ML17229B017
| ML17229B017 | |
| Person / Time | |
|---|---|
| Site: | Saint Lucie  |
| Issue date: | 02/18/1999 |
| From: | Stall J FLORIDA POWER & LIGHT CO. |
| To: | NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| References | |
| L-99-40, NUDOCS 9903020313 | |
| Download: ML17229B017 (40) | |
Text
CATEGORY 1 REGULA'L dY INFORMATION DISTRIBUTIO SYSTEM (RIDS)
ACCESSION NBR:9903020313 DOC.DATE: 99/02/18 NOTARIZED: NO FAClL:50-389 St. Lucie Plant, Unit 2, Florida Power
& Light Co.
AUTH.NAME AUTHOR AFFILIATION STALL,J.A.
'Florida Power
& Light Co.
RECIP.NAME RECIPIENT AFFILIATION Records Management Branch (Document Control Desk)
DOCKET ¹ 05000389
SUBJECT:
Requests approval of Relief Request 22 re ISI plan for second ten-yr interval.NRC action requested to be complete by Aug 1999 to support planning for Spring 2000 Unit 2 refueling outage (SL2-12).
A DISTRIBUTION CODE: A047D COPIES RECEIVED:LTR ENCL SIZE:
T TITLE: OR Submittal: Inservice/Testing/Re'lief from ASME Code
- GL-89-04 p
NOTES:
Q RECIPIENT ID CODE/NAME PD2-3 LA GLEAVES,W INTERNAL: ACRS ER 1
NUDOCS -ABSTRACT RES/DET/EIB COPIES LTTR ENCL 1
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1 1
1 RECIPIENT ID CODE/NAME PD2-3 PD AEOD/SPD/RAB NRR/DE/ECGB OGC/HDS3 RES/DET/EMMEB COPIES LTTR ENCL 1
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NOTE TO ALL "RIDS" RECIPIENTS:
PLEASE HELP US TO REDUCE WASTE. TO HAVE YOUR NAME OR ORGANIZATION REMOVED FROM DISTRIBUTION LISTS OR REDUCE THE NUMBER OF COPIES RECEIVED BY YOU OR YOUR ORGANIZATION, CONTACT THE DOCUMENT CONTROL DESK (DCD)
ON EXTENSION 415-2083 TOTAL NUMBER OF COPIES REQUIRED:
LTTR 14 ENCL 13
i
Florida Power &Light Company, 6351 S. Ocean Drive. Jensen Beach, FL 34957 February 18, 1999 L-99-40 10 CFR 50.4 10 CFR 50.55a U. S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, DC 20555 RE:
St. Lucie Unit 2 Docket No. 50-389
, In-Service-Inspection Plan Second Ten-Year Interval Relief R uest 22 Pursuant to 10 CFR 50.55a, (Footnote 6) and 10 CFR-50.55a (a)(3), Florida Power and Light Company (FPL) requests approval of relief request 22. Relief Request 22 incorporates Code Case N-622, Ultrasonic lamination ofRPVand Piping and,'Bolts and Studs,Section XI, Division I, in lieu of the requirements of Appendix I, ArticleI 2000.
The Code Case willbe used for the performance of the required volumetric examinations of Class 1 component welds as specified in Table IWB-2500-1 Category B-A and B-D of the 1989 Edition of ASME Section XI.
FPL has determined pursuant to 10 CFR 50.55a (a)(3) that the proposed alternatives would provide an acceptable level of quality and safety, or that compliance with the specified requirements would result in hardship or unusual difficultywithout a compensating increase in the level of quality and safety.
ASME approved Code Case N-622 for use on December 11, 1998.
NRC action is requested to be complete by August 1999 to support planning for the Spring 2000 Unit 2 refueling outage (SL2-12).
Please contact us if there are any questions about this submittal.
Very truly yours, J. A. Stall Vice President St. Lucie Plant JAS/GRM Enclosure ted%'
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cc:
Regional Administrator, Region II, USNRC Senior Resident Inspector, USNRC, St. Lucie Plant 99030203i3 9902i8 PDR ADQCK 05000389 8
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t St. Lucie Unit 2 Docket No. 50-389 L-99-40 Enclosure Page 1
St. Lucie Unit 2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 22 A.
COMPONENT IDENTIFICATION:
Class:
1 Reactor Pressure Vessel Pressure-retaining welds in vessels examined at St. Lucie Unit 2.
B.
EXAMINATIONREQUIREMENT:
Rules for In-Service Inspection of Nuclear Power Plant Components,Section XI, 1989 Edition
',', Exam",
,:" Cat;:.;:..'::::!':..',::,'.": Exa'mination',RequIr'em'ents:':,',.:,,'::,:,'.:,.,",..'-! ',;:.';:",,:,
B-A B1.10 B1.11 B1.12 Essentially 100% volumetric examination of longitudinal and circumferential shell welds (does not include shell to flange weld)
In accordance with A endix I Article I-2000.
B-A B-A B1.20 B1.21 B1.22 B1.30 Essentially 100% volumetric examination of accessible length of circumferential and meridional head welds in accordance with A
endix I, Article I-2000.
Essentially 100% volumetric examination ofthe shell to flange weld in accordance with A endix I Article l-2000.
B-A B-D B1.40 B3.90 Essentially 100% volumetric and surface examination of head to flan e weld in accordance with A endix I, Article l-2000.
Essentially 100% volumetric examination of nozzle-to-vessel welds in accordance with A endix I Article l-2000.
C.
ASME Code Case N460: Alternative Examination Coverage for Class 1 and Class 2 Weids RELIEF REQUESTED:
Pursuant to 10 CFR 50.55a (a)(3)Oi, FPL requests to use the alternative requirements of Code Case N-622 in lieu ofthe requirements ofAppendix I, Article I -2000 for the performance ofthe required volumetric examinations of Class 1 component welds as specified in Table IWB-2500-1 Category B-Aand B-D ofthe 1989 Edition ofASME Section XI. These examinations will be performed during the second inspection interval.
D.
BASIS FOR RELIEF'PL is currently required to perform in-service examinations of selected welds in accordance with the requirements of 10 CFR 50.55a, plant technical specifications, and the 1989 Edition of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code,Section XI, Rules for In-Service Inspection of Nuclear Power Plant Components.
This Code edition invokes the examination requirements ofAppendix I, Article 1-2000 that essentially prescribes twenty (20) year old examination methodology.
This examination methodology is typically "qualified" by calibration on side drilled holes in a calibration block fabricated from similar material.
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t St. Lucie Unit 2 Docket No. 50-389 L-99-40 Enclosure Page 2 St. Lucie Unit 2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 22 Later Code Editions and Code Case N-622 describe a performance demonstration based examination methodology that has been proven to be superior to the current requirements.
These demonstrations have been conducted using full sized vessel specimens that contain fatigue cracks replicating the actual conditions that could be encountered.
We believe the use of Code Case N-622, which delineates this newer demonstrated examination methodology, will provide added assurance that the reactor vessel welds have remained free of service related flaws thus enhancing quality and ensuring plant safety and reliability. This willbe particularly evident in the important under-clad region where the performance demonstrations have resulted in examination technique enhancements that transcend Code requirements.
Furthermore, examinations performed using these newer techniques willallow us to achieve greater coverage ofthe Code required volume, thereby eliminating or substantially reducing areas of reduced coverage described in the previously approved Relief Request No. 1. The implementation ofthe methodology of Code Case N-622 is also expected to reduce on-vessel examination time by as much as 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, which translates to significant cost savings and reduced personnel radiation exposure.
E.
