ML17279A730

Feedwater Nozzle Insp Rept for Refueling Outage RF87A, Spring 1987. No Recordable Indications Found

ML17279A730
Person / Time
Site:	Columbia
Issue date:	12/07/1987
From:	John Baker WASHINGTON PUBLIC POWER SUPPLY SYSTEM
To:
Shared Package
ML17279A728	List: ML17279A727 ML17279A730
References
NUDOCS 8712220150
Download: ML17279A730 (72)

Text

WASHINGTON PUBLIC POWER SUPPLY SYSTEM NUCLEAR PLANT NO. 2 FEEDXATER NOZZLE INSPECTION REPORT FOR REFUELING OUTAGE RF87A SPRING 1987 Prepared By: ce Date

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Reviewed By: ~< f> /i/.~,'ate Manager, ngsneering ystems upport i~/>lax Manager, WNP- Generation ngsneenng Manager, P ant echnacal Date Approved By: iL '""

P ant nager Date 7~~~~0>W 871209 PDR ADOCK 05000397 6 PDR

t SlNNARY This report addresses feedwater nozzle inspections for WNP-2 between the first refueling outage (April 1986) and the second refueling outage (April 1987).

This report is required by NUREG-0619, Section 4.4.3.

Ultrasonic examination of one reactor feedwater nozzle was performed during the Spring 1987 refueling outage. No recordable indications were found. The Plant had experienced 11 startup/shutdown cycles during this inspection period.

During this period the feedwater control system operated as described in the RF86A feedwater nozzle inspection report (Reference 1). There were no system or procedure changes that affected thermal cycling of the feedwater nozzle.

The low flow ("startup") valve, RFW-FCV-10, was replaced with two valves during refueling outage RF87A. The operation of the feedwater system with these new valves will be discussed in the next feedwater nozzle inspection report since they were installed after this repor ting period.

The Supply System plans to continue its augmented feedwater nozzle inspection at the next refueling outage as committed in the WNP-2 ISI Program Plan. That is one feedwater nozzle bore, inner radius and safe-end will be ultrasonically examined from the reactor outside diameter (OD) at the next scheduled refueling outage (April 1988).

NDE INSPECTION During the second refueling outage, RF87A, at WNP-2, the Supply System performed ultrasonic examination of one reactor feedwater nozzle safe-end, bore and inner radius from the vessel OD. This examination is part of WNP-2's commitment described in FSAR Section 5.2.4.10 and Inservice Inspection Program Plan Section 5.3.2 to ultrasonically examine one feedwater nozzle from the OD each refueling outage for the first six refueling outages.

The Supply System has developed an angle beam shear wave technique that is unique to the WNP-2 feedwater nozzle design. The procedure was qualified on the WNP-2 feedwater nozzle mock-up which is a feedwater nozzle from the scrapped Douglas Point Unit 1 reactor vessel. The inner radius, Zone 1, of. the nozzle is scanned 'using a 72 degree angle transducer. The inner radius, Zone 2, and bore region, Zone 3, are scanned using a 25 degree angle transducer. The procedures used, OCI 6-4, Revision 3, and OCI 6-13, Revision 4, are contained in Appendix I to this report.

Calibration data for reactor feedwater nozzle inner radius examinations have been predetermined using the WNP-2 feedwater nozzle mock-up. This allows the examiner to use the reactor vessel calibration block representing the shell course containing the feedwater nozzle for calibration. The transfer data is contained in Table I of procedure OCI 6-4. Indications that exceed 25% full screen height (FSH) are recorded and indications that exceed 50% FSH are evaluated.

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The examinati ons were performed by two teams of Supply System examiners certified to either Level II or Level III UT per the Supply System ().A. program.

During the examination they were under the direct supervision of the Supply System Level III responsible for the technique and procedure development.

No recordable indications were found.

Total examiner radiation dose was less than 0.5 Man Rem.

SYSTEM AND PROCEDURE CHANGES THAT AFFECT FEEDMATER FLOW No changes were made to the feedwater system or operating procedures during this inspection period. The feedwater system was operated as described in "Feedwater Nozzle Inspection Report for Refueling Outage RF86A" (Reference 1). The reactor feedwater drive turbine low speed stops were reduced to allow the turbine speed level control to operate at lower flow r ates. This reduced the time the startup level control valve (RFM-FCV-10) was required to operate, thus reducing the nozzle thermal cycling due to the valves on/off cycling. This cycling was analyzed after refueling outage RF86A. The analysis concluded that the estimated feedwater nozzle life exceeds forty years with the present WNP-2 feedwater system design and operation.

The startup level control valve (RFM-FCV-10) was replaced during RF87A with two valves capable of controlling flow at low flow power levels. Since these valves were installed after the fast operating period their effect on the thermal cycling of the RFM nozzles will be reported in the next feedwater nozzle inspection report.

STARTUP/SHUTDOWN CYCLES MNP-2 experienced eleven (ll) startup/shutdown cycles since the last feedwater nozzle inspection report (Reference 1). This brings the total cycles since initial heatup (April 1984) to 56. The data for Outage RF87A was compiled from the 1986 Annual Operating Report and the Monthly Core Energy Output worksheets.

NEXT SCHEDULED EXAMINATIONS The Supply System will perform an ultrasonic examination from the outside diameter (OD) of the reactor vessel on one reactor feedwater nozzle inner radius, bore and safe-end per the commitment in FSAR Section 5.2.4.10 and the Inservice Inspection Program Plan Section 5.3.2 during the refueling outage scheduled for Spring 1988.

