ML031920588
| ML031920588 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 06/30/2003 |
| From: | Abney T Tennessee Valley Authority |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| Download: ML031920588 (46) | |
Text
Tennessee Valley Authority, Post Office Box 2000, Decatur, Alabama 35609-2000 June 30, 2003 10 CFR 50.55a(a)(3)(i)
U.S. Nuclear Regulatory Commission ATTN: Document Control Desk Mail Stop: OWFN P1-35 Washington, D.C. 20555-0001 Gentlemen:
In the Matter of ) Docket Nos. 50-260 Tennessee Valley Authority ) 50-296 BROWNS FERRY NUCLEAR PLANT (BFN) - UNITS 2, AND 3 - AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM - REQUESTS FOR RELIEF 2-ISI-21, AND 3-ISI-17 FOR EXAMINATION OF PIPING WELD OVERLAYS In accordance with 10 CFR 50.55a(a)(3)(i), TVA is requesting relief from certain inservice inspection (ISI) requirements in Section XI of the ASME Section XI, Appendix VIII, Supplement 11 for BFN Units 2 and 3. The specific requirements for which relief is requested relate to the qualification requirements for inspecting piping weld overlays using ultrasonic testing (UT).
The enclosure to this letter contains BFN Units 2, and 3 requests for relief 2-ISI-21, and 3-ISI-17 for NRC review and approval.
ASME Section XI, Appendix VIII requirements are mandated and supplemented by 10 CFR 50.55a(b)(2)(xiv), (xv), and (xvi).
Appendix VIII of ASME Section XI, 1995 Edition with 1996 Addenda is specified in the CFR. The BFN Units 2 and 3 Inservice Inspection (ISI) Programs for nondestructive examination complies with the 1995 Edition, 1996 Addenda of ASME Section XI, and supplemented as required to incorporate ASME Section XI, Appendix VIII.
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U.S. Nuclear Regulatory Commission Page 2 June 30, 2003 TVA recently was advised by the Electric Power Institute (EPRI),
staff that prior to performing ultrasonic examination of Class 1 Reactor Coolant System (RCS) weld overlays (reference NRC GL 88-01, and Boiling Water Reactor Vessel and Internals Project (BWRVIP)-75), relief from ASME Section XI, Appendix VIII, Supplement 11 requirements is necessary. TVA was also informed that two options exist: (1) adopt ASME Code Case N-653, "Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds,Section XI, Division 1," with some modifications, or, (2) use the EPRI Performance Demonstration Initiative (PDI) Program in lieu of the ASME Code Section XI, Appendix VIII, Supplement 11 requirements. EPRI has worked with the NRC staff to develop a sample request for relief, using option 2 above, to ensure sufficient information is submitted for NRC review. of this letter contains BFN Unit 2 request for relief 2-ISI-21 for NRC review and approval. Enclosure 2 of this letter provides BFN Unit 3 request for relief 3-ISI-17. The technical content each of the requests for relief is consistent with the EPRI sponsored PDI model including updates resulting from requests for additional information issued to other utilities (i.e., Southern Nuclear Operating Company (SNC), for Plant Hatch and Carolina Power and Light, for Brunswick Steam Electric Plant).
TVA requests approval of these requests for relief by January 16, 2004, to support resource planning for the Unit 3, Cycle 11 (Spring 2004) refueling outage.
U.S. Nuclear Regulatory Commission Page 3 June 30, 2003 There are no new regulatory commitments in this letter. If you have any questions, please contact me at (256) 729-2636.
Si cerel T. E. Aey and Industry Affa rs Enclosures (Via NRC Electronic Distribution)
Mr. Stephen J. Cahill, Branch Chief U.S. Nuclear Regulatory Commission Region II Sam Nunn Atlanta Federal Center 61 Forsyth Street, SW, Suite 23T85 Atlanta, Georgia 30303-8931 NRC Resident Inspector Browns Ferry Nuclear Plant 10833 Shaw Road Athens, Alabama 35611-6970 Mr. Kahtan N. Jabbour, Senior Project Manager U.S. Nuclear Regulatory Commission One White Flint, North (MS 08G9) 11555 Rockville Pike Rockville, Maryland 20852-2739
ENCLOSURE 1 TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)
UNIT 2 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM (THIRD TEN-YEAR INSPECTION INTERVAL)
REQUEST FOR RELIEF 2-ISI-21 (See Attached)
TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)
UNIT 2 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM (THIRD TEN-YEAR INSPECTION INTERVAL)
REQUEST FOR RELIEF 2-ISI-21 Executive Summary: In accordance with 10 CFR 50.55a(a)(3)(i),
TVA is requesting relief from inservice inspection requirements of the 1995 Edition through 1996 Addenda of ASME Section XI, Appendix VIII, Supplement 11, "Qualification Requirements For Full Structural Overlaid Wrought Austenitic Piping Welds," of the ASME Boiler and Pressure Vessel Code. The Performance Demonstration Initiative (PDI)
Program for implementing the Supplement 11 qualification program for overlay welds is not in strict compliance with the requirements of Supplement 11 of the 1995 Edition through the 1996 Addenda. TVA proposes to use the PDI Program for implementation of Appendix VIII, Supplement 11 as amended in the attachment to this request for relief. The amendments to Supplement 11 as shown in the attachment were coordinated with PDI, NRC, and Pacific Northwest National Laboratory (PNNL).
Unit: Two (2)
System(s): Recirculation (RECIRC), Core Spray (CS), and Reactor Water Clean Up (RWCU) Systems Components: Piping Welds with Structural Weld Overlay ASME Code Class: ASME Code Class 1 ASME Section XI Edition: 1995 Edition, 1996 Addenda Code Table: Westinghouse Owners Group (WOG) topical Report WCAP-14572, Revision 1-NP-A, Table 4.1-1 E1-2
Examination Category: R-A, Risk-Informed Piping Examinations Examination Item Number: R1.16, Elements Subject To Intergranular Stress Corrosion Cracking (IGSCC)
Code Requirement: The 1995 Edition of ASME Section XI, with addenda through 1996, WCAP-14572, Revision 1-NP-A, Table 4.1-1, Examination Category R-A, Item No. R1.16, requires a volumetric (UT) examination of the pipe weld including the overlay. The UT examination must be performed using personnel, procedures, and equipment qualified in accordance with Appendix VIII, Supplement 11.