ALTERNATIVEEXAMINATIONS:
1)
Perform examinations in accordance with Code Case N-622 2)
Conduct mechanized ultrasonic examinations of 100% of all wetds to the extent practical using Performance Demonstration Initiative (PDI) qualified procedures and personnel.
G.
3)
Periodic system pressure tests per Category B-P, Table IWB-2500-1 IMPLEMENTATIONSCHEDULE:
Second In-Service Inspection Interval ATTACHMENTSTO THE RELIEF'ode Case N-622
I St. Lucie Unit 2 Docket No. 50-389 L-99-40 Enclosure R/R 22 Attachment lof31 Code Case N-622 Ultrasonic Examination of RPV and Piping and Bolts and StudsSection XI, Division 1 Applicability:
1989 Edition with the 1989 Addenda and Later Editions and Addenda through the 1998 Edition Inquiry:
What alternative requirements may be used for ultrasonic examination of RPV, piping, bolts and studs in lieu of Appendices I and VIII?
Reply:
It is the opinion of the Committee that, in lieu of the ultrasonic examination requirements for RPV and piping and bolts and studs of Appendices I and VIII,the following requirements may be used.
Passed Main Committee 12/1 1/98
CHAPTER A A.1 PIPING EXAMINATIONCOVERAGE Page 2 of31 (a) The required piping examination volume shall be examined in two axial directions.
When examination in the circumferential direction is required, the circumferential examination shall be performed in two directions.
(b) Alternatively, when examinations offerritic welds Rom both sides is not possible, full coverage credit may be claimed Rom a single side using a procedure qualified for single-side examination in accordance with Chapter B, Supplement 3. When examination of austenitic welds Rom both sides is not possible, fullcoverage credit may be claimed from a single side using a procedure qualified for single-side examination in accordance with Chapter B, Supplement 2, with all flaws on the opposite side ofthe weld.
A.2 REACTOR PRESSURE VESSEL SHELL WELDS (a) The clad-to-base-metal interface region, including at least 15% T (measured from clad-to-base-metal interface), shall be examined from four directions, using a procedure qualified in accordance with Chapter B, Supplement 4.
Examination directions shall include scans parallel and perpendicular to the weld.
(b) Ifthe clad-to-base-metal-interface procedure demonstrates detectability offlaws with a tiltangle relative to the weld centerline ofat least 45 deg., the remainder ofthe examination volume is considered fullyexamined ifcoverage is obtained in one parallel and one perpendicular direction. This shall be accomplished using a procedure and personnel qualified for single-side examination in accordance with Chapter B, Supplement 6. Subsequent examinations may be performed using examination techniques qualified for a tiltangle ofat least + 10 deg.
A.3 REACTOR PRESSURE VESSEL NOZZLE-TO-SHELLWELDS (a) Examinations Conducted from the Inside (1) The clad-to-base-metal interface and the adjacent examination volume to a depth ofat least 15% T (measured Rom the clad-to-base-metal interface) shall be examined from four orthogonal directions, using a procedure qualified in accordance with Chapter B, Supplement 4.
(2) When the examination volume defined in (1) cannot be effectively examined in.all four directions, the examination shall be augmented by examination from the nozzle bore, using a procedure qualified in accordance with Chapter B, Supplement 7.
(3) The remainder ofthe examination volume not covered by (1) or by a combination of(1) and (2) shall be examined in at least one radial direction &om:
(a) the nozzle bore using a procedure qualified in a accordance with Chapter B, Supplenient 7, or (b) the vessel shell using a procedure qualified for single-sided examination in accordance with Chapter B, Supplement 6.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No.l, Page 97 1
Page 3 of31 (b) Examinations Conducted from the Outside (1) The clad-to-base-metal interface and the adjacent examination volume to a depth ofat least 15% T (measured Qom the clad-to-base-metal interface) shall be examined
&om one radial and two opposing circumferential directions using a procedure qualiQed in accordance with Chapter B, Supplement 4, for examination performed in the radial direction, and Supplement 5B, for examination performed in the circumferential directions.
R 4
(2) The remainder ofthe examination volume not covered by (1) shall be examined in at least one radial direction using a procedure qualified for a single-side examination in accordance with Chapter B, Supplement 6.
A.4 BOLTS ANDSTUDS Ultrasonic examination ofbolts and studs shall be performed using procedure and personnel qualified in accordance with Chapter B, Supplement 8.
The volume specified in IWB-2500 and IWC-2500 shall be examined.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No.l, Page 97 1
CHAPTER 8 PERFORMANCE DEMONSTRATIONFOR ULTRASONICEXAMINATIONSYSTEMS Page 4 of31 B-1000 SCOPE B-1100 GENERAL (a)
This Chapter provides requirements for performance demonstration for ultrasonic examination procedures and personnel used to detect and size flaws.
(b) Each organization (e.g., Owner or vendor) shall have a written program that ensures compliance with this Case.
Each organization that performs ultrasonic examinations shall qualify its procedures and personnel in accordance with this Case.
The organization may
'contract implementation ofthe program.
(c) Performance demonstration requirements apply to personnel who detect, record, or interpret indications or size flaws in welds or components.
(d) The performance demonstration requirement specified in this Case do not apply to personnel whose involvement is limited to mounting a scanning device, marking pipe, or other situations where knowledge ofultrasonics is not important.
(e)
Operators of fully-automated data collection.systems need not be qualified to
~ the requirements ofthis Case, provided that (I) the data analyst is qualified to the requirements of this Case, and is responsible for system calibration and verifying systems sensitivity; (2) the analyst is responsible for establishment ofexamination sensitivity; and (3) the system meets the definition ofautomated system, below.
g Systems used for acquisition (collection) ofultrasonic data are classified as automated, semi-automated, or manual, as define below.
(I) Automated system - A system that is fullysoftware-controlled by input parameters or specification from an operator and that digitally acquires and'records the complete real-time output for each transducer during the collection process.
All system calibrations, examination, and scanning parameters used during collection are verifiable during off-line analysis. Allrequired real-time information (e.g., A-scan waveforms, C-scan or B-scans images) can be processed offline for analysis.
No adjustments to the ultrasonic parameters can be made without knowledge and concurrence ofthe analyst.
(2) Semi-automated system or manual system.
A system that is not fully software-controlled, i.e., that requires an operator to make ultrasonic parameter adjustments during the collection process, that will affect the off-line analysis.
The following are some characteristics ofsemi-automated or manual systems:
(a) complete real-time output for each transducer is not recorded; (b) all system calibrations, and examination, and scanning parameters cannot be verified during off-line analysis; Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 I
Page 5 of31 (c) the examination cannot be reconstructed &om the recorded data;
~
(d) adjustments to the ultrasonic parameters can be made without knowledge and concurrence ofthe analyst.
B-2000 GENERAL EXAMINATIONSYSTEM REQUIREMENTS B-2100 PROCEDURE REQUIREMENTS (a) The examination procedure shall contain a statement ofscope that specifically defines the limits ofprocedure applicability (e.g., materials, thickness, diameter, and product form).
(b) The procedure shall provide specific instructions. with sufficient detail to assure that the Owner can determine that the qualified procedure is followed during field applications.
(c) The examination procedure shall specify a single value or a range of values for the variables listed in B-2100(e).
(d) Any calibration method may be used provided it is described and complies with B-2100(e)(5).