REFERENCES

1. Feedwater Nozzle Inspection Report for Refueling Outage RF86A, issued November 25, 1986.

APPENDIX I Procedure gCI 6-4, Revision 3 Procedure (HAGI 6-13, Revision 4

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NO QCI 6-4 WASKNGTON PUBLIC POWER SUPPLY SYSTEM IICV NDo CI'I'KCTIVC DATC NDE &. I INSTRUCTIQN 7-24-86 QUAUTY API CCTINO HAND ULTRASONIC EXNINATION BWR NOZZLE INNER RADIUS 1.0 PURPOSE AND SCOPE 1.1 This procedure defines the requirements for manual, pulse-echo ul trasonic examination of the IMR nozzle inner radius, (Zones 1, 2, and 3), ASME Section XI, Category B-D. Scanning by this pro-cedure is done from the reactor vessel O.D. wall and nozzle sur-faces using refracted shear wave search units. Figure 1 illus-trates the Zones which can be effectively scanned from the outside surfaces of the vessel .plate and nozzle.

1.2 This procedure covers the angle beam shear wave technique that is unique to the nozzle design. Specific refraction angles have been determined by individual nozzle geometry as depicted in Figures 2, 3 and 4.

1.3 This instruction is intended to meet the requirements of Sections V and XI of the ASME Boiler and Pressure Vessel Code (1980 with Addenda through Nnter 1980).

1.4 NR f:alibration Data listed in Table I have been predet~rmined from the Supply System's feedwater nozzle mockup so the qualified examiner need only use the vessel calibration'block representing the shell course containing the nozzle.

2. 0 DEF IN IT IONS None.

3. 0 REQUIREMENTS 3.1 Personnel Qualifications 3.1.1 Personnel performing examinations to the requirements of this instruction shall be a certified to at least Level II, in ul.trasonics in accordance with the requirements of Reference 6.2 and (b) below. Supply System personnel shall be (a) certified to at least Level II in accordance with Reference 6.3 and (b) qualified using the Supply System BMR feedwater nozzle mockup and this ul trasonic examination procedure.

WIIITTCN CY CHCC SY L IIIIOATC AL Sm N A I M S verson DCPTo AttlIOVA TC UFO CD CI KJ Ilannah Rev. 2 dated 5/8/86 1 ov 20 WWMZ II4

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OCI 6-4 Rev. 3 At least one person responsible for reviewing the results of the ultrasonic examination shall be a Supply System person certified as an ultrasonic Level III in accordance with Reference 6.3 in addition to meeting the requirements

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of (b) above.

3.2 Radial Clearance The thermal insulation should be clear of the nozzle and vessel to create a free space 12 inches out from the nozzle cylinder outer surface.

3.3 ~Eui ment The pulse-echo, ultrasonic, flaw detection instrument shall be equipped with a fine gain or attenuation control graduated in units no larger than 2 d8. Instruments con-sidered acceptable for this examination are listed below; however, other instruments may be used has been qualified.

if the aedel type Krautkramer USIP-1 1 Nortec NDT 131 or 131D 3.3.2 Single el,ement ceramic transducers, 3/4" x 1", with a nominal frequency of 2.25 MH shall be used with specific wedges, Figure 5. The refracted angle within the material shall be within the limits shown in Table I. Addition-ally, data may be taken with other sizes, frequencies, and angles, after completing the examination to the above r equirements.

3.3.3 Ultragel II or its equivalent shall be used as the liquid coupl ant.

3.3.4 The vessel calibration standard listed in Table I shall be used. This standard corresponds to the shell thickness containing the subject nozzle.

3.3.5 IM-2 RNPAS or modified Type DC (square ended semi-circle) sweep calibration reference blocks.

3.3.6 Flashlight for reading instrument control knobs.

3.4 Surface Pre aration The contact surface shall be clean and free of dirt, dust, weld spatter, loose paint, or other material which would interfere with free novement of the transducer or impair transmission of ultra-sonic ener gy into the material ..

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OCI 6-4 Rev. 3 3.5 Scannin S eed Limit The scanning speed shall not exceed 3 inches per second.

3.6 Nozzle Indentification Prior to the examfnatfon, the nozzles shill be marked and identi-fied fn accordance with a nozzle marking plan as illustrated in Figure 6. Carter 's marks-a-lot broad tfp marker fs the accepted pen device.

3.7 General Reoufrements for Cal fbratfon Cal fbratfon shall include the complete ul trasonic examination system. Any change in couplants, cables, or ultrasonic instru-ments shall be cause for recalibration. Sweep cal fbrations may be made with a standar d angle beam wedge using the IIW or similar curved block, and must be repr esentative of the metal path expected for the zone to be examfned, reference Table I.

3.7.1 Instrument Calibration - Prfor to Ne initiation of scheduled examinations, the ul trasonic instrument shall be checked for amplitude control linearity per paragraphs 3.7.2 and 3.7.3, respectively.

3.7.2 Anplftude Linearity Check.- An angle beam search unit shall be positioned on a chlibration block and signals obtafned from two reflectors. The, search unit position shall be adjusted to give a 2:1 ratio of amplitudes between the two reflectors. The gain control (sensitiv-ity) shall be adjusted and the larger signal brought to 80% of full screen height (FSH), adjusting positfon necessary to maintain the 2:1 sfgnal ratio. Mfthout if moving the search unit, adjust the gain control to succes-sively set the larger signal from 100 to 20 FSH fn 10 increments or 2 dB steps. The smaller amplitude must be 50% of the large ampl ftude within 5% of FSH. Instruments that do not meet these requirements shall not be used.

3;7.3 Amplitude Control Lfnearfty Check - The angle beam search unit shall be positioned on a cal fbration block and a peaked signal ampl ftude obtained from a hole or notch.

The fndfcatfon shall be brought as near as possible to 80 FSH wfth the dB control. If necessary, the final adjust-ment to 80% FSH fs made with the variable gain control or dB switch. Using only the dB control, the dB changes indicated below shall be made and the resulting ampl ftude compared with the allowable ampl ftude limits as specified below. Instruments that 'do not meet these limits shall not be used. The procedure shall be repeated for 40 and 20% FSH amplitudes.