Code Requirements From Which Relief Is Requested: Relief is requested from the requirement to qualify personnel, procedures, and equipment in accordance with Appendix VIII, Supplement 11 as stated in the 1995 Edition through the 1996 Addenda of the ASME Section XI Code.
List Of Items Associated With The Relief Request: BFN Unit 2 Weld Overlays in the Risk-Informed ISI Program that require examination:
WELD # SYSTEM PIPE SIZE CATEGORY GR-2-15 RECIRC 12.0" E DSRWC-2-03 RWCU 6.0" E DSRWC-2-04 RWCU 6.0" E DSRWC-2-05 RWCU 6.0" E E1-3
Weld Overlays in the tPN Unit 2 Risk-Informed ISI Program that currently do not require examination:
WELD # SYSTEM PIPE SIZE CATEGORY TCS-2-421 Cs 12.0" E GR-2-45 RECIRC 12.0" E GR-2-59 RECIRC 28.0" E GR-2-61 RECIRC 28.0" E GR-2-64 RECIRC 28.0" E Basis For Relief Request: The requirements of ASME Section XI, Appendix VIII, Supplement 11, as stated in the 1995 Edition through the 1996 Addenda are not practical to implement. The requirements were amended to improve the implementation process. The amended requirements are contained in the attachment to this relief request. The EPRI sponsored PDI amendments to Supplement 11, as shown in the attachment, were coordinated with PDI, NRC, and PNNL.
The proposed amended requirements of Supplement 11 for the qualification of personnel, procedures, and equipment will provide an alternative with an acceptable level of quality and safety.
Alternate Requirement: TVA proposes to utilize personnel, procedures, and equipment qualified in accordance with ASME section XI, Appendix VIII, Supplement 11, as amended by the attachment, which is the EPRI administered PDI Program.
Justification For The Granting Of Relief: The proposed amended criteria (as shown in the attachment) to the requirements of the ASME Section XI, 1995 Edition with addenda through 1996, Appendix VIII, Supplement 11, which were coordinated through PDI, NRC, and PNNL, provides an alternative with an acceptable level of quality and safety.
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1.
NOTE: This request for relief (RFR) is consistent with one submitted by Brunswick Steam Electric Plant to the NRC by letters dated July 16, 2002, and February 11, 2003.
The NRC approved the request for relief by letter dated March 26, 2003.
Implementation Schedule: This request for relief is applicable to the BFN Unit 2, ASME Section XI Third Ten-Year ISI inspection interval which expires on May 24, 2011.
Attachment:
Table - Comparison of ASME Section XI, Appendix VIII, Supplement 11, Code Case N-653, and PDI Alternative E1-5
ATTACHMENT 2-ISI-21 Comparison of ASHE Section XI, Appendix VIII, Supplement 11, Code Case N-653, and PDI Alternative E1-6
SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements 4 WROUGHT AUSTENITIC PIPING WELDS 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the No Change No Change requirements listed herein, unless a set of specimens is designed to accommodate specific limitations stated in the scope of the examination procedure (e.g., pipe size, weld joint configuration, access limitations). The same specimens may be used to demonstrate both detection and sizing qualification.
1.1 General. The specimen set shall No Change No Change conform to the following requirements.
(a) Specimens shall have sufficient volume No Change No Change to minimize spurious reflections that may interfere with the interpretation process.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements 41 It WROUGHT AUSTENITIC PIPING WELDS (b) The specimen set shall consist of at least No Change (b) The specimen set shall consist of at least three specimens having different nominal three specimens having different nominal pipe diameters and overlay thicknesses. pipe diameters and overlay thicknesses.
They shall include the minimum and They shall include the minimum and maximum nominal pipe diameters for which maximum nominal pipe diameters for which the examination procedure is applicable. the examination procedure is applicable.
Pipe diameters within a range of 0.9 to 1.5 Pipe diameters within a range of 0.9 to 1.5 times a nominal diameter shall be times a nominal diameter shall be considered equivalent. If the procedure is considered equivalent. If the procedure is applicable to pipe diameters of 24 inches or applicable to pipe diameters of 24 inches or larger, the specimen set must include at larger, the specimen set must include at least one specimen 24 inches or larger but least one specimen 24 inches or larger but need not include the maximum diameter. need not include the maximum diameter.
The specimen set must include at least one The specimen set shall include specimens specimen with overlay thickness within -0.1 with overlays not thicker than 0.1 inches inches to +0.25 inches of the maximum more than the minimum thickness, nor nominal overlay thickness for which the thinner than 0.25 inches of the maximum procedure is applicable. nominal overlay thickness for which the examination procedure is applicable.
(c) The surface condition of at least two No Change No Change specimens shall approximate the roughest surface condition for which the examination procedure is applicable.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (d) Flaw Conditions (1) Base metalflaws. All flaws must be (1) Base metal flaws. All flaws must be in (1) Base metal flaws. All flaws must be in cracks in or near the butt weld heat-affected or near the butt weld heat-affected zone, or near the butt weld heat-affected zone, zone, open to the inside surface, and open to the inside surface, and extending at open to the inside surface, and extending at extending at least 75 percent through the least 75 percent through the base metal least 75 percent through the base metal base metal wall. Flaws may extend 100 wall. Intentional overlay fabrication flaws wall. Intentional overlay fabrication flaws percent through the base metal and into the shall not interfere with ultrasonic detection shall not interfere with ultrasonic detection overlay material; in this case, intentional or characterization of the cracking. or characterization of the base metal flaws.
overlay fabrication flaws shall not interfere Specimens containing IGSCC shall be used Specimens containing IGSCC shall be used with ultrasonic detection or characterization when available. when available. At least 70 percent of the of the cracking. Specimens containing (a) At least 70 percent of the flaws in the flaws in the detection and sizing tests shall IGSCC shall be used when available. detection and sizing tests shall be cracks. be cracks and the remainder shall be Alternative flaw mechanisms, if used, shall alternative flaws. Alternative flaw provide crack-like reflective characteristics mechanisms, if used, shall provide crack-and shall be limited by the following: like reflective characteristics and shall be limited by the following:
(1) Flaws shall be limited to when implantation of cracks precludes obtaining a (a) The use of Alternative flaws shall be realistic ultrasonic response. limited to when the implantation of cracks produces spurious reflectors that are (2) Flaws shall be semi-elliptical with a tip uncharacteristic of actual flaws.
width of less than or equal to 0.002 inches.