(e) The examination procedure shall specify the following essential variables:
, (1) instrument or system, including manufacturer and model or series ofpulser, receiver, and amplifier, including:
(a) instrument settings for center frequency, pulse width, and filteringor smoothing; (b) operation, e.g., voltage, spike, square wave, tone burst; (2) search units, including:
(a) center frequency and either bandwidth or waveform duration as defined in B-4000; (b) mode ofpropagation and nominal inspection angles; (c) number, size, shape, and configuration ofactive elements and wedges or shoes; (3) search unit cable, including:
(a) type; (b) maximum length; (c) maximum number ofconnectors; (4) detection and sizing techniques, including:
(a) scan pattern and beam directions; (b) maximum scan speed; (c) minimum and maximum pulse repetition rate (bolting only);
(d) minimum spatial sample spacing in scan and index directions, i.e., sample surface distance between points where an A-scan is recorded(automated systems);
(e) extent ofscanning and action to be taken for access restrictions; (5) methods of calibration for detection and sizing (e.g., actions required to insure that the sensitivity and accuracy of the signal amplitude and time outputs of the examination
- system, whether displayed,
- recorded, or automatically processed, are repeated from examination to examination);
(6) inspection and calibration data to be recorded; (7) method ofdata recording; (8) recording equipment (e.g., strip chart, analog tape, digitizing) when used; (9) methodology and criteria for discrimination of indications (e.g., geometric versus flaw indications and for length and depth sizing offlaws);
(1 0) surface preparation requirements; Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 6 of31 (11) any other identifiable factor that could substantially influence the effectiveness of the examination.
B-2200 PERSONNEL REQUIREMENTS Personnel shall meet the requirements ofAppendix VIIand shall be qualified in accordance with 4B-3000.
B -3000 QUALIFICATIONTEST REQUIREMENTS B -3100 QUALIFICATIONTEST REQUIREMENT$
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B -3110 DETECTION (a) Qualification test specimens shall meet the requirements of the appropriate Supplement listed in Table B-3110-1 (b) The examination procedure and personnel are qualified for detecting flaws upon successful completion of the performance demonstration specified in the appropriate Supplement listed in Table B-3110-1.,
(c) For piping welds whose requirements are in course of preparation the requirements of Appendix III,as supplemented by Table I-2000-1, shall be met.
B-3120 SIZING (a) Qualification test specimens shall meet the requirements of the appropriate Supplement listed in Table B-3110-1.
(b) The examination procedure, and personnel are qualified for sizing flaws upon successful completion of the performance demonstration specified in the appropriate Supplement listed in Table B-3110-1.
(c) For piping welds whose requirements are in course of preparation, the requirements of Appendix III,as supplemented by Table I-2000-1, shall be met.
(d) RMS error shall be calculated as follows:
t/2 RMS ~
where m; = measured flaw size t;= true flaw size n = number offlaws measured Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 7 of31 TABLEB-3110-1 COMPONENT QUALIFICATIONSUPPLEMENTS Component Type Piping Welds Wrought Austenitic Ferritic Cast Austenitic Dissimilar Metal Overlay Coordinated Implementation Vessels Clad-to-Base-Metal Interface Region Nozzle Inside Radius Section Reactor Vessel Welds Other Than Clad-to-Base-Metal Interface Nozzle-to-Vessel Weld Coordinated Implementation Bolts and Studs Applicable Supplement 2
3
[Note (1)]
Appendix VIII,Supplement 10 Appendix VIII,Supplement 11 Appendix VIII,Supplement 12 4
SAorSB 6
7 13 8
NOTE:
(1) In the course ofpreparation B-3130 ESSENTIAL VARIABLERANGES (a) Any two procedures with the same essential variable [B-2100(d)] are considered equivalent.
- Pulsers, search units, and receivers that vary within the tolerance specified in B-4100 are considered equivalent.
When the pulser, search units, and receivers vary beyond the tolerances of B-4100, or when the examination procedure allows more than one value or range for an essential variable, the qualification test shall be repeated at the minimum and maximum value, as applicable from B-4100 (e.g., at the lowest and highest allowed settings or frequencies) for each essential variable with all other variables remaining at nominal values.
Changing the essential variable may be accomplished during successive personnel performance demonstrations.
Each examiner need not demonstrate qualification over the entire range of every essential variable.
(b)When the procedure does not specify a range for essential variables and establishes criteria for selecting values, the criteria shall be demonstrated during the procedure qualification.
B-3140 REQUALIFICATION When a change in an examination procedure causes an essential variable to exceed a qualified range, the examination procedure shall be requalified for the revised range.
Passed Main Committee 12/I I/98, Published January 99, "Mechanical Engineering", Volume 121/No. I, Page 97 I
Page 8 of31 B-4000 ESSENTIAL VARIABLETOLERANCES BQ100 PROCEDURE MODIFICATIONS B-4110 PULSERS, RECEIVERS, AND SEARCH UNITS Components ofthe same make, model number and physical description are substitutable without further consideration, The qualified procedure may be modified to substitute or replace pulsers, receivers, or search units without requalification when the followingconditions are met.
(a) Instruments with reject, damping, or pulse tuning controls, have discrete settings specified in the procedure.
(b) Pulsers and receivers shall be evaluated using ASTM E 1324, Guide for Measuring Some Electronic Characteristics ofUltrasonic Instruments, with the followingexceptions:
(1) The lower (F/) and upper (Ft/) limits for receivers shall be determined between frequencies that are 6 dB below the peak &equency.
(2) The receiver center &equency (Fp) shall be determined by:
Fc+ Fu Fc=
2 (3) The receiver bandwidth (BW) shall be determined by:
Fu-Fc BW'=
x 100 Fc (c) Search units shall be evaluated using ASTM E 1065, Evaluation of the Characteristics of Ultrasonic Search Units.
(d) Examination systems shall be evaluated using Supplement l.
(e) Replacements of the instrument or the pulser section of the instrument system shall be with the following tolerances of the original equipment as measured into a
50
- ohm, non-inductive, non-capacitive, resistive load:
(1) pulse amplitude, + 10%;
(2) pulse rise time, + 10%;
(3) pulse duration, + 10%.
(t)
Replacements of the instrument or the receiver section ofthe instrument system shall be within the following tolerances ofthe original equipment:
(1) lower and upper frequency limits at the -6 dB point, + 0.2 MHz; (2) center fiequency for instrument receivers with bandwidths less than 30%, + 5%;
(3) center frequency for instrument receivers with bandwidths equal to or greater than 30%, + 10%.
(g) Replacement search units ofthe same manufacturer's model, size, and nominal frequency may be used without requalification.
(h) Replacement search units not of the same manufacturer's model, that are of the same nominal size and &equency, shall be within the following tolerances of the original search units:
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page9of31 (1) propagation mode is the same; (2) measured angle, + 3 deg.;
(3) center frequency for search units withbandwidths less than 30%, + 5%;
(4) center frequency for search units with bandwidths equal to or greater than 30%, + 10%;
(5) waveform duration, + 1/2 cycle or 20%, whichever is greater (measured at -20 dB), or bandwidth, + 10%;
(i) As an alternative to (e) through (h)
- above, equipment replacement, including interconnecting
- cabling, is acceptable if the examination system is within the following tolerances ofthe original system, as measured according to the requirements ofSupplement 1:
(I) system center &equency+ 5%, for examination systems with bandwidths less than 30%;
(2) system center &equency +10%, for examination systems with bandwidths equal to or greater than 30%;
(3) system bandwidth, -10% and no upper limit.
B-4120 SEARCH UNITCHARACTERIZATION Characterization measurements of the search unit shall be made using either a sinusoidal tone burst technique or shock excitation.
When using shock excitation, the characterization pulser and UT instrument pulser shall be the same withinthe limits ofB 4110(e).
B-4200 COMPUTERIZED SYSTEM ALGORITHMS When the performance demonstration uses prerecorded data, algorithms for automated decisions may be altered when the altered algorithms are demonstrated to be equivalent to those qualified.
When the performance demonstration results meet the acceptance requirements of B-3000, the algorithm shall be considered qualified.
