 101-12liC & 101 142CEXAM TYPE - PARALLELAREAS OF LIMITATIONS DUE TOSURVEILLANCE SPECIMEN CAPSULES

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