(b) Flaws shall be semi-elliptical with a tip width of less than or equal to 0.002 inches.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PD1 PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements A WROUGHT AUSTENITIC PIPING WELDS (2) Overlayfabricationflaws. At least 40 No Change No Change percent of the flaws shall be non-crack fabrication flaws (e.g., sidewall lack of fusion or laminar lack of bond) in the overlay or the pipe-to-overlay interface. At least 20 percent of the flaws shall be cracks.
The balance of the flaws shall be of either type.
(e) Detection Specimens (1) At least 20 percent but less than 40 (1) At least 20 percent but less than 40 (1) At least 20 percent but less than 40 percent of the flaws shall be oriented within percent of the base metal flaws shall be percent of the base metal flaws shall be
+20 degrees of the pipe axial direction. The oriented within +20 degrees of the pipe oriented within +20 degrees of the pipe remainder shall be oriented axial direction. The remainder shall be axial direction. The remainder shall be circumferentially. Flaws shall not be open oriented circumferentially. Flaws shall not oriented circumferentially. Flaws shall not to any surface to which the candidate has be open to any surface to which the be open to any surface to which the physical or visual access. The rules of candidate has physical or visual access. candidate has physical or visual access.
1WA-3300 shall be used to determine whether closely spaced flaws should be treated as single or multiple flaws.
(2) Specimens shall be divided into base and (2) Specimens shall be divided into base (2) Specimens shall be divided into base over-lay grading units. Each specimen shall metal and overlay fabrication grading units. metal and overlay fabrication grading units.
contain one or both types of grading units. Each specimen shall contain one or both Each specimen shall contain one or both types of grading units. Flaws shall not types of grading units. Flaws shall not interfere with ultrasonic detection or interfere with ultrasonic detection or I characterization of other flaws. characterization of other flaws.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements 9 WROUGHT AUSTENITIC PIPING WELDS (a)(J)A base grading unit shall include at (a)(l) A base metal grading unit shall (a)(l)A base metal grading unit includes the least 3 inches of the length of the overlaid include at least 1inch of the length of the overlay material and the outer 25 percent of weld. The base grading unit includes the overlaid weld. The base metal grading unit the original overlaid weld. The base metal outer 25 percent of the overlaid weld and includes the outer 25 percent of the overlaid grading unit shall extend circumferentially base metal on both sides. The base grading weld and base metal on both sides. The for at least 1 inch and shall start at the weld unit shall not include the inner 75 percent of base metal grading unit shall not include the centerline and be wide enough in the axial the overlaid weld and base metal overlay inner 75 percent of the overlaid weld and direction to encompass one half of the material, or base metal-to-overlay interface. base metal overlay material, or base metal- original weld crown and a minimum of 0.50 to-overlay interface. inches of the adjacent base material.
(a)(2) When base metal cracking penetrates (a)(2) When base metal cracking penetrates (a)(2) When base metal flaws penetrate into into the overlay material, the base grading into the overlay material, the base metal the overlay material, the base metal grading unit shall include the overlay metal within grading unit shall not be used as part of any unit shall not be used as part of any overlay 1 inch of the crack location. This portion of overlay fabrication grading unit. fabrication grading unit.
the overlay material shall not be used as part of any overlay grading unit.
(a)(3) When a base grading unit is designed (a)(3) Sufficient unflawed overlaid weld and (a)(3) Sufficient unflawed overlaid weld and to be unflawed, at least 1 inch of unflawed base metal shall exist on all sides of the base metal shall exist on all sides of the overlaid weld and base metal shall exist on grading unit to preclude interfering grading unit to preclude interfering either side of the base grading unit. The reflections from adjacent flaws. reflections from adjacent flaws.
segment of weld length used in one base grading unit shall not be used in another base grading unit. Base grading units need not be uniformly spaced around the specimen.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b)(1) An overlay grading unit shall include (b)(l) An overlay fabrication grading unit (b)(l) An overlay fabrication grading unit the overlay material and the base metal-to- shall include the overlay material and the shall include the overlay material and the overlay interface of at least 6 square inches base metal-to-overlay interface for a length base metal-to-overlay interface for a length The overlay grading unit shall be of at least 1 inch of at least 1 inch.
rectangular, with minimum dimensions of 2 inches.