B-4300 CALIBRATIONMETHODS Alternative calibration methods may be demonstrated equivalent to those described in the qualified procedure without requalification.
This demonstration of equivalence shall be conducted for each beam angle and mode ofpropagation to which it applies, as follows.
(a) Calibrate the examination system in accordance with the alternative methods.
(b) Compare the sensitivity of the alternative calibration method to that of the qualified calibration method.
(c) The alternative calibration method is acceptable when the system sensitivity is no more than 2 dB below that obtained by the qualified method.
B-5000 RECORD OF QUALIFICATION B-5100 GENERAL The organization's performance demonstration program shall specify the documentation that shall be maintained as qualification records. Documentation shall include identification of personnel, NDE procedures, equipment and specimens used during qualification, and results of the performance demonstration.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 10 of31 CHAPTER B SUPPLEMENTS SUPPLEMENT 1 EVALUATING ELECTRONIC CHARACTERISTICS OF ULTRASONICSYSTEMS 1.0 SYSTEM FREQUENCY CHARACTERISTICS 1.1 The frequency response, also known as the frequency spectrum, shall be determined by measuring the amplitude of the pulse echo response, from a target as a function of frequency.
This response shall be used as a basis for establishing the center frequency and bandwidth of the ultrasonic system.
CAUTION: The required output signal test point &om the ultrasonic instrument may require access to ultrasonic circuitry inside the instrument chassis.
The use of high impedance test probes may also be required ifthe signal ofinterest is not buffered.
1.2 Connect the ultrasonic instrument including the search unit and, ifapplicable, the wedge, as shown in Fig. S1-1A.
The output signal Rom the ultrasonic instrument that is used in data analysis for flaw detection or flaw sizing (i.e., the output signal after amplification, filtering, and video detection) shall.be input to a device that is capable of measuring the frequency spectrum (e.g., a spectrum analyzer or a digitizing circuit with a sofbvare package that determines the frequency response ofwaveforms). Ifa digitizing circuit is used, the rate ofdigitizing shall be at least five times the nominal (labeled) frequency ofthe search unit.
(a) Ifthe receiver or transmitter provides variable signal filtering or &equency control, the signal controls shall be set as specified in the examination procedure. Check all connections in the test setup to ensure that it is safe to turn on the ultrasonic system.
(1) Flat or non-focused search units shall be adjusted so that the distance (Zo) from the face ofthe search unit to the target is 2 in. (see Fig. Sl-1B). A smooth, flat block with minimum dimensions 2 in. x 2 in. x 1 in. thick is the target. Using a manipulator, adjust the search unit angle with respect to the block until the return echo is maximized indicating that the sound field is perpendicular to the block. Adjust the receiver section gain controls until the ultrasonic signal amplitude from the block is 80% of full scale without saturating the ultrasonic signal. Plot the frequency spectrum ofthe ultrasonic signal as shown in Fig. S1-2A.
(2) Determination of the frequency response for focused search units shall follow the same procedure for flat search units, except that the distance Zo shall be adjusted to maximize echo from the target.
1.3 System Frequency Response Results (a) Lower Frequency Limit (Fg)-The lower &equency limit (MHz) at a specific frequency control setting is the lowest frequency on the frequency response curve that is 6 dB below the maximum amplitude as shown in Fig. S 1-2A.
(b) Upper Frequency Limit (Ft/)
The upper frequency limit (MHz) at a specific frequency control setting is the highest frequency on the frequency response curve that is 6 dB below the maximum amplitude as shown in Fig. S1-2A.
(c) Center Frequency (Fc )
The center frequency (MHz) at a specific frequency control setting shall be calculated in accordance with B-4110, (b)(2).
(d) Bandwidth (BF)- The bandwidth (%) at a specific frequency control setting shall be calculated in accordance with B-4110, (b)(3).
Passed Main Comminee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 11 of31 (e) The system frequency response results, (a) through (d) above, shall be obtained for the remaining receiver and transmitter control module setting combinations used in the performance demonstration. These values shall be recorded.
Ultrasonic instrument Search uillt Signal output after amplification filtering or "video detection Gate Echo Sync pulse Target Delay generator Gate width generator Spectrum analyzer oi'igitizer Echo Time Excitation pulse.
Stepless gate time Gated echo from target Frequency response FIG: S1-1A System Configuration Passed Main Comminee 12/1 1/98, Published January 99, Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 12 of31 To test system
'Water Manipuhrtor Search unit Glass block target Figure.
S 1-1B Test Configuration Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121No. 1, Page 97 1
Page 13 of 31 10
-8 dB Ft Fu 1
2 3,
4 6
8 7
8 9
10 11 12 Frequency, MHz Figure Sl-2a Frequency Response Curve Passed Main Committee 12/11/98, Published january 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
SUPPLEMENT 2QUALIFICATIONREQUIREMENTS FOR WROUGHT AUSTENITICPIPING WELDS Page 14 of31 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the requirements listed herein, unless a set ofspecimens is designed to accommodate specific limitations stated in the scope of the examination procedure (e.g., pipe size, access limitations). The same specimens may be used to demonstrate both detection and sizing qualification.
1.1 General.
(a) Specimens shall have sufficient volume to minimize spurious reflections that may interfere with the interpretation process.
(b) The specimen set shall consist ofat least four specimens having different nominal pipe diameters and thickness. The set shall include pipe specimens not thicker than 0.1 in. more than the minimum thickness, nor thinner than 0.5 in. less than the maximum thickness for which the examination procedure is applicable. It shall include the minimum, +NPS 1/2, and maximum pipe diameters and thickness for which the examination procedure is applicable. If the procedure is applicable to pipe diameters of 24 in. or larger, the specimen set must include at least one specimen 24 in. or larger in diameter but need not include the maximum diameter.
(c) The specimen set shall include examples ofthe followingfabrication condition:
(1) unground weld reinforcement (crowns);
(2) wide crowns, such that the total crown width is 1 V2 to 2 times the nominal pipe wall thickness; (3) geometric conditions that normally require discrimination from flaws (e.g.,
counterbore, weld root conditions such as excessive ID reinforcement);
(4) typical limited-scanning surface conditions (e.g., diametrical shrink, single-side access due to safe ends or fittings).
(d) Allflaws in the specimen set shall be cracks.
(I) Mechanical fatigue cracks and either IGSCC or thermal fatigue cracks shall be used.
No more than 25% ofthe flaws shall be mechanical fatigue cracks.
(2) At least 50% of the cracks shall be coincident with fabricated conditions described in (c) above.
1.2 Detection Specimens (a) Specimens shall be divided into grading units.
Each grading unit shall include at least 3 in. of weld length. Ifa grading unit is designed to be unflawed, at least 1 in. of unflawed material shall exist on either side ofthe grading unit. The segment ofweld length used in one grading unit shall not be used in another grading unit. Grading units need not be uniformly
, spaced around the pipe specimen.
(b) Detection sets for personnel qualification shall be selected from Table S2-1. The number ofunflawed grading units shall be at least twice the number offlawed grading units.
(c) For the initial procedure qualification, detection sets shall include the equivalent of three personnel qualification sets.
Extension of qualifications to qualify new values of essential variables requires at least one personnel qualification set.
(d) When the procedure is intended to detect IGSCC, at least four field-removed, IGSCC-flawed grading units shall be included in the detection test set.
(e) Flawed grading units shall meet the following criteria for flaw depth, orientation, and type.
(1) A minimum of 1/3 of the flaws, rounded to the next higher whole number, shall have depths between 5% and 30% of the nominal pipe wall thickness. At least 1/3 of the flaws, rounded to the next higher whole number, shall have depths greater than 30% of the nominal pipe wall thickness.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. I, Page 97 1
Page 15 of31 (2) At least one and a maximum of 10% of the flaws, rounded to the next higher whole
- number, shall be oriented axially.