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QCI 6-4 Rev. 3 Initial Aapl itude dB Control Anpl itude Limits Set of a FSH Change (: FSH)

, 80 32 to 48 80 -12 16 to 24 40 + 6 64 to 96 20 +12 64 to 96 3.7.4 Recalibration (Sweep Only) - If the indication from the calibration reflector has moved on the sweep line more than one inch of metal pa&, correct the sweep range cali-bration and note the correction on the calibration data sheet. If recordable refl ectors are noted on the examina-tion data sheets, those data sheets shall be voided. A new calibration shall be made and recorded, and the voided examination areas shall be rewxamined.

3.7.5 Recalibration (Anplitude Only) - If the amplitude of the calibration notch has changed by more than 10% FSH when a check is made on %e r eference block, all data sheets the last positive calibration check shall be marked 'ince void. A new calibration shall be recor ded and the voided examination areas re-examined. The voided sheets may be di scarded.

Calibration shall be performed at %e beginning of each series of examinations. A calibration verification shall be made at intervals not exceeding four hours during the examinations.

4.0 CALIBRATION AND EXNINATION An initial instrument sweep calibration shall be made for shear wave velocity by using the examination search unit with a conven-tional angle beam shear wav'e wedge and the IIW, Rompas or modified DC +pe curved calibration block. Sweep calibration data is listed in Table I for each nozzle. The oscilloscope's screen shall read directly in inches of metal path and the data entered on the calibration data sheet, Figure 7.

4.1.1 Zone 1 - Using a Rompas block, direct the ultrasonic beam toward the large radius, with the exit point of the trans-ducer at the radius center mark on the block, maximize the CRT signals by moving the transducer forward and back.

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. CCI 6-4 Rev. 3 Adjust the "Range" and "Delay" controls until the first reflection signal is at "2" on the horizontal graticule line on the CRT and the following signals appear at "5" and "8". Lock the range control knob and delay the signal at "8" to zero position. Signals should now appear at zero, 3, 6 and 9e Next, delay the signal at 6 to zero.

Signals should again appear at zero, 3, 6 and 9. If they do not, make minor adjustments s'o they do. The CRT is now calibrated for 14 to 24 inches of metal path.

4.1.2 Zone 2 - Using the transducer with the convex 25'hear wedge, obtain peaked signals from the 1/2 to 3/4 "T" holes in calibration block No. 120. Adjust the range and sweep to obtain reflection signals at positions 3.5 and 5.4.

Delay the signal at 5.4 to the 0.4 position. The CRT is now calibrated for 5 to 15 inches of metal path.

4.1.3 Zone 3 - Using the transducer with the flat 25'hear wedge, calibrate as in 4.1.2.

4. 2 Anpl itude Gal ibr ation. Basic calibration shall be established wi su scient ga>n so that 2X scanning can be performed without changing the variable gain control. To determine the basic sensi-tivity level of 1X, the search unit shall be held on the appli-cable vessel calibration standard, with the echo amplitude from the side drilled hole at 3/4 T maximized. The gain controls shall now be adjusted so that the echo amplitude is brought to 50 FSH.

The gain (control ) shall then be increased by the nuaber of dB listed in Table I.

CAUTION: Care must be exercised during calibration to assure the sasear wave cosponent fs used for c.alSbr ation since there <s also a strong longitudinal wave component generated by the angle beam transducer, especially for Zone 2 and 3 calibration. A peaked shear wave signal from the 3/4 T hole should appear at approxi-mately Se7 inches metal path when the transducer is approximately 2-3/8 inches surface distance from a line normal to the hole centerline. The refracted longitudinal wave should produce a peaked signal at approximately 4-3/4 inch metal path at a surface distance of 6-1/2 inches.

4. 3 Examination A &vel II or III UT examiner shall view the CRT display during the examination. A record of each nozzle inner radius examination shall be made on examination data sheets (Figure 8), which shall be numbered in sequence with calibration data sheets. Scanning shall be performed at 2X above the primary gain level (1X).

Neasurement and recording of ul trasonic indications shall be done at the 1X level.

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e QCI 6-4 Rev. 3 Zone - 1 The inner radius Zone 1 shall be scanned in two directions from the vessel plate as shown in Figure 9. Scanning shall progress cir'cumferentially.around the nozzle using the moving azimuth tech-nique. The operator shall occasional]g rotate the wedge toward the bore axis to obtain a direct reflection signal from the inner radius as a check to confirm penetration. A secondary technique may be used in addition to the moving azimuth technique, the scan-ning shall follow a continuous line around the nozzle using a fixed azimuth. A minimum of three scans shall be made as shown in Figure 9 (0.5 in. overlap). The movable pointer on the transducer wedge shall be positioned in the groove marked "CN" for scanning counter clockwise and "N" for scanning clockwise. The pointer shall be aimed at the nozzle bore axis during scanning to the extent practicable. The examiner shall reference Figure 10 for transducer orientation.

Zone " .2 The inner surface of the nozzle shall be scanned from the exterior surface of the nozzle using the appropriate search units in two directions: clockwise (N) and counterclockwise (CN) (Figure 11). A circumferential scanning pattern spaced at intervals not exceeding 0.25 in. (3/4 in. overlap) shall be followed around the nozzle body to obtain full coverage of the inner surface Zone 2.

Zone - 3 The nozzle forging and the inside bore shall be examined to the maxirmm extent possible using the cylindrical surface for scanning (Figure 12). The scan path of the search unit shall overlap the adjacent scan by a mininvm of 0.50 inch. The search unit shall be scanned circumferentially around the nozzle for ging so the angle beam shear wave covers all 360'f the circumference in both the clockwise and countercl ockwise dir ections.

4. 4 ~lh Ih Ch Indications in the region of the blend radius which have an ampli-tude greater than 50% FSH at the 2X scanning level and which travel in time position on the CRT shall be investigated to deter-mine maxirmm ampli tude.

Indications in the region of the blend radius which exceed 25% FSH at the primary reference level (1X) and which travel in time posi-tion on the CRT, shall be recorded on the examination data sheet.