(b)(2) An overlay grading unit designed to (b)(2) Overlay fabrication grading units (b)(2) Overlay fabrication grading units be unflawed shall be surrounded by designed to be unflawed shall be separated designed to be unflawed shall be separated unflawed overlay material and unflawed by unflawed overlay material and unflawed by unflawed overlay material and unflawed base metal-to-overlay interface for at least base metal-to-overlay interface for at least base metal-to-overlay interface for at least 1 inch around its entire perimeter. The 1 inch at both ends. Sufficient unflawed 1 inch at both ends. Sufficient unflawed specific area used in one overlay grading overlaid weld and base metal shall exist on overlaid weld and base metal shall exist on unit shall not be used in another overlay both sides of the overlay fabrication grading both sides of the overlay fabrication grading grading unit. Overlay grading units need unit to preclude interfering reflections from unit to preclude interfering reflections from not be spaced uniformly about the adjacent flaws. The specific area used in adjacent flaws. The specific area used in specimen. one overlay fabrication grading unit shall one overlay fabrication grading unit shall not be used in another overlay fabrication not be used in another overlay fabrication grading unit. Overlay fabrication grading grading unit. Overlay fabrication grading units need not be spaced uniformly about units need not be spaced uniformly about the specimen. the specimen.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENMC PIPING WELDS (b)(3) Detection sets shall be selected from (b)(3) Detection sets shall be selected from (b)(3) Detection sets shall be selected from Table VIII-S2-1. The minimum detection Table VIII-S2-l. The minimum detection Table VIII-S2-1. The minimum detection sample set is five flawed base grading units, sample set is five flawed base metal grading sample set is five flawed base metal grading ten unflawed base grading units, five flawed units, ten unflawed base metal grading units, ten unflawed base metal grading overlay grading units, and ten unflawed units, five flawed overlay fabrication units, five flawed overlay fabrication overlay grading units. For each type of grading units, and ten unflawed overlay grading units, and ten unflawed overlay grading unit, the set shall contain at least fabrication grading units. For each type of fabrication grading units. For each type of twice as many unflawed as flawed grading grading unit, the set shall contain at least grading unit, the set shall contain at least units. twice as many unflawed as flawed grading twice as many unflawed as flawed grading units. For initial procedure qualification, units. For initial procedure qualification, detection sets shall include the equivalent of detection sets shall include the equivalent of three personnel qualification sets. To three personnel qualification sets. To qualify new values of essential variables, at qualify new values of essential variables, at least one personnel qualification set is least one personnel qualification set is required. required.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING 6
WELDS
( Sizing Specimen (1) The minimum number of flaws shall be (1) The minimum number of flaws shall be (1) The minimum number of flaws shall be ten. At least 30 percent of the flaws shall ten. At least 30 percent of the flaws shall ten. At least 30 percent of the flaws shall be overlay fabrication flaws. At least be overlay fabrication flaws. At least be overlay fabrication flaws. At least 40 percent of the flaws shall be cracks open 40 percent of the flaws shall be cracks open 40 percent of the flaws shall be open to the to the inside surface. to the inside surface. For initial procedure inside surface. Sizing sets shall contain a qualification, sizing sets shall include the distribution of flaw dimensions to assess equivalent of three personnel qualification sizing capabilities. For initial procedure sets. To qualify new values of essential qualification, sizing sets shall include the variables, at least one personnel equivalent of three personnel qualification qualification set is required. sets. To qualify new values of essential variables, at least one personnel qualification set is required.
(2) At least 20 percent but less than No Change No Change 40 percent of the flaws shall be oriented axially. The remainder shall be oriented circumferentially. Flaws shall not be open to any surface to which the candidate has physical or visual access.
(3) Base metal cracking used for length No Change (3) Base metal flaws used for length sizing sizing demonstrations shall be oriented demonstrations shall be oriented circumferentially. circumferentially.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (4) Depth sizing specimen sets shall include No Change (4) Depth sizing specimen sets shall include at least two distinct locations where at least two distinct locations where a base cracking in the base metal extends into the metal flaw extends into the overlay material overlay material by at least 0.1 inch in the by at least 0.1 inch in the through-wall through-wall direction. direction.
2.0 CONDUCT OF PERFORMANCE DEMONSTRATION The specimen inside surface and The specimen inside surface and The specimen inside surface and identification shall be concealed from the identification shall be concealed from the identification shall be concealed from the candidate. All examinations shall be candidate. All examinations shall be candidate. All examinations shall be completed prior to grading the results and completed prior to grading the results and completed prior to grading the results and presenting the results to the candidate. presenting the results to the candidate. presenting the results to the candidate.
Divulgence of particular specimen results or Divulgence of particular specimen results or Divulgence of particular specimen results or candidate viewing of unmasked specimens candidate viewing of unmasked specimens candidate viewing of unmasked specimens after the performance demonstration is after the performance demonstration is after the performance demonstration is prohibited. prohibited. The overlay fabrication flaw prohibited. The overlay fabrication flaw test and the base metal flaw test may be test and the base metal flaw test may be performed separately. performed separately.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements ..
WROUGHT AUSTENITIC PIPING WELDS 2.1 Detection Test.
Flawed and unflawed grading units shall be Flawed and unflawed grading units shall be Flawed and unflawed grading units shall be randomly mixed. Although the boundaries randomly mixed. Although the boundaries randomly mixed. Although the boundaries of specific grading units shall not be of specific grading units shall not be of specific grading units shall not be revealed to the candidate, the candidate revealed to the candidate, the candidate revealed to the candidate, the candidate shall be made aware of the type or types of shall be made aware of the type or types of shall be made aware of the type or types of grading units (base or overlay) that are grading units (base metal or overlay grading units (base metal or overlay present for each specimen. fabrication) that are present for each fabrication) that are present for each specimen. specimen.
2.2 Length Sizing Test (a) The length sizing test may be conducted No Change No Change separately or in conjunction with the detection test.
(b) When the length sizing test is conducted No Change No Change in conjunction with the detection test and the detected flaws do not satisfy the requirements of 1.1(f), additional specimens shall be provided to the candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements ..1 WROUGHT AUSTENITIC PIPING WELDS (c) For a separate length sizing test, the No Change No Change regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.
(d) For flaws in base grading units, the (d) For flaws in base metal grading units, (d) For flaws in base metal grading units, candidate shall estimate the length of that the candidate shall estimate the length of the candidate shall estimate the length of part of the flaw that is in the outer that part of the flaw that is in the outer that part of the flaw that is in the outer 25 percent of the base wall thickness. 25 percent of the base metal wall thickness. 25 percent of the base metal wall thickness.
2.3 Depth Sizing Test.
For the depth sizing test, 80 percent of the The candidate shall determine the depth of (a) The depth sizing test may be conducted flaws shall be sized at a specific location on the flaw in each region. separately or in conjunction with the the surface of the specimen identified to the detection test.
candidate. For the remaining flaws, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.
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SUPPLEMENT I - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS II I. r (b) When the depth sizing test is conducted in conjunction with the detection test and the detected flaws do not satisfy the requirements of 1. (f), additional specimens shall be provided to the candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.
(c) For a separate depth sizing test, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements I
WROUGHT AUSTENITIC PIPING WELDS 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria.
Examination procedures, equipment, and Examination procedures are qualified for (a) Examination procedures are qualified personnel are qualified for detection when detection when all flaws within the scope of for detection when:
the results of the performance the procedure are detected and the results demonstration satisfy the acceptance of the performance demonstration satisfy criteria of Table VIII-S2-1 for both the acceptance criteria of Table VIII-S2-1 detection and false calls. The criteria shall for false calls. Examination equipment and be satisfied separately by the demonstration personnel are qualified for detection when results for base grading units and for the results of the performance overlay grading units. demonstration satisfy the acceptance criteria of Table V1II-S2-1 for both detection and false calls. The criteria shall be satisfied separately by the demonstration results for base metal grading units and for overlay fabrication grading units.