The remainder of the flaws shall be oriented circumferentially.
1.3 Sizing Specimens (a) The minimum number offlaws shall be ten.
(b) Flawsinlengthsizingsamplesetsshallmeet the requirements of para.
1.2(e)(l), when giveninconjunction with a detection test.
When the length sizing test is administrated independently, the flaw depth requirements do not apply.
(c) Flaws in the depth sizing sample set shall be distributed as follows:
Flaw Depth
% Wall Thickness 5-30%
31-60%
61-100%
Minimum Percenta e ofFlaws 20%
20%
20%
The remaining flaws shall be in any ofthe above categories.
(d) When the procedure is intended to size IGSCC, at least three IGSCC flaws shall be included in the test set.
These IGSCC flaws may be field-removed or fabricated by laboratory methods.
2.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS Flaw location and specimen identification shall be obscured to maintain a "blind test."
Divulgence of particular specimen results or candidate viewing of unmasked specimens after the performance demonstration is prohibited.
0 2.1 Detection Test.
(a) Flawed and unflawed grading units shall be randomly mixed.
(b) Detection tests shall include length sizing.
2.2 Length and Depth Sizing Tests (a) Each reported flaw in the detection test shall be length sized.
(b) When only length sizing is being tested, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length ofthe flaw in each region.
(c) For the depth sizing test, the regions ofeach specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth ofthe flaw in each region.
3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria.
(a) Personnel demonstrations shall meet the requirements of Table S2-1 for both detection and false calls.
(b) Procedure qualifications shall demonstrate detectability of each flaw, within the scope of the procedure.
Successful personnel demonstrations may be combined to satisfy the requirements for procedure qualifications.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 16 of31 (c) Ifthe procedure is intended to detect IGSCC, failure to detect more than one of the IGSCC flaws is unacceptable for personnel qualifications.
3.2 Sizing Acceptance Criteria (a) The RMS error of the flaw lengths estimated by ultrasonics, as compared with the true lengths, shall not exceed 0.75 in.
(b) The RMS error of the flaw depths estimated by ultrasonics, as compared with the true depths, shall not exceed 0.125 in.
TABLES2-1 PERFORMANCE DEMONSTRATIONDETECTION TEST ACCEPTANCE CRITERIA Detection Test Acceptance Criteria False Call Test Acceptance Criteria No. ofFlawed Grading Units 5
6 7
8 9
10ll 12 13 14 15 16 17 18 19 MinimumDetection Criteria 5
6 6
7 7
8 9
9 10 10ll 12 12 13 13 No. of Unflawed Grading Units 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 Maximum Number ofFalse Calls 0
1 a
2 2
3 3
3 4
5 5
6 6
7 7
SUPPLEMENT 3 QUALIFICATIONREQUIREMENTS FOR FERRITIC PIPING WELDS Qualification of examination procedures, and personnel for ferritic pipe examination shall be accomplished by satisfying the requirements of Supplement 2, except that the sample material shall be ferritic and the sample set defects shall be mechanically or thermally induced fatigue cracks.
In addition, the set shall include pipe specimens not thicker than 0.1 in. more than the minimum thickness, nor thinner than 1.0 in. less than the maximum thickness for which the examination procedure is applicable.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 17 of31 SUPPLEMENT 4QUALIFICATIONREQUIREMENTS FOR THE CLADTO BASE-METALINTERFACE OF REACTOR VESSEL 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the requirements listed herein unless a set of specimens is designed to accommodate specific limitations stated in the scope of the examination procedure.
The same specimens may be used to" demonstrate both detection and sizing qualifications.
1.1 Detection Specimens.
(a) Specimens shall have sufficient volume to minimize spurious reflections. Specimens need not contain a butt weld.
Specimen length and width shall be at least 12 in.
There shall be at least 10 sq. A ofclad surface in the specimen set.'b)
Specimen thickness:
(1) When. the examination procedure requires the examination to be performed from the vessel ID (clad surface),
the specimen minimum thickness shall be 3 in. or the maximum thickness ofthe vessel (whichever is less).
(2) When the examination procedure requires the examination to be performed from the vessel OD surface, the specimen shall be at least 90% ofthe maximum thickness to be examined.
(c) The performance demonstration shall be on the same type cladding as that to be-examined, with the following exceptions:
(I) Demonstration on shielded metal arc welding (SMAW) single-wire cladding is transferable to multiple wire or strip-clad processes.
(2) Demonstration of multiple-wire or strip-clad is considered equivalent but is not transferable to SMAWtype clad.
(d) The surface condition ofthe test specimens shall be representative ofthe general condition ofthe vessel scanning surface.
(e) The detection test matrix shall include flaws with the followingdescription.
(1) Flaw type. At least 70% of the flaws shall be cracks.
Notches are limited to when the examination is performed Rom the clad surface, i.e., no corner-trap applications.
Machined notches shall meet the followingrequirements:
(a) Notches shall have a maximum width of 0.010 in. at the tip. The width at the clad-to-base-metal interface shall not exceed 0.020 in.
(b) Notches shall conform to the following:
(1) Notch depth shall not exceed 0.25 in.
(2) Notches shall be semi-elliptical.
(2) For procedure qualification, at least 40% of the flaws shall be oriented parallel to the clad direction, +10 deg., and at least 40% shall be oriented perpendicular to the clad direction,
+10 deg. For personnel qualification, at least 20% in either direction is sufficient.
(3) The flaw sizes shall be uniformly distributed in through-wall depths among the followingranges:
a) 0.075-0.200 in.
) 0.201-0.350 in.
c) 0.351-0.550 in.
~
(d) 0.551-0.750 in.
(4) No flaw shall have an aspect ratio (depth/length) less than 0.1.
(5)Flaws smaller than 50% ofthe allowable flaw size, as defined in IWB-3500, need not be included as detection flaws.
For procedures applied Rom the inside surface, the minimum Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 18 of31 thickness specified in the scope of the procedure shall be used to calculate a/t. For procedures applied &om the outside surface, the thickness ofthe test specimen shall be used to calculate a/t.
(t)The number of flaws in a personnel detection demonstration shall be selected Rom Table S4-1.
(g) For initial qualification detection sets for procedure qualification shall include the equivalent ofthree personnel qualification sets.
Extension ofqualifications to qualify new value ofessential variables requires at least one personnel qualification set.
(h)The requirements of IWA-3000 shall be used to determine whether closely-spaced flaws are to be treated as separate flaws.
(i)
Flaw location and specimen identification shall be obscured to maintain a "blind test."
TABLES4-1 PERFOEUfANCE DEMONSTRATIONDETECTION TEST ACCEPTANCE CRITERIA n
Number ofFlaws Minimum Detection Criteria 7
8 9
10 11 12 13 14 15 16 17 18 19 20 7
8 9
10 11 11 12 13 14 14 15 16 17 18 1.2 Sizing Specimens (a) Personnel qualification demonstrations shall contain at least 10 flaws, at least 70% of which shall be cracks.
(b) Procedure qualifications shall include the equivalent ofthree personnel qualification sets.
(c) Sizing specimens shall conform to the requirements of 1.1(b), 1.1(c), 1.1(d), and 1.1(e) 2.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS 2.1 Detection Test (a) Flaw locations shall be obscured to maintain a "blind test." Divulging particular specimen results or candidate viewing ofunmasked specimens is prohibited.
(b) Ifa flaw is reported withinthe greater of 1.0 in. or 10% ofthe metal path length to the flaw, from its true location (x, y, and z) it shall be considered detected.