Report signal amplitude in % FSH, metal path in inches, search unit direction as clockwise (N) or counterclockwise (CN), and search unit position.

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QCI 6-4 Rev. 3 4.5 Reference Points for Ph sical Measurement Reference points for physical measurement of azimuth shall be in accordance with the nozzle reference plan shown in Figures 10, ll, and 12.

4.6 CRT Dis la Photos Photos of the CRT display shall be taken at the option of the Level III Examiner to further document the ultrasonic signal character. Pertinent data shown below shall be recorded on the back of each photo.

1. Report No.

2. ISI Drawing No.

3. Zone No.

4. Sweep Distance

5. Indication No.

5, 0 DATA PROCESSING 5.1 The recorded data shall be reviewed by a level III Examiner to determine i f additional examination and/or interpretation is r equi r ed.

5.2 Recorded indications shall .be plotted on a" scale no less than quarter size and reviewed by the Level III Examiner.

6. 0 REFERENCE 6.1 Anerican Society of hhchanical Engineers Boiler and Pressure Vessel Code, 1977 Edition through Sumner 1978 Addenda.

6.1.1 Section XI - "Rules for Inservice Inspection of Nuclear Power Plant Components".

6.1.2 Section Y - Nondestructive 'Examination".

6.2 American Society for Nondestructive Testing, June 1975 Edition.

Recomnended Practice SNT-TC-lA "Nondestructive Testing Personnel Quali fication and Certi fication".

6.3 The Supply System "Program Manual for Qualification and Certifica-tion of Examination, Testing and Inspection Personnel OlC-034".

6.4 Nozzle forging drawings - General Electric/CBI Nuclear Page 7 of 20

1 QCI 6-4 Rey. 3 TABLE I ULTRASONIC CALIBRATION DATA FOR EKAHINATION OR BMR NOZZLE INNER RADII NOZZLE TYPE - N4 FEENATER ACOUSTIC ANGLES CRT CAL TRANSFER DEGREES1 'ISPLAYED STANDARD SENS IT IYITY A 8 C QfEEP dB GAIN INCREASE Zone 1 22 70 70 14" to 24" UT 1202 14 Zone 2 22 253, 63-70 5" to 15" UT 120 Zone 3 0-10 25 63 -5" to 15" UT 120 12

1. -

See Figures 2A, 28, 3 and 4

2. The 5/1& in. dia., 3/4 T hole (5.06 in belm the contact sur-face) shall be used for calibration.

3. Convex shoe Page 8 of 20

QCI 6-4 Rev. 3 I~

NOZZLE EXAMINATION ZONES FIGURE 1 Page 9 ot'0

~ I al I l a QCI 6-4 Rev. 3 Yessel Plate Scan Midth Scan Start Dimension a

2A. NOMINAL ENTRY POINT FOR SOUND BEAM FOR ZONE 1 A ~ Skew Angle (offset)

B ~ Refracted Angle C Intercept Angle Ultrasonic Search Unit Assembly with Compound Ar gl e 5) gati A 0(

2B. SOUND BEAM GEOMETRY IN NOZZLE FOR ZONE 1 Page lO of 2G Figures 2A and 2B

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OCI 6-4 Rev. 3 SCAN AREA SECTIONAL VIEW OF NOZZLE FIGURE 3 SOUND BEAM GEOMETRY, BODY ZONE 2 SECTIONAL VIEW OF FIGURE 4 SOUND BEAM NOZZLE CYLINDER GEOMETRY, ZONE 3 FIGURES 3 and 4 PeSe 11 0< 2it'

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ZONE 2, CONVEX CONTACT SURFACE

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ZONE 3, CONCAVE CONTACT SURFACE FIGURE 5 TRANSDUCER MEDGE CONFIGURATIONS Page 12 of 20

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QCI 6-4 Rev. g NOZZLE NUMBER LOCATED ON TAPER LINES MARKED ON NOZZLE 800Y UJ lkl l/1 I COME 4J( L4 P

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W LaJ LaJ RADIAL LINES EXTEND WOe~ 2" PAST REF. CIRCLE W

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arrccnva aAVC NDE & I INSTRUCTION 4-10-87 ASJ AP CTltt4 Ques geo ULTRASONIC EX&INATION OF PIPING WELDS (IlANUAL) 1.0 PURPOSE AND SCOPE

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1. 1 This instruction defines the method for manual contact ultrasonic examination of similar and dissimilar metal welds in piping systems 0.2 to 6.0 inches in thickness. The methods outlined in this instruction meet the requirements of the ASNE Boiler and Pressure Vessel Code,Section XI, 1980 Edition through Winter 1980 Addenda and Appendix III.

1.2 These examinations may be performed by Supply System personnel or by a Supply System Contractor under Supply System supervision.

2. 0 DEFINITIONS None 3.0 PROCEDURE 3.1 Personnel Oualifications 3.1.1 Supply System personnel shall be certified in accordance with Reference 6.2.

3.1. 2 Contractor personnel shall be certified to the contractor' guality Assurance Program provided the program has been approved by the Supply System. As an alternative, the contractor personnel shall be certified in accordance with Reference 6.2.

3.1.3 Personnel designated as trainees may assist the Level II or III in performance of the examinations to this instruction.

3.1.4 Level I individuals shall perform only specific setups, calibrations, tests or record data to the requiremnts of.

this instruction and shall implement this instruction only with the direct participation of a Level II or higher individual. The Level I shall not independently evaluate or accept the results of the examinations performed to this instruction; 3.1. 5 Examination teams shall include at least one Level II or Level III UT examiner.

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/.' <<~l<j~ Rev. 3 ~OP 19 WHAT It%

gCI 6-13 Rev. 4 3.2 Ultrasonic Instruments - The pulse-echo, ultrasonic flaw detection instruments sha be equipped with a stepped gain control, gradu-ated in units no larger than 2 dB. Instruments considered accep-table for examination are listed below; other instruments may be used if the model type is qualified.