(1) All flaws within the scope of the procedure are detected and the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for false calls.
(2) At least one successful personnel demonstration has been performed meeting the acceptance criteria defined in (b).
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements S WROUGHT AUSTENITIC PIPING WELDS (b) Examination equipment and personnel are qualified for detection when the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls.
(c) The criteria in (a), (b) shall be satisfied separately by the demonstration results for base metal grading units and for overlay fabrication grading units.
3.2 Sizing Acceptance Criteria.
Examination procedures, equipment, and No Change No Change personnel are qualified for sizing when the results of the performance demonstration satisfy the following criteria.
(a) The RMS error of the flaw length No Change (a) The RMS error of the flaw length measurements, as compared to the true flaw measurements, as compared to the true flaw lengths, is less than or equal to 0.75 inches. lengths, is less than or equal to 0.75 inches.
The length of base metal cracking is The length of base metal flaws is measured measured at the 75 percent through-base- at the 75 percent through-base-metal metal position. position.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b) All extensions of base metal cracking This requirement is omitted. This requirement is omitted.
into the overlay material by at least 0.1 inches are reported as being intrusions into the overlay material.
(c) The RMS error of the flaw depth (b) The RMS error of the flaw depth (b) The RMS error of the flaw depth measurements, as compared to the true flaw measurements, as compared to the true flaw measurements, as compared to the true flaw depths, is less than or equal to 0.125 inches. depths, is less than or equal to 0.125 inches. depths, is less than or equal to 0.125 inch.
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ENCLOSURE 2 TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)
UNIT 3 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM (SECOND TEN-YEAR INSPECTION INTERVAL)
REQUEST FOR RELIEF 3-ISI-17 (See Attached)
TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)
UNIT 3 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM (SECOND TEN-YEAR INSPECTION INTERVAL)
REQUEST FOR RELIEF 3-ISI-17 Executive Summary: In accordance with 10 CFR 50.55a(a)(3)(i),
TVA is requesting relief from inservice inspection requirements of the 1995 Edition through 1996 Addenda of Section XI, Appendix VIII, Supplement 11, "Qualification Requirements For Full Structural Overlaid Wrought Austenitic Piping Welds", of the ASME Boiler and Pressure Vessel Code. The Performance Demonstration Initiative (PDI)
Program for implementation of the Supplement 11 qualification program for overlay welds is not in strict compliance with the requirements of Supplement 11 of the 1995 Edition through the 1996 Addenda. TVA proposes to use the PDI Program for implementation of Appendix VIII, Supplement 11 as amended in attachment to this request for relief. The amendments to Supplement 11 as shown in attachment were coordinated with PDI, NRC, and Pacific Northwest National Laboratory (PNNL).
Units: Three (3)
System(s): Recirculation (RECIRC), and Residual Heat Removal (RHR) Systems Components: Piping Welds with Structural Weld Overlay ASME Code Class: ASME Code Class 1 Section XI Edition: 1995 Edition, 1996 Addenda Note: The ASME Section XI Code of record (component selection) for BFN Unit 3 is the 1989 Edition, No addenda. However, TVA has adopted the 1995 Edition, 1996 Addenda for E2-2
nondestructive examination at all of its nuclear plants. Reference TVA letter to NRC dated August 10, 2001. The NRC approved TVA's request by letter dated May 24, 2002.
Code Table: Westinghouse Owners Group (WOG) Topical Report WCAP-14572, Revision 1-NP-A, Table 4.1-1 Examination Category: R-A, Risk-Informed Piping Examinations Examination Item Number: R1.16, Elements Subject To Intergranular Stress Corrosion Cracking (IGSCC)
Code Requirement: The 1995 Edition of ASME Section XI, with addenda through 1996, WCAP-14572, Revision 1-NP-A, Table 4.1-1, Examination Category R-A, Item No. R1.16, requires a volumetric (UT) examination of the pipe weld including the overlay. The UT examination must be performed using personnel, procedures, and equipment qualified in accordance with Appendix VIII, Supplement 11.
Code Requirements From Which Relief Is Requested: Relief is requested from the requirement to qualifypersonnel, procedures, and equipment in accordance with Appendix VIII, Supplement 11 as stated in the 1995 Edition through the 1996 Addenda of the ASME Section XI Code.
List Of Items Associated With The Relief Request: Weld Overlays that currently require examination in the Unit 3 Risk-Informed ISI Program WELD # SYSTEM PIPE SIZE CATEGORY GR-3-53 RECIRC 28.0" E DSRHR-3-11 RHR 20.0" E E2-3
Weld Overlays in the BFN Unit 3 Risk-Informed ISI Program that currently do not require examination:
WELD # SYSTEM PIPE SIZE CATEGORY GR-3-03 RECIRC 28.0" E GR-3-27 RECIRC 28.0" E GR-3-54 RECIRC 28.0" E GR-3-57 RECIRC 28.0" E GR-3-59 RECIRC 28.0" E GR-3-60 RECIRC 28.0" E GR-3-64 RECIRC 28.0" E Basis For Relief:
The requirements of ASME Section XI, Appendix VIII, Supplement 11, as stated in the 1995 Edition through the 1996 Addenda are not practical to implement. The requirements were amended to improve the implementation process. The amended requirements are contained in the attachment to this relief request. The EPRI sponsored PDI amendments to Supplement 11, as shown in the attachment, were coordinated with PDI, NRC, and PNNL.
The proposed amended requirements of Supplement 11 for the qualification of personnel, procedures, and equipment will provide an alternative with an acceptable level of quality and safety.
Alternate Requirement: TVA proposes to utilize personnel, procedures, and equipment qualified in accordance with ASME section XI, Appendix VIII, Supplement 11 as amended by the Attachment, which is the EPRI administered PDI Program.