Allother reported flaws shall be considered false calls.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No.1, Page 97 1
Page 19 of 31 2.2 Length and Depth Sizing Test (a) Each reported flawin the detection test shall be length sized.
(b) When only length sizing is being tested, the 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.
(c) For the depth sizing test, the regions ofeach specimen containing a flaw to be sized shall be identified to the candidate.
The candidate shall determine the maximum depth ofthe flaw in each region.
3.0 ACCEPTANCE CRITERIA
~.
3.1 Detection Acceptance Criteria (a) Procedure qualifications shall demonstrate detectability of each flaw within the scope'of the procedure.
(b) Personnel are qualified if the results of the performance demonstration satisfy the
. acceptance criteria ofTable S4-1 and no flaw greater than 0.25 in. depth is missed.
(c) For procedure and personnel demonstrations, the number of false calls shall not exceed A/10, rounded to the next whole number, where A is the total scan area of specimens "in the test measured in square feet.
3.2 Sizing Acceptance Criteria (a) The RMS error of the flaw lengths estimated by ultrasonics, as compared with the true lengths, shall not exceed 0.75 in.
(b) The RMS error of the flaw depths estimated by ultrasonics, as compared with the true depths, shall not exceed 0.15 in.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 20 of31 SUPPLEMENT SAQUALIFICATIONREQUIREMENTS FOR NOZZLEINSIDE RADIUS SECTION EXAMINATIONSFROM THE INSIDE SURFACE I
Examination procedures and personnel are qualified for nozzle inside radius section examination.
From the inside radius section examination, Rom the inside
- surface, when the following requirements are met.
Personnel qualified for detection or depth sizing in accordance with the requirements of Supplement 4, are qualified in accordance with this Supplement, with no additional demonstration, provided the procedure used by the personnel to qualify in accordance with Supplement 4, other than changes required to adapt to the nozzle geometry, is also qualified in accordance with this Supplement.
1.0 SPECIMEN REQUIREMENTS (a) For PWR vessels, both the inlet and outlet configurations shall be included in the demonstration.
(b) Flaws shall meet the requirements of Supplement 4, except that they shall be oriented as shown in IWB-2500-7.
The entire size distribution need not be contained in every specimen, provided one or more examples ofthe smallest category are included.
(c) The minimum nozzle diameter contained in the scope ofthe procedure shall be included.
(d) Qualification on clad nozzle mockups may be used for qualification for examination of unclad nozzles. Qualifications on unclad nozzle mockups shall not be used for qualification for examination ofclad nozzles.
1.1 Detection Specimens Detection specimens shall conform to the followingrequirements.
(a)There shall be a minimum ofthree flaws in each specimen.
(b)The specimen set shall contain a minimum of 10 flaws.
1.2 Sizing Specimens (a)The sizing test matrix shall contain a minimum of 10 flaws; at least 50% of which shall be cracks.
(b)Any notches included in the test set shall meet the requirements and limitations of Supplement 4, 1.1 (e).
2.0 CONDUCT OF PERFORMANCE DEMONSTRATION 2.1 Detection Test Procedure and equipment qualifications shall be performed as a "blind test."
2.2 Depth Sizing (a) Depth sizing willbe performed without knowledge ofthe true flaw depths.
(b)The sizing results Rom each ofthe specimens shall be combined for grading.
3.0 ACCEPTANCE CRITERIA (a) Examination procedures and equipment are qualified if each flaw is detected and identified.
The number of false calls shall not exceed D/10 rounded up to the next whole number, where D is the nominal nozzle ID in. Ifonly a portion of a nozzle is examined, proportional credit for false calls shall be allowed.
The total number of false calls shall not exceed 3.
(b) Personnel not previously qualified to Supplement 4 are qualified for detection if the requirements for procedure qualification in (a) above are satisfied.
(c)
Examination procedures, equipment, and personnel (not previously qualified to Supplement 4) are qualified for depth sizing ifthe results of the sizing demonstration meet the sizing acceptance criteria ofSupplement 4.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. I, Page 97 I
Page 21 of 31 SUPPLEMENT 58 QUALIFICATIONREQUIREMENTS FOR NOZZLE INSIDE RADIUS SECTION EXAMINATIONSFROM THE OUTSIDE SURFACE 1.0 PROCEDURE REQUIREMENTS The examination procedure shall include or provide for the following:
(a) A computational model that calculates misorientation angles and the maximum metal path distance to the required inspection volume. Misorientation angle is shown in Fig. SSB-1.
These calculations apply to the central ray ofthe ultrasonic beam.
(b) A scope statement that specifies the maximum acceptable misorientation angle and metal path for the examinations.
(c) Divisionofthe surface ofthe required examination volume into grids of 1.0 in. or less in the nozzle axis direction and 10 deg. or less ofazimuth.
(d) Documenting the misorinetation angle and metal path distance in each grid cell location for each search or scan.
(e) Documenting the search unit or scan that produc'es the minimum misorientation angle when multiple search units are used.
2.0 SPECIMEN REQUIREMENTS Demonstration specimens shall meet the requirements of Supplement 4, except as modified by (a) through (e).
Flaw depths shall be distributed over the range of depths required by Supplement 4.
'(a) One or more fullsize or sections offullsize nozzle mockups shall be used.
(b) Nozzle mockup material and configurations shall be representative ofnozzles installed in operating reactor
- vessels, but may be any thickness,
- diameter, or radius suitable for demonstration in accordance with 3.0, below.
(c) Flaws shall be uniformly distributed in examination zones A and B of Fig. SSB-2.
At least half of the flaws shall be located within+45 deg. of nozzle azimuth angles 90 deg. or 270 deg.
(d) Allflaws shall be located in the required inspection volume and shall be oriented in the radial axial plane ofthe nozzle inside radius as shown in Fig. IWB-2500-7.
(e) For in nozzles with bore diameters not more than 4 in. at least 50% of the flaws in the demonstration test set shall be cracks; the balance may be notches.
The maximum misorientation shall be demonstrated with cracks.
3.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS 3.1 Procedure Qualification Demonstrations (a) The qualification shall demonstrate the following:
(1) Examination surfaces to be used, i.e., vessel plate, outer blend radius, and nozzle boss; (2) Maximum metal path length; (3) Maximum misorientation angles.
(b) The demonstration shall include at least 10 flaws for detection and sizing, in one or more mockups.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 22 of31 Inci4enc ggagy Mhorienamioa Intt+
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Page 23 of31 (c) The initial demonstration shall be performed as a "blind test."
(d) After a successful initial demonstration, the scope of the procedure, 1.0 (b), may be extended by (1) additional demonstrations on additional mockups or (2) nonblind demonstrations on at least one flaw using scan parameters calculated to provide the desired maximum path length or misorientation angles.
Detection shall be demonstrated to specific criteria listed in the examination procedure for any extension of procedure scope.
3.2 Procedure Qualification Documentation.
The examination procedure, modeling program and methods, and the qualification results shall be documented to the extent necessary to determine that inservice examinations produce equivalent or smaller misorinetation angles than the procedures demonstrated.
3.3 Personnel Qualification (a) Personnel previously qualified in accordance with the requirements of Supplement 4, for the same type ofprocedure (manual or automated), from the outside surface, using the same type ofinstruments and data recording and analysis equipment, shall be qualified as follows:
(I) Successful demonstration shall include at least three additional flaws for each scan
'urface which is qualified.
(2) Examinations shall be conducted Rom each of the scan surfaces covered by the procedure.
(3) The candidate shall demonstrate a selection of essential variables covered by the procedure, but need not demonstrate the fullrange.
(b) Personnel not previously qualified in accordance with the requirements of Supplement 4 shall be qualified as follows:
(1) The candidate shall demonstrate the procedure on one or more mockups.