Krautkramer USIP-11 KRautkramer VSL-48 Nortec NDT-131 or 131D 3.3 Transducers 3.3.1 Strai ht Beam - Single or dual element ceramic type trans-ducers vi ng an area from 0.049 to.l.0 square inch shall be used. Base material exami nations and thickness measurements will normally be conducted using a 2.25 or 5.0 MHz longitudinal wave transducer; however, other fre-quencies may be used where metallurgical characteristics prevent effective use of 2.25 or 5.0 MHz transducers.

3.3.2 An le Beam - Single or dual element ceramic type trans-ducers aving an area from 0.049 to 1.0 square inch shall be used. The initial examination will normally be con-ducted using 2.25 MHz shear wave transducers with a beam angle of 43 to 47 degrees. Other angles and wave modes may be used for evaluation or indications and where wall thickness or geometric configuration impedes effective use of the 45 degree angle. The tolerance for other angles shall be +3 degrees. Transducers of other frequencies and wave modes may also be used for evaluation of indications or where metallurgical characteristics prevent effective use of 2.25 MHz shear wave transducers. The transducer exit point and beam angle shall be verified, prior to examination, using an II}l ( International Institute of Melding) or Rompas calibration block.

3.4 Cou lant - Ultragel II or an equivalent shall be used as the iquid couplant. Certification of acceptable sulfur and halogen content shall be obtained and made available for each lot or batch number.

(a) Couplant shall be analyzed for sulfur content in accordance with ASTM 0129-64. The sulfur content of the residue shall not exceed 1% by weight.

(b) Couplants shall be analyzed for chloride content in accordance with ASTN 0808-63. The chloride content of the residue shall not exceed 1X by weight.

Page 2 of 19

()CI 6-13 Rev. 4 3.5 Calibration Blocks - Calibration blocks shall be as specified in Section 14 of the Inservice Inspection Program Plan or as specified by the Responsible Technical Organization (RTO).

3.6 Surface Pre aration - The finished contact surfac s shall be free rom we d sp atter or any roughness that would interfere with free movement of the search unit or coatings which would impair the transmission of ultrasonic vibrations.

3.7 Instrument Calibration - The ultrasonic instrument linearity shall be checked each day prior to its use and documented on the Cali-bration Oata Sheet shown in Attachment 7.2. Linearity shall be determined in accordance with the requirements of Paragraphs ( a) and (b) below:

(a) Screen Hei ht Linearit Check - To verify the ability of the ultrasonic instrument to meet screen height linearity requirements, position an angle beam search unit so that responses can be observed from any two reflectors in a calibration block. Adust the search unit position to give a 2 to 1 ratio of amplitudes between the responses, with the larger set at SC of full screen height (FSH).

Mithout moving the search unit, adjust the gain control to successively set the larger signal from 100% to 20% FSH in 1(C increments or in 2 dB increments if the instrument is

, equipped with a stepped gai n control. The smaller signal amplitude must be 50K of the larger amplitude signal within 5% FSH. Instruments that do not meet this requirement shall not be used.

(b) A litude Control Linearit Check - To verify the accuracy o the amp ftude contro n the ultrasonic instrument, position a search unit so that a response from a reflector in the calibration block is peaked on the screen. The signal amplitude shall be brought as near as possible to 8(C FSH with the dB control. If necessary, the final adjustment to 80% FSH can be made with the variable gain control. Using only the dB control, the dB changes indi-cated below shall be made and the resulting amplitude compared with the allowable amplitude limits. The proce-dure shall be repeated for 40% and 20% FSH amplitudes.

The initial settings and readings shall be estimated to the nearest 1% of full screen. Instruments that do not meet this requirement shall not be used.

Page 3 of 19

l I

QCI 6-13 Rev. 4 Initial Amplitude dB Control Amplitude Limits Set at FSH ~Chan e in 5 FSH 80 -6 32 to 48 80 -12 16 to 24 40 +6 64 to 96 20 +12 64 to 96 3.8, General Requirements for Examination Gal ibrati'on 3.8.1 Calibration shall be performed from the surface of the calibration block which corresponds to the component surface to be examined.

3.8.2 The calibration block temperature shall be within 25'F of the component being examined.

3.8.3 Calibration shall include the complete ultrasonic examina-tion system. Any change in couplants, cables, transducers, wedges, ultrasonic instruments, or any other parts of the examination system shall be cause for a calibration check.

(a) At least every 4 hours during an examination; (b) At the start and finish of each completed examination; (c) At each change of examiners; (d) In the event of loss of power; and (e) If any part of the examination system has been changed, such as, search units, cables or ultrasonic instruments; (f) If the operator suspects a malfunction.

3.8.5 Calibration checks may be performed on a secondary refer-ence, such as an IIM, Rompas block or equivalent, provided the response from the block has been referenced after initial calibration. The tolerances of 3.8.7 and 3.8.8 shall apply for this operation.

3.8. 6 Final calibration shall be performed on the calibration block used for initial calibration.

3.8.7 Recalibration (Swee Onl ) - If the indication from any o t e ca ibration re ectors has moved on the sweep line more than 10%, correct the sweep range calibration and note the correction on the Calibration Data Sheet. If Page 4 of 19

I l

()CI 6-13 Rev. 4 recordable indications were noted on the Examination Data Sheets, those data sheets shall be voided. A new calibra-tion shall be made and recorded and the voided examination areas shall be ~xamined.

3.8.8 Recalibration (Am litude Onl ) - If the amplitude of any o the ca rat on re ectors has changed by more than 2 dB, all data sheets since the last acceptable calibration check shall be marked void. A new calibration shall be made and recorded and the voided examination areas reexamined.