Justification For The Granting Of Relief: The proposed amended criteria (as shown in the attachment) to the requirements of the ASME Section XI, 1995 Edition with addenda through 1996, Appendix VIII, Supplement 11, which were coordinated through PDI, NRC, and PNNL, provides an alternative with an acceptable level of quality and safety.
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NOTE: This request for relief (RFR) is consistent with one submitted by Brunswick Steam Electric Plant to the NRC by letters dated July 16, 2002 and February 11, 2003.
The NRC approved the request for relief by letter dated March 26, 2003.
Implementation Schedule: This request for relief is applicable to the Unit 3 second Ten-Year ISI inspection interval which expires on November 18, 2005.
Attachment:
Table - Comparison of ASME Section XI, Appendix VIII, Supplement 11, Code Case N-653, and PDI Alternative E2-5
ATTACHMENT 3-ISI-17 Comparison of ASME Section XI, Appendix VIII, Supplement 11, Code Case N-653, and PDI Alternative E2-6
SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements ,,
WROUGHT AUSTENITIC PIPING WELDS 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the No Change No Change requirements listed herein, unless a set of specimens is designed to accommodate specific limitations stated in the scope of the examination procedure (e.g., pipe size, weld joint configuration, access limitations). The same specimens may be used to demonstrate both detection and sizing qualification.
1.1 General. The specimen set shall conform to the following requirements. No Change No Change (a) Specimens shall have sufficient volume No Change No Change to minimize spurious reflections that may interfere with the interpretation process.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b) The specimen set shall consist of at least No Change (b) The specimen set shall consist of at least three specimens having different nominal three specimens having different nominal pipe diameters and overlay thicknesses. pipe diameters and overlay thicknesses.
They shall include the minimum and They shall include the minimum and maximum nominal pipe diameters for which maximum nominal pipe diameters for which the examination procedure is applicable. the examination procedure is applicable.
Pipe diameters within a range of 0.9 to Pipe diameters within a range of 0.9 to 1.5 times a nominal diameter shall be 1.5 times a nominal diameter shall be considered equivalent. If the procedure is considered equivalent. If the procedure is applicable to pipe diameters of 24 inches or applicable to pipe diameters of 24 inches or larger, the specimen set must include at larger, the specimen set must include at least one specimen 24 inches or larger but least one specimen 24 inches or larger but need not include the maximum diameter. need not include the maximum diameter.
The specimen set must include at least one The specimen set shall include specimens specimen with overlay thickness within with overlays not thicker than 0.1 inches
-0.1 inches to +0.25 inches of the maximum more than the minimum thickness, nor nominal overlay thickness for which the thinner than 0.25 inches of the maximum procedure is applicable. nominal overlay thickness for which the examination procedure is applicable.
(c) The surface condition of at least two No Change No Change specimens shall approximate the roughest surface condition for which the examination procedure is applicable.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements . .,
WROUGHT AUSTENITIC PIPING WELDS (d) Flaw Conditions (1) Base metalflaws. All flaws must be (1) Base metal flaws. All flaws must be in (1) Base metal flaws. All flaws must be in cracks in or near the butt weld heat-affected or near the butt weld heat-affected zone, or near the butt weld heat-affected zone, zone, open to the inside surface, and open to the inside surface, and extending at open to the inside surface, and extending at extending at least 75 percent through the least 75 percent through the base metal least 75 percent through the base metal base metal wall. Flaws may extend wall. Intentional overlay fabrication flaws wall. Intentional overlay fabrication flaws:
100 percent through the base metal and shall not interfere with ultrasonic detection shall not interfere with ultrasonic detection into the overlay material; in this case, or characterization of the cracking. or characterization of the base metal flaws.
intentional overlay fabrication flaws shall Specimens containing IGSCC shall be used Specimens containing IGSCC shall be used not interfere with ultrasonic detection or when available. At least 70 percent of the when available. At least 70 percent of the characterization of the cracking. Specimens flaws in the detection and sizing tests shall flaws in the detection and sizing tests shall containing IGSCC shall be used when be cracks. Alternative flaw mechanisms, if be cracks and the remainder shall be available. used, shall provide crack-like reflective alternative flaws. Alternative flaw characteristics and shall be limited by the mechanisms, if used, shall provide crack-following: like reflective characteristics and shall be limited by the following:
(1) Flaws shall be limited to when implantation of cracks precludes obtaining a (a) The use of Alternative flaws shall be realistic ultrasonic response. limited to when the implantation of cracks produces spurious reflectors that are (2) Flaws shall be semi-elliptical with a tip uncharacteristic of actual flaws.
width of less than or equal to 0.002 inches.
(b) Flaws shall be semi-elliptical with a tip width of less than or equal to 0.002 inches.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements t .,
WROUGHT AUSTENITIC PIPING WELDS (2) Overlayfabricationflaws. At least 40 No Change No Change percent of the flaws shall be non-crack fabrication flaws (e.g., sidewall lack of fusion or laminar lack of bond) in the overlay or the pipe-to-overlay interface. At least 20 percent of the flaws shall be cracks.
The balance of the flaws shall be of either type.
(e) Detection Specimens (1) At least 20 percent but less than 40 percent of the flaws shall be oriented (1) At least 20 percent but less than 40 (1) At least 20 percent but less than within +20 degrees of the pipe axial percent of the base metal flaws shall be 40 percent of the base metal flaws shall be direction. The remainder shall be oriented oriented within +20 degrees of the pipe oriented within +20 degrees of the pipe circumferentially. Flaws shall not be open axial direction. The remainder shall be axial direction. The remainder shall be to any surface to which the candidate has oriented circumferentially. Flaws shall not oriented circumferentially. Flaws shall not physical or visual access. The rules of be open to any surface to which the be open to any surface to which the IWA-3300 shall be used to determine candidate has physical or visual access. candidate has physical or visual access.
whether closely spaced flaws should be treated as single or multiple flaws.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements ..
WROUGHT AUSTENITIC PIPING WELDS (2) Specimens shall be divided into base (2) Specimens shall be divided into base (2) Specimens shall be divided into base and metal and overlay fabrication grading units. metal and overlay fabrication grading units.
over-lay grading units. Each specimen shall Each specimen shall contain one or both Each specimen shall contain one or both contain one or both types of grading units. types of grading units. Flaws shall not types of grading units. Flaws shall not interfere with ultrasonic detection or interfere with ultrasonic detection or characterization of other flaws. characterization of other flaws.