(2) The demonstration shall contain at least the minimum number of detection and depth sizing flaws specified in Supplement 4.
(3) The demonstration shall include examinations Rom each ofthe scan surfaces described in the procedure.
(4) The demonstration need not cover the fullrange ofall the essential variables.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 24 of31 4.0 ACCEPTANCE CRITERIA 4.1 Detection Acceptance Criteria (a) Examination procedures are qualified ifeach flaw is detected and identified. The number of false calls shall not exceed D/10, rounded up to the next whole number, where D is the nominal nozzle ID, in. The number of false calls shall not exceed three. Ifonly a portion of a nozzle is examined, proportional credit for false calls".is-be allowed.
The number of false calls shall not exceed three.
(b) Personnel previously qualified in accordance with the requirements of3.3(a) are qualified, if each of the flaws presented are detected.
The number of false calls shall not exceed the number specified in 4.1(a).
(c) Personnel not previously. qualified in accordance with the requirements of Supplement 4 are qualified, ifthe results of the demonstration meet the requirements of Table S4-1.
The number offalse calls shall not exceed the number specified in 4.1(a).
4.2 Depth Sizing Acceptance Criteria (a) Examination procedures are qualified ifthe results of the sizing demonstration meet the requirements of, Supplement 4, 3.2.
(b) Personnel previously qualified in accordance with the requirements'of 3.3(a) are qualified, if the results Rom the sizing test, when added to the candidate's results from Supplement 4, meet the acceptance criteria ofSupplement 4, 3.2.
(c) Personnel not previously qualified in accordance with the requirements of Supplement-4 are qualified ifthe results of the demonstration meet the acceptance criteria of Supplement 4,
3.2.
5.0 COMPONENT EXAMINATIONS The computational model shall be used to demonstrate that the proposed examination variables are within the bounds the qualification demonstration.
(a) Documentation showing coverage and misorientation angle shall be provided for each nozzle examination performed.
The documentation shall be used to demonstrate that the component examination willachieve misorientation angles that do not exceed the misorientation angles for which the procedure was qualified.
(b) Modeling need not be applied for repeated examination ofnozzles ofthe same design.
(c) Ifthe misorientation angle or metal path ofthe component examination exceeds that ofthe qualification, additional angles and directions may be applied to examine these areas without need for requalification, provided the demonstrated misorientation angle or path length can be achieved.
(d) If5.0(c) cannot be met, the area shall be declared an area ofno coverage.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 25 of31 SUPPLEMENT 6 QUALIFICATION REQUIREMENTS FOR REACTOR VESSEL WELDS OTHER THANCLAD-TO-BASEMETALINTERFACE 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the requirements listed herein unless a set of specimens is designed to accommodate specific limitations stated in the scope of the examination procedure. The same specimens may be used to demonstrate both detection and sizing qualification.
1.1 Detection Specimens.
(a) Specimens shall have sufficient volume to minimize spurious reflections.
The specimen need not contain a weld.
Specimen length and width shall be at least 12 in. There shall be at least 10 sq ftofscan surface in the specimen set.
(b) The specimen set shall contain at least one sample that is at least 90% of the maximum thickness to be examined. The specimen set shall contain one or more flaws in each of the locations and size ranges shown in Table S6-1.
(c) When the examination procedure requires the examination to be performed Rom the vessel ID (clad surface), the cladding on the mockup shall be ofthe same type as the cladding on the component to be examined, with the followingexceptions:
(1) demonstration on shielded metal arc weld (SMAW) single-wire cladding is transferable to multiple-wire or strip-clad processes; (2) demonstration on multiple-wire or strip-clad is considered equivalent but is not transferable to SMAWtype clad.
TABLES6-1 DETECTION AND SIZING TEST FLAWS AND LOCATIONS Flaw Depth, In. (Notes 2,3, and4)
Flaw Locations Inner 10% ~ Note (1)
Outer 10%
11-30% T 31-60% T 61-89% T 0.075-0200 0.201-0.3.50 0.351-0.550 0.551-0.750 0.751-2.0 LEGEND:
x Applies to detection and sizing flaws S Applies only to sizing flaws T Thickness ofthe test specimen which contains the flaw NOTES:
(/) Does not apply to clad vessels (see Supplement 4).
(2) Flaws smaller than 50% ofallowable flaw size specified in IWB-3500 need not be included as detection flaws without regard for their designation as S or X (3) Flaws equal to or less than the allowable flaw size may be used as detection flaws without regard to their position in the Table.
(4) The thickness ofthe test specimen shall be used to determine the a/t ratios in IWB-3500.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No.1, Page 97 I
Page 26 of31 (d) The surface condition of the test specimens shall be representative ofthe general condition ofthe vessel scanning surface.
(e) The detection test matrix shall include flaws with the followingdescription.
(J) Flaw Type. At least 55% of the flaws shall be cracks. The balance of flaws may be cracks, or fabrication defects (e.g., lack offusion and slag inclusions).
(2) Detection and sizing examinations shall include either surface connected flaws or flaws with unflawed ligaments ofmore than 0.2 in. Procedure demonstrations shall include examples ofboth.
(3) A weld direction shall be established, whether or not the specimen contains a weld. For procedure qualification, at least of40% ofthe flaws shall be oriented parallel to the clad direction
+10 deg. and at least 40% shall be oriented perpendicular to the clad direction +10 deg.
For personnel qualification, at least 20% in either direction7s sufficient.
(4) Flaws for the detection test matrix shall be selected from the detection test flaws included in Table S6-1
~ The flaws selected shall provide a demonstration of the minimum and maximum metal path ranges to be demonstrated as well as a uniform distribution of flaw sizes and locations.
(5) The number offlaws in a personnel detection demonstration shall be selected from Table S6-2.
Procedure qualifications shall include at least 20 flaws uniformly distributed over the ranges defined in Table S6-1.
(6) The requirements ofIWA-3000 shall be used to determine whether closely-spaced flaws are to be treated as separate flaws.
1.2 Sizing Specimens (a) Qualification demonstrations shall contain at least 10 flaws for personnel and 20 for procedures at least 55% ofwhich shall be cracks.
The remainder may be manufacturing defects, such as slag, lack offusion, or combinations thereof.
(b) Sizing specimens shall conform with the requirements of 1.1(b), 1.1(c), 1.1(d), and 1.1(e),
except that the test matrix shall be selected Rom the sizing and detection test flaws included in Table S6-1.
2.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS 2.1 Detection Test (a) Flaw locations shall be obscured to maintain a "blind test." Divulging particular specimen results or candidate viewing ofunmasked specimens is prohibited.
(b) Ifa flaw is reported within the greater of 1.0 in. or 10% of the metal path length to the flaw, Rom its true location (x, y, and z) it shall be considered detected. Allother reported flaws shall be considered false calls.
2.2 Length and Depth Sizing Test (a) Each reported flaw shall be length sized.
(b) For the length sizing test, the regions ofeach specimen containing a flaw to be sized shall be identified to the candidate.
The candidate shalldetermine the length of the flaw in each region.
(c) When only depth sizing is being tested, the regions of each specimen containing a flaw to be sized shall be identified to the candidate.
The candidate shall determine the maximum depth ofthe flaw in each region.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 27 of31 TABLES6-2 PERFORMANCE DEMONSTRATIONPERSONNEL DETECTION TEST ACCEPTANCE CRITERIA NUMBEROF FLAWS MINIMUMDETECTION CRITERIA 7
8 9
10ll 12 13 14 15 16 17 18 19 20 7
8 9
10 11ll 12 13 14 14 15
'6, 17 18 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria (a) Procedure qualifications shall demonstrate detectability of each flaw within the scope of the rocedure.