3.8.9 All required calibration data shall be recorded on the Ultrasonic Calibration Data Sheet, Attachment 7.2.

3.9 ualification - Prior to use of this instruction, the calibration techniques in 4.0 shall be demonstrated in the presence of an Authorized Nuclear Inspector. The successfu'1 completion of these calibrations shall be documented on Calibration Sheets, Attachment 7.2. These calibrations shall serve as a generic qualification for record purposes only as the instruction is essentially quali-fied upon, each successful calibration used during the course of the weld examinations.

4.0 PROCEDURE 4.1 An le Beam Calibration 4.1.1 Calibrate the instrument sweep to the required sound path distance using an IIW, Rompas or an equiva1<<nt block having known dimensions. The sweep calibration shall be suffici-ent to include all reflectors required to construct the distance-amplitude correction (DAC) curve.

4.1. 2 For the examination of piping welds using the 1/2 "Y" path technique, the calibration shall be performed in accordance with the following to detect reflectors parallel or trans-verse to the 'weld:

(a) Position the search unit for maximum response from the side drilled hole (1/8, 2/8 or 3/8 node) which produces the highest amplitude signal. For this operation, the centerline of the search unit shall be at least 3/4" from the nearest side of the calibration block to avoid using the reflection from the hole and the side of the block. Adust the instrument gain .to set this signal at 8% of full screen height and mark the location and amplitude of the signal on the screen.

Page 5 of 19

I QCI 6-13 Rev. 4 (b) Without changing the instrument controls, maximize the signal of the two remaining holes and mark their amplitudes and locations on the screen.

(c) As an alternate, if the calibration block is designed such that it only contains a 1/2 T side drilled hole, position the search unit for maximum response from this hole. Then adjust the instrument gain to set this signal at 80K of full screen height and mark the location and amplitude of the signal on the screen.

Without changing the instrument controls, maximize the signal from this hole at the 6/8 node position and mark the amplitudes and locations on the screen.

(d) Connect these points on the screen with a line and extrapolate the curve an additional 1/4 T to cover the full examination thickness. This completes the construction of the DAC curve only.

(e) To determine the primary reference level, position the search unit to obtain the maximum response from the notch at the 1/2 "Y" path location. Adjust the amplitude of the notch to be equal to the DAC curve.

This is the primary DAC reference level.

Record and plot all calibration data on the appropri-ate areas of the Calibration Data Sheet.

(g) After the primary DAC reference level has been established on the pipe calibration standard, a cali-bration reference response may be established on a Rompas or other standard reference block. The response shall include both sweep and amplitude calibration points and the gain setting used to establish them. This information shall be recorded on the appropriate area of the Calibration Data Sheet.

This reference response may then be used to perform calibration checks. Final calibration, however, shall be performed on the pipe calibration standard.

4.1.3 For the examination'of piping welds using the 1 "Y" path or greater technique, the calibration shall be performed in accordance with the following to detect reflectors parallel or transverse to the weld:

(a) Position the search unit for maximum response from the circumferrential notch on the opposite side of the calibration block and adjust the instrument gain to set the response at 8% of full screen height.

Mark the location and amplitude on the screen.

Page 6 of 19

()CI 6-13 Rev. 4 (b) Mithout adjusting the gain, obtain responses from the notches at 1 and l-l/2 or greater "Y" path locations.

Mark the locations and amplitudes on the screen.

(c) Connect the points with a line. This is the primary DAC reference level.

(d) Record and plot all calibration data on the appropri-ate areas of the Calibration Data Sheet as shown in Attachment 7.2.

(e) After the primary DAC reference level has been established on the pipe calibration standard, a calibration reference response may be established on a Rompas or other standard reference block. The response shall include both sweep and amplitude calibration points and the gain setting used to establish them. This information shall be recorded on the appropriate area of the Calibration Data Sheet.

This reference response may then be used to perform calibration checks. Final calibration, however, shall be performed on the pipe calibration standard.

4.2 Strai ht Beam Calibration - Preservice Ins ection Onl 4.2.1 Calibrate the instrument sweep to a distance sufficient to include the thickness of the material being exami ned using an IIM, Rompas or an equivalent block having known dimensions.

4.2.2 For the examination of piping, fabricated from plate material, for laminar reflectors, calibration shall be performed according to the following:

(a) Position the search unit on the part to be examined using sufficient gain.to produce a back reflection from the part of at least 805 full screen height.

(b) Record and plot all calibration data on the appropri-ate areas of the Calibration Data Sheet.

4.3 Strai ht Beam Examination of Plate Material - Preservice ns ection n 4.3.1 This examination shall be performed on'ly on pipe and/or fittings fabricated froa plate material.

Page 7 of 19

QCI 6-13 Rev. 4 4.3.2 For detection of laminar reflectors in plate material, the search unit shall be placed on the base material and mani-pulated to ensure coverage of the entire area through which the sound must pass during the angle beam examination.

4.3.3 The instrument gain shall be adjusted during the examina-tion to maintain a back reflection of at least 50 full screen height while scanning.

4.4 An le Beam Examination of Welds 4.4.1 For detection of reflectors parallel to the weld, the search unit shall be placed on the contact surface with the beam essentially perpendicular to the weld centerline.

The search unit shall be manipulated to ensure the sound beam passes through the entire area of interest using the 1/2 or 1-1/2 or greater "Y" path examination technique from both sides of the weld. Physical or other limitations which prevent complete examination of the area of interest shall be documented on the Examination Data Sheet.

4.4.2 For detection of reflectors transverse to the weld, the search unit shall be placed on the weld with the beam directed along the weld in two opposite directions.

4.4.3 As an alternate, if the weld contour is such that the examination cannot be performed from the weld crown, the search unit shall be placed directly adjacent to the weld edge. The sound beam shall be directed parallel to the weld and the search unit manipulated laterally and longi-tudinally. Physical or other limitations which prevent complete examination of the weld area shall be documented on the Examination Data Sheet.

4' ' Welds that cannot be exami ned from at least one side usi ng the angle beam technique shall be examined by another volumetric method.