(a)(1) A base grading unit shall include at (a)(l) A base metal grading unit shall (a)(l) The base metal grading unit includes least 3 inches of the length of the overlaid include at least 1 inch of the length of the the overlay material and the outer 25 weld. The base grading unit includes the overlaid weld. The base metal grading unit percent of the original overlaid weld. The outer 25 percent of the overlaid weld and includes the outer 25 percent of the overlaid base metal grading unit shall extend base metal on both sides. The base grading weld and base metal on both sides. The circumferentially for at least 1 inch and shall unit shall not include the inner 75 percent of base metal grading unit shall not include the start at the weld centerline and be wide the overlaid weld and base metal overlay inner 75 percent of the overlaid weld and enough in the axial direction to encompass material, or base metal-to-overlay interface. base metal overlay material, or base metal- one half of the original weld crown and a to-overlay interface. minimum of 0.50" of the adjacent base material.
(a)(2) When base metal cracking penetrates (a)(2) When base metal cracking penetrates (a)(2) When base metal flaws penetrate into into the overlay material, the base grading into the overlay material, the base metal the overlay material, the base metal grading unit shall include the overlay metal within grading unit shall not be used as part of any unit shall not be used as part of any overlay 1 inch of the crack location. This portion of overlay fabrication grading unit. fabrication grading unit.
the overlay material shall not be used as part of any overlay grading unit.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (a)(3) When a base grading unit is designed (a)(3) Sufficient unflawed overlaid weld and (a)(3) Sufficient unflawed overlaid weld and to be unflawed, at least 1 inch of unflawed base metal shall exist on all sides of the base metal shall exist on all sides of the overlaid weld and base metal shall exist on grading unit to preclude interfering grading unit to preclude interfering either side of the base grading unit. The reflections from adjacent flaws. reflections from adjacent flaws.
segment of weld length used in one base grading unit shall not be used in another base grading unit. Base grading units need not be uniformly spaced around the specimen.
(b)(1) An overlay grading unit shall include ()(1) An overlay fabrication grading unit (b)(1) An overlay fabrication grading unit the overlay material and the base metal-to- shall include the overlay material and the shall include the overlay material and the overlay interface of at least 6 square inches. base metal-to-overlay interface for a length base metal-to-overlay interface for a length The overlay grading unit shall be of at least I inch. of at least 1 inch.
rectangular, with minimum dimensions of 2 inches.
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SUPPLEMENT 1 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements I d.
WROUGHT AUSTENITIC PIPING WELDS (b)(2) An overlay grading unit designed to (b)(2) Overlay fabrication grading units (b)(2) Overlay fabrication grading units be unflawed shall be surrounded by designed to be unflawed shall be separated designed to be unflawed shall be separated unflawed overlay material and unflawed by unflawed overlay material and unflawed by unflawed overlay material and unflawed base metal-to-overlay interface for at least base metal-to-overlay interface for at least base metal-to-overlay interface for at least 1 inch around its entire perimeter. The 1 inch at both ends. Sufficient unflawed 1 inch at both ends. Sufficient unflawed specific area used in one overlay grading overlaid weld and base metal shall exist on overlaid weld and base metal shall exist ony unit shall not be used in another overlay both sides of the overlay fabrication grading both sides of the overlay fabrication grading grading unit. Overlay grading units need unit to preclude interfering reflections from unit to preclude interfering reflections from not be spaced uniformly about the adjacent flaws. The specific area used in adjacent flaws. The specific area used in specimen. one overlay fabrication grading unit shall one overlay fabrication grading unit shall not be used in another overlay fabrication not be used in another overlay fabrication grading unit. Overlay fabrication grading grading unit. Overlay fabrication grading units need not be spaced uniformly about units need not be spaced uniformly about the specimen. the specimen.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b)(3) Detection sets shall be selected from (b)(3) Detection sets shall be selected from (b)(3) Detection sets shall be selected from Table VIII-S2-1. The minimum detection Table VIII-S2-1. The minimum detection Table VIII-S2-1. The minimum detection sample set is five flawed base grading units, sample set is five flawed base metal grading sample set is five flawed base metal grading ten unflawed base grading units, five flawed units, ten unflawed base metal grading units, ten unflawed base metal grading overlay grading units, and ten unflawed units, five flawed overlay fabrication units, five flawed overlay fabrication overlay grading units. For each type of grading units, and ten unflawed overlay grading units, and ten unflawed overlay grading unit, the set shall contain at least fabrication grading units. For each type of fabrication grading units. For each type of twice as many unflawed as flawed grading grading unit, the set shall contain at least grading unit, the set shall contain at least units. twice as many unflawed as flawed grading twice as many unflawed as flawed grading units. For initial procedure qualification, units. For initial procedure qualification, detection sets shall include the equivalent of detection sets shall include the equivalent of three personnel qualification sets. To three personnel qualification sets. To qualify new values of essential variables, at qualify new values of essential variables, at least one personnel qualification set is least one personnel qualification set is required. required.
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SUPPLEMENT 11- QUAIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS 69 Sizing Specimen (1) The minimum number of flaws shall be (1) The minimum number of flaws shall be (1) The minimum number of flaws shall be ten. At least 30 percent of the flaws shall ten. At least 30 percent of the flaws shall ten. At least 30 percent of the flaws shall be overlay fabrication flaws. At least be overlay fabrication flaws. At least be overlay fabrication flaws. At least 40 percent of the flaws shall be cracks open 40 percent of the flaws shall be cracks open 40 percent of the flaws shall be open to the to the inside surface. to the inside surface. For initial procedure inside surface. Sizing sets shall contain a qualification, sizing sets shall include the distribution of flaw dimensions to assess equivalent of three personnel qualification sizing capabilities. For initial procedure sets. To qualify new values of essential qualification, sizing sets shall include the variables, at least one personnel equivalent of three personnel qualification qualification set is required. sets. To qualify new values of essential variables, at least one personnel qualification set is required.