) Personnel are qualified if the results of the performance demonstration satisfy the acceptance criteria of Table S6-2 and no surface connected flaw greater than 0.25 in. depth or imbedded flaw (distance from nearest surface exceeds 10%T) greater than 0.5 in. was missed.
(c) For procedures and personnel demonstrations, the number of false calls, shall not exceed A/10, rounded to the next whole number, where A is the total scan area ofspecimens in the test measured in square feet.
3.2 Sizing Acceptance Criteria (a) The RMS error ofthe flaw lengths estimated by ultrasonics, as compared with the true lengths, shall not exceed 0.75 in.
(b) The RMS error ofthe flaw depths estimated by ultrasonics, as compared with the true depths, shall not exceed 0.25 in.
(c)The slope ofthe linear regression line shall be at le'ast 0.7. The slope ofthe linear regression line is calculated as shown in Fig. S6-1.
Passed Main Committee 12/1 1/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 28 of31 APPENDIX VIIIMANDATORY LINEA. Linear regression line, Y <<a <<bx. giving the best fitof n data points (xt. Yt),... (x~ y) obtained by the (east.square method
- where, YI I
y intercept -b N
N b
slope of the regression line ND;yf- (~wf)(Zyf)
N~~P - (~f)2 I00 80 60 0
I 40 20 (xt, yt) dt xn. Yn A
8 n
<<number of data points True 5 Through Wal(2 LINE 8: Ideal line, y <<x (perfect UT measurements).
CORRELATION COEFFICIENT: Correlation coefficient. defined as nary - (<<a.) (~Y )
InZx)2- (<<~.)2) In<<Y.2 (ZY.)2I is a measure of "how well" the least-souare regression line fits the data with respect to the ideal of y <<x.
MEAN OEVIATION:Mean deviation is an indicator of accuracy of the meaeirements defined as ldtl ld2I
-" Id I
Mean Oeviation <<
n NOTES:
(t) Srandanf iHarbernarfcaf rabies, 25th ed., William II. Beyer, Ph. O., Ed., CRC press, Inc., 'Boca Raton, F L. )929.
(2) Percent througn-wsll units aooly to Suoolernents 2 and 3. Flaw depth units apply to Supplements 4 through 7.
FIG.
S6-1 OEFINITION OF STATISTICAL PARAMETERS Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering". ~roiume 121/No. I, Page 97 I
Page 29 of31 SUPPLEMENT 7QUALIFICATIONREQUIREMENTS FOR NOZZLE-TO-VESSEL WELDEXAMINATIONSCONDUCTED FROM THE BORE Successful demonstrations in accordance with Supplements 4 and 6 qualify procedures and personnel for nozzle-to-vessel weld examinations conducted from the bore, when the following requirements are met.
(a) The demonstration shall contain at least four flaws in one or more full-scale nozzle mock-ups.
The specimens shall comply with supplement 6, 1.1, except that, flaw locations and orientations shall be selected from Table S7-1. At least one flaw from each category shall be included. At least 75% of the flaws shall be cracks or fabrication flaws.
The balance may be notches.
At least one flaw parallel to the weld shall provide a metal path distance with 10% of the equivalent path length to the weld centerline ofthe thickest component to be examined.
(b) For detection, the requirements of Supplement 6, 2.1 apply.
Each flaw shall be detected with no false calls.
(c) For length sizing, the sizing results shall be added to the results of Supplements 4 and 6.
The combined results shall meet the acceptance standards ofSupplement 6, 3.2.
(d) For depth sizing, the flaw depths shall distributed over the ranges ofSupplement 4, 1.1 for the inner 15% ofthe wall thickness, and Supplement 6, 1.1 for the remaining wall thickness. For the inner 15%, the depth sizing results shall be combined with the sizing results from Supplement 4. For the remaining wall thickness, the depth sizing results shall be combined with the sizing results from Supplement 6.
The combined results shall meet the depth sizing acceptance criteria ofSupplement 4, 3.2 and Supplement 6, 3.2, respectively.
TABLE S7-1 FLAWLOCATIONSANDORIENTATIONS Parallel to Weld Perpendicular to Weld Inner 15%
OD Surface Subsurface XXX Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
0 Page 30 of 31 SUPPLEMENT 8 QUALIFICATIONREQUIREMENTS FOR BOLTS AND STUDS 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the requirements listed herein, unless a set of specimens is designed to accommodate specific limitations stated in the scope of the examination procedure.
1.1 Specimens shall conform to the followingrequirements.
(a) The qualification process shall be performed with a full-scale section bolt or stud that is sufficient to contain the beam path and demonstrate the scanning technique.
(b) The qualification specimen shall be of similar chemical composition, tensile properties, and metallurgical structure as the bolt or stud to be examined.
The scan surface of the qualification specimen shall have a configuration similar to the bolt or stud to be examined.
(c) Circumferentially oriented notches shall be located in the. procedure qualification specimens at the minimum and maximum qualified metal paths.
Notches located within one diameter of the end of the bolt or stud opposite the search unit are suitable for demonstrating the maximum metal path distance. Personnel qualification specimens may have notches at any location within the inspection volume.
These notches are required on the outside threaded surface and the inner bore hole surface of bored studs with maximum depths and reflective areas as specified in Table S8-1.
(d) Additional notches may be located within the range specified in (c) above, provided they do not interfere with detection ofother notches.
2.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS Specimen identification and notch locations shall be obscured to maintain a "blind test." A flaw shall be considered detected when the notch, as defined in 1.1, is found. The reported notch axial location shall be within the greater of+1/2 in., or+5% ofthe bolt or stud length, ofthe true location.
3.0 ACCEPTANCE CRITERIA 3.1 Examination procedures and personnel are qualified for detection when each qualification notch (as described in 1.1) has been detected and its"response equals or exceeds the reporting criteria specified in the procedure. The notch response shall have a minimum peak signal to peak noise ratio of2:1.
Bolt or Stud Diameter Larger than 4 in.
2 in. to 4 in.
TABLE S8-1 MAXIMUMNOTCH DIMENSIONS
- Depth, in.'.157 0.107 Reflective Area, sq. in.
0.059 0.027 Note (1) For threaded surfaces, depth is measured from bottom of thread root to bottom of notch.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
Page 31 of31 SUPPLEMENTS 13REQUIREMENTS FOR COORDINATED IMPLEMENTATIONOF SELECTED ASPECTS OF SUPPLEMENTS 4 AND 6 1.0 GENERAL Candidates meeting the requirements of this Supplement in its entirety are considered qualified to Supplements 4 and 6. Detection and sizing may be performed separately.
2.0 COMBINEDSUPPLEMENT 4 AND SUPPLEMENT 6 QUALIFICATION Personnel qualification for Supplement 4 and 6 may be combined as follows:
(a)For detection, the total number ofSupplement 4 and 6 flaws shall be at least 10 of which at least 50% shall be Supplement 4 flaws and at least 5 shall be from Supplement 6.
(b)For sizing, the total number of Supplement 4 and 6 'flaws shall be at least 10, of
. which at least 50% shall be Supplement 4 flaws. At least 50% ofthe flaws in any sizing shall be cracks.
3.0 ACCEPTANCE CRITERIA (a) Examination personnel are qualified for detection and length sizing when the results ofany combined performance demonstration satisfy the acceptance ofSupplement 4.
(b) Examination personnel are qualified for depth sizing when Supplement 4 and 6 flaws are sized within the respective acceptance criteria ofthose supplements.
Passed Main Committee 12/11/98, Published January 99, "Mechanical Engineering", Volume 121/No. 1, Page 97 1
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