4.5 Scannin Re uirements for An le Beam Examination 4.5.1 Area of Interest - The area of interest is the volume of material which is to be examined and shall include the inner 1/3 T of the weld and 1/4 inch of adjacent base material on both sides of the weld as measured from the weld crown edge.

Page 8 of 19

gCI 6-13 Rev. 4 4.5.2 The area of interest shall be examined from both sides, when possible, with the search unit directed normal to the weld for detection of reflectors parallel to the weld using the I/2 or I or greater "Y" path examination technique whichever is applicable.

4.5.3 For examfnation of reflectors transverse to the weld, .the search unit shall be placed on the weld crown when possible, and directed parallel to the weld. Scanning shall be performed in both directions along the weld.

4.5.4 For longitudinal weld seams adjacent to circumferential welds the entire weld length shall be examined during preservice examination. For fnservice examination, only the first I foot of the weld for Class I and 2-1/2 T for Class 2, need be examined. All other welds shall be examined for their full length.

4.5. 5 The angle beam coverage for examination of reflectors paraIIel to the weld using the I/2 "V" path examination

. technique shall be sufficient to permft the sound beam to cover the inner I/3 T of the weld and at least I/4 inch of the adjacent base material on both sides of the weld edge.

Manipulatfon of the search unit over the weld crown may be required to achieve this coverage using the I/2 "Y" examination technique.

4.5.6 Fot the 1-1/2 "V" path technique, the minimum coverage shall be in accordance with the chart below and in all cases shall be sufficient to cover the lower I/3 of the weld and I/O inch of the base material adjacent to the wel d.

Beam Required Scan Oistance Measured from the

~Ae le Meld Centerline - Pi e Thickness is "T" 45 At least 3-1/2 T 60 At least 5 T 4.5.7 The manual scanning rate shall not exceed 6.0 inches per second. Each pass of the search unit shall overlap a minimum of l(C of the transducer piezoelectric element dimension perpendicular to,the dfrectfon of scan.

4.6 Scannfn Sensftivit - For angle beam examfnatfon, scanning shall be pe ormed at a annfmum of 2X (6 dB) above the prfmary reference level. Sfx dB increases the signal amplitude by a factor of approximately 2, making the primary reference curve a 50% DAC curve. Recording of indications requires the signal to be adjusted Page 9 of 19

OCI 6-13 Rev. 4 to the point where it is equal to the DAC curve using the dB control. Signal amplitude can then be determined from the following chart using the observed change in the dB control.

dB Gain - % DAC dB Gain - I DAC 0 - 100 0 -'100

-1 - 112 +1 - 90

-2 - 125 +2 - 80

-3 - 141 +3 - 70

-4 - 159 +4 - 63

-5 - 178 +5 - 56

-6 - 200 +6 - 50

-7 - 224 +7. -. 45

-9 - 282 +8 - 36

-10 - 316 +9 - 32

-ll - 355 +10 - 28

-12 - 400 +12 - 25

-13 - 447 +13 - 22

-14 - 501 +14 - 20

-15 - 562 +15 - 18

-16 - 631 +16 - 16

-17 - 708 +17 - 14

-18 - 794 +18 >>. 13

-19

-20

- 891 +19 -

ll

-1000 +20 10 4.7 Meld Thickness Measurement - Thickness measurements may be taken at or near the 0 degree reference point.and at 90 degree intervals around each weld on which a data plot is performed. The measure-ments will be made on:

(a) The weld centerline; (b) In the heat affected zone as near as possible to each edge of the weld; and (c) On the base material on each side of the weld.

4.7.1 In addition, the location of the pipe'ounterbore transi-tion should be determined when possible and the distance from the weld centerline documented on the Examination Data Sheet.

4.7.2 All measurements shall be documented on the appropriate area of the Examination Data Sheet shown in Attachment 7.1.

Page 10 of 19

L QCI,6-13 Rev. 4 4.8 Data Recordin for Straf ht Beam Examination - If the response from the aminar ref ector exceeds the remaining back reflection response fn an area exceeding 3/4" fn its longest dimension, the following data shall be recorded on the Examination Data Sheet.

(a) Indfcatforr Number - Assign a number, begfnn&g with 1, to eac indiv ua indication which fs recorded.

(b) Location Interval - Record the search unit location interva wit respect to the stamped degree location numbers on the weld.

(c) ~Beam An 'le - Record the search unit beam angle (0').

- Record the surface (1 or 2) on which the (d) Scan Surface I g>>1'. *

• 13.

(e) Sound Path - Record the sound path distance to the re ectore Len th - Record the major dimension of the reflector in t e 0% DAC length column.

(g) Prepare a sketch showing the area fn which the reflector exceeds the remaining back reflection and attach ft to the Examinatfon Data Sheet.

4.9 Data Recordi for An le Beam Examination of Ferrftfc Steel Melds-If the maximum signal amplitude equals or exceeds 5 of the primary reference level, the following data shall be recorded on the Examination Data Sheet.

(a) Indfcatfon Number - Assign a number beginning with 1 to (b) Location Interval - Record the search unft location 3 g numbers on the weld.

~

(c) Beam An le - Record the search unit beam angle, typically or (d) Scan Surface - Record the surface (1 or 2) on which the 31 . 3 I 1.3.

(e) Beam Direction - Beam direction doctments the search unit

~ I 3 be A, B, C or D. See Attachment 7.4.

(f) Sound Path - Record the sound path distance to the indica-tion at the peak amplitude'ocation.

Page 11 of 19

QCI 6-13 Rev. 4 (g) Extent - This information, recorded in degrees, fs used to describe the extent of intermittent or continuous geometric indications. If a more thorough description is requirede this blank may be used to reference the notes section.

(h) Dam able - If an indication is dampable on the surface of t e part, it should be stated in this column.

(i) Aptitude - Record the maximum amplitude of the signal as a percentage of the primary reference level.

(5) Len th - Record the 50~ to 50 and 100% to 100 DAC length o each indication.

(k) Search Unit Position - Record, in inches, the distance (L) rom the search unit to the smaller stamped location number and the distance from the exit point to the weld center-line (M) for longitudinally oriented indications or the distance from the search unit centerline to the weld centerline (M) for transversely oriented indications.

These measurements shall be taken at the maximum amplitude location. See Attachment 7.5.

(1) Throu h Mall Dimension - If the maximum signal amplitude equa s or exceeds DAC, record the minimum and maximum sound path distance and search unit location as the search unit is moved toward and away from the reflector. These

'easurements shall be taken at the 100 DAC level. The minimum and maximum sound path readings may not necessarily be at the point of maximum signal amplitude, nor do they have to be on the same scan line. Each indication shall be fully investigated to determine the points at which the minimum and maximum readings occur.

4.10 Data Recordin for An le Beam Examination of Austenitic and issimi ar eta e ds - ny crac - i e indication, regard ess of amp itude, sha e recorded and investigated to determine it' shape, identity and location.

E All indications 50% DAC or greater determined to be geometrical or metallurgical in origin shall be recorded.

Are other indications determined not to be geometrical or metallurgical in origin shall be recorded ff they are 20 of the distance amplitude correction (DAC) curve or greater.

(a) Indication Number - Assign a number, beginning with 1, to (b) Location Interval - Record the search unit location inter-val with respect to the stamped degree location numbers on the weld.

Page 12 of 19

QCI 6-13 Rev. 4 (c) ~Beam An le - Record the search unit beam ang'le (0'l.

(d) Scan Surface - Record the surface (1 or 2) on which the II I ppg . I << I 3.3.

(e) Beam Direction - Beam direction documents the search unit onentatson with respect to thd'weld. Beam direction will be A, 8, C or D. See Attachment 7.4.

(e) Sound Path - Record the sound path distance to the reflector.

(g) fxtent - This information, recorded in degrees, is used to describe the extent of intermittent or continuous geometric indications. If a more thorough description is required, this blank may be used to reference the notes section.

(h) Dam able - If an indication fs dampable on the surfac'e of t e part, ft should be stated fn this column.

(f) Amplitude - Record the maximum amplitude of the signal as a percentage of the primary reference level.

Len th - Record the 20% to 20% (when required), 50 to 50>>

an 0>> to 100~ OAC length of each indication, Search Unit Position - Record, in inches, the distance (L) rom e scarc un'o the smaller stamped location number and the distance from the exit point to the weld center-line (M) for longitudinally oriented indications or .the distance from the search unit centerline to the weld centerline (M) for transversely oriented indications.

These measurements shall be taken at the maximum amplitude location. See Attachment 7.5.

Throu h Mall Dimension'- If the maximum signal amplitude equa s or exceeds DAC, record the minimum and maximum sound path distance and search unft locatfon as the search unit fs moved toward and away from the reflector. These measurements shall be taken at the 100% OAC level. The minimum and maximum sound path readings may not necessarily be at the point of maximum signal amplitude, nor do they have to be on the same scan line. Each indicatfon shall be fully fnvestfgated to determine the points at which the minimum and maxfmum readings occur.

4.11 Exami natf on Records

4. 11.1 A Calibration Data Sheet (Attachment 7.2) shall be prepared for each calfbratfon.

Page 13 of 19

L QCI 6-13 Rev. 4 4.11.2 An Examination Data Sheet shall be prepared for each weld examined and shall be related, by number, to a Calibration Data Sheet.

5. 0 EVALUATION I

5.1 All indications detected in the area'of interest which produce signal amplitudes greater than 100% of the DAC reference level shall be individually reported and an evaluation made in accordance with Paragraph IMB-3514.of ASME Section XI, 1980 Edition Minter 1980 Addenda (Reference 6.l.l).

5.2 Any area where complete examination cannot be performed due to obstructions, configuration of weld, etc., shall be recorded and reported.

5.3 All data shall be submitted to the Supply System UT Level III for review. The Level III shall evaluate the examination data and indicate the status of the indication in the Evaluation column of the Ultrasonic Examination Data Sheet. The Level III shall also complete the Data Evaluation Form in accordance with NDEhI Instruction 12-8.

6.0 REFERENCES

6.1 American Society of Mechanical Engineers Bciler and Pressure Vessel Code, 1980 Edition through Minter 1980 Addenda.

6.1.1 Section XI - "Rules for Inservice Inspection of Nuclear Power Plant Components".

6.2 The Supply System "Program Manual for gualification and Certifica-tion of Examination, Testing and Inspection Personnel MNC-034".

7.0 ATTACHMENTS 7.1 Examination Data Sheet 7.2 Calibration Data Sheet 7.3 Examination Surfaces 7.4 Beam Directions 7.5 Search Unit Location and Orientation Page 14 of 19

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QGI 6-13 Rev. 4 lrASHIHCTOH PUBLIC POWER SUPPLY SYSTEM ULTRASONIC EXAMINATIONDATA SHEET atfoar No~ RCU-001

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~OO I SZSS fAOC I Of Examination Data Sheet ATTACHMENT 7.1 Page 15 of 19

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Ca1ibration Data Sheet ATTACHMENT <7.2 Page 16 of 19

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'l gCI 6-13 Rev. 4 bEAMDRECIIOH A TRANSDUCER PODIIING TOWARD SURFACE 41 III C

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> z A-b O 0-90 2 D Beam Directions ATTACHMENT 7.4 Page 18 of 19

0 l QCI 6-13 Rev. 4

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Search Unft Locatfon and Orfentatfon ATTACHNENT 7.5 Page 19 of 19

APPENDIX II Drawing UTCB-250, Sheet 2 of 2, Revision 0 "WNP-2 FW Nozzle Mock-up UT-122" Drawing UTCB-208, Revision 1 "UT Calibration Block, UT-120 RPV b'2 and 83 Shell Rings

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