(2) At least 20 percent but less than No Change No Change 40 percent of the flaws shall be oriented axially. The remainder shall be oriented circumferentially. Flaws shall not be open to any surface to which the candidate has physical or visual access.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (3) Base metal cracking used for length No Change (3) Base metal flaws used for length sizing sizing demonstrations shall be oriented demonstrations shall be oriented circumferentially. circumferentially.
(4) Depth sizing specimen sets shall include No Change (4) Depth sizing specimen sets shall include at least two distinct locations where at least two distinct locations where a base-cracking in the base metal extends into the metal flaw extends into the overlay material overlay material by at least 0.1 inches in the by at least 0.1 inches in the through-wall through-wall direction. direction.
2.0 CONDUCT OF PERFORMANCE DEMONSTRATION The specimen inside surface and The specimen inside surface and The specimen inside surface and identification shall be concealed from the identification shall be concealed from the identification shall be concealed from the candidate. All examinations shall be candidate. All examinations shall be candidate. All examinations shall be completed prior to grading the results and completed prior to grading the results and completed prior to grading the results and presenting the results to the candidate. presenting the results to the candidate. presenting the results to the candidate.
Divulgence of particular specimen results or Divulgence of particular specimen results or Divulgence of particular specimen results or candidate viewing of unmasked specimens candidate viewing of unmasked specimens candidate viewing of unmasked specimens after the performance demonstration is after the performance demonstration is after the performance demonstration is prohibited. prohibited. The overlay fabrication flaw prohibited. The overlay fabrication flaw test and the base metal flaw test may be test and the base metal flaw test may be performed separately performed separately.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAII) (Provided for Information Only) Supplement 11 Requirements .. ..
WROUGHT AUSTENITIC PIPING WELDS 2.1 Detection Test.
Flawed and unflawed grading units shall be Flawed and unflawed grading units shall be Flawed and unflawed grading units shall be randomly mixed. Although the boundaries randomly mixed. Although the boundaries randomly mixed. Although the boundaries of specific grading units shall not be of specific grading units shall not be of specific grading units shall not be revealed to the candidate, the candidate revealed to the candidate, the candidate revealed to the candidate, the candidate shall be made aware of the type or types of shall be made aware of the type or types of shall be made aware of the type or types of grading units (base metal or overlay grading units (base metal or overlay grading units (base or overlay) that are fabrication) that are present for each fabrication) that are present for each present for each specimen. specimen. specimen.
2.2 Lengh Sizing Test (a) The length sizing test may be conducted No Change No Change separately or in conjunction with the detection test.
(b) When the length sizing test is conducted No Change No Change in conjunction with the detection test and the detected flaws do not satisfy the requirements of 1.1(f), additional specimens shall be provided to the candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.
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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements .# A, WROUGHT AUSTENITIC PIPING WELDS (c) For a separate length sizing test, the No Change No Change regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.
(d) For flaws in base grading units, the (d) For flaws in base metal grading units, (d) For flaws in base metal grading units, candidate shall estimate the length of that the candidate shall estimate the length of the candidate shall estimate the length of part of the flaw that is in the outer that part of the flaw that is in the outer that part of the flaw that is in the outer 25 percent of the base wall thickness. 25 percent of the base metal wall thickness. 25 percent of the base metal wall thickness.
2.3 Depth Sizing Test.
For the depth sizing test, 80 percent of the The candidate shall determine the depth of (a) The depth sizing test may be conducted flaws shall be sized at a specific location on the flaw in each region. separately or in conjunction with the the surface of the specimen identified to the detection test.
candidate. For the remaining flaws, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements e ... S WROUGHT AUSTENITIC PIPING WELDS (b) When the depth sizing test is conducted in conjunction with the detection test and the detected flaws do not satisfy the requirements of 1.1(f), additional specimens shall be provided to the candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.
(c) For a separate depth sizing test, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements " ^A. .,
WROUGHT AUSTENITIC PIPING WELDS 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria.
Examination procedures, equipment, and Examination procedures are qualified for (a) Examination procedures are qualified personnel are qualified for detection when detection when all flaws within the scope of for detection when:
the results of the performance the procedure are detected and the results demonstration satisfy the acceptance of the performance demonstration satisfy criteria of Table VIII-S2-1 for both the acceptance criteria of Table VIII-S2-1 detection and false calls. The criteria shall for false calls. Examination equipment and be satisfied separately by the demonstration personnel are qualified for detection when results for base grading units and for the results of the performance overlay grading units. demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls. The criteria shall be satisfied separately by the demonstration results for base metal grading units and for overlay fabrication grading units.
I) All flaws within the scope of the procedure are detected and the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for false calls.
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SUPPLEMENT 1 1 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements -r," - A.
WROUGHT AUSTENITIC PIPING WELDS (2) At least one successful personnel demonstration has been performed meeting the acceptance criteria defined in (b).
(b)Examination equipment and personnel are qualified for detection when the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls.
(c) The criteria in (a), (b) shall be satisfied separately by the demonstration results for base metal grading units and for overlay fabrication grading units.
3.2 Sizing Acceptance Criteria.
Examination procedures, equipment, and No Change No Change personnel are qualified for sizing when the results of the performance demonstration satisfy the following criteria.
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SUPPLEMENT 11- QUALIFICATION CODE CASE N-653 PDI PROGRAM:
REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (a) The RMS error of the flaw length No Change (a) The RMS error of the flaw length measurements, as compared to the true flaw measurements, as compared to the true flaw lengths, is less than or equal to 0.75 inches. lengths, is less than or equal to 0.75 inches.
The length of base metal cracking is The length of base metal flaws is measured measured at the 75 percent through-base- at the 75 percent through-base-metal metal position. position.
This requirement is omitted. This requirement is omitted.
(79 All extensions of base metal cracking into the overlay material by at least 0.1 inches are reported as being intrusions into the overlay material.
(c) The RMS error of the flaw depth (b) The RMS error of the flaw depth (b) The RMS error of the flaw depth measurements, as compared to the true flaw measurements, as compared to the true flaw measurements, as compared to the true flaw depths, is less than or equal to 0.125 inches. depths, is less than or equal to 0.125 inches. depths, is less than or equal to 0.125 inches